1004E20 ENGINE - DISMANTLE AND REASSEMBLE FOLLOWING OPERATION 1004E10 - WASH AND CHECK DISMANTLED PARTS - REFIT CYLINDER HEAD AND OIL SUMP - DOES NOT INCLUDE REPAIRS TO CYLINDER HEAD AND AUXILIARY UNIT - Fiat - STILO - eLearn

3363549 - 1004E20 ENGINE - DISMANTLE AND REASSEMBLE FOLLOWING OPERATION 1004E10 - WASH AND CHECK DISMANTLED PARTS - REFIT CYLINDER HEAD AND OIL SUMP - DOES NOT INCLUDE REPAIRS TO CYLINDER HEAD AND AUXILIARY UNIT

) 1. Position the flywheel lock.

	Description	Code
1	Counter-torque	1.860.846.000

2. Undo the bolts (2a) and remove the clutch plate (2b).

1. Position crankshaft gear locking tool as shown in the figure.

	Description	Code
1	Counter-torque	1.870.763.000

Work with flywheel retaining tool 1860846000 fitted.

2. Undo the bolt securing the crankshaft gear and remove it.

1. Undo the bolts fixing the engine flywheel.2. Remove the engine flywheel together with plate (2a) and the flywheel retainer positioned previously.

1. Undo the fixing bolts (1a) and remove the crankshaft rear cover (1b).

1. Undo bolt (1a) and remove the rigid engine coolant pump inlet pipe (1b) with sealing ring.2. Undo the bolts (2a) and nut (2b) remove the water pump (2c).

1. Remove the engine oil filter using a suitable tool.2. Remove the oil pressure sending unit.3. Undo bolts (3a) and remove the engine block front cover (3b) with the built-in oil pump complete with crankshaft front oil seal (3c) and intake chamber (3d).4. Remove the engine block front cover gasket.

1. Using the service bolts, fit tool (1a) to rotate the crankshaft.

	Description	Code
1a	Flange	1.860.815.000

Rotate the crankshaft using the tool fitted previously until cylinders 1 and 4 are at T.D.C.1. Undo the bolts (1a) and remove the connecting rod cap (1b) for cylinders 1 and 4.2. Remove the cylinders 1 and 4 connecting rod lower half-bearings.3. Remove the cylinders 1 and 4 connecting rod - piston assemblies.4. Remove the cylinders 1 and 4 connecting rod upper half-bearings.Carry out the same operations to remove the pistons and connecting rods for cylinders 2 and 3.Remove the tool for rotating the crankshaft.

	Description	Code
-	Flange	1.860.815.000

1. Use a dial gauge on a magnetic base to check that the crankshaft end float is within specified values.

	Measurement		Value
1	End float (mm)		0.055 ÷ 0.265

If the value for the crankshaft endfloat does not correspond with the recommended figures, when refitting, regrind the crankcase seat and use suitable thrust washers (fastened to the central main bearing half) oversized by 0.127mm.1. Unscrew bolts (1a) and (1b) and remove the lower crankcase that acts as the main bearing caps.2. Remove the lower main journal half-bearings.3. Remove the crankshaft.4. Remove the upper main journal half-bearings.

The central main bearing half incorporates the crankshaft thrust ring halves.

Hoist the crankcase using a hydraulic hoist with chains and remove the crankcase from the support brackets. Place on a suitable workbench. Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH1. Remove the coolant chamber plugs from the crankcase using a steel drift.2. Remove the lubrication duct plug from the crankcase using a steel drift.

Check the condition of the piston cooling oil sprays.1. If they are blocked, remove the oil sprays (1a) using a steel drift (1b). Insert the drift guide hole on on the nozzle surface to prevent the drift from slipping during the extraction operation and removing the cylinder liner.

	Description	Code
1b	Drift	1.860.395.000

Whenever the oil sprays are removed, they must not be reused but must be replaced.

Refitting ( Removing

) Wash and check the appearance of all compents removed.Fit the water/oil sealing plugs in the crankcase using suitable fitting tools and spread with a suitable sealant.

	Type	Component	Description	Qty.
-	Sealant	CRANKCASE PLUGS	Loktite 270	-

1. Use tool (1a) and a plastic mallet to fit the new oil sprays (1b).

	Description	Code
1a	Fitting tool	1.860.313.000

1. Using a calibrated metal rule (1a) and a feeler gauge (1b), check the planarity of the cylinder head - cylinder block/crankcase support surface.2. If the measurement does not correspond to the recommended values, regrind the cylinder head support surface.

	Measurement		Value
2	Cylinder head support surface flatness (mm)		< 0.1

1. Measure the diameter of the cylinder bores and check that they correspond to the recommended figures.

	Measurement		Value
-	Cylinder liner diameter (mm)	Category A	70.800 - 70.810
Category B	70.810 - 70.820
Category C	70.820 - 70.830

Check that the ovality of the cylinder liners is within the recommended limits.

	Measurement		Value
-	Cylinder liner ovality (mm)		± 0.05

Check that the taper of the cylinder liners is within the recommended limits.

	Measurement		Value
-	Cylinder liner taper (mm)		± 0.005

If the cylinder bore, taper or ovality measurements are not within the recommended limits, ream the cylinder bores following the recommended oversizes.

In the case of reaming, all the bores must have the same oversize.

	Measurement		Value
-	Cylinder liner bore diameter oversize (mm)		0.4

Clean the lubrication ports in the crankshaft using an air jet.Check the static balance of the crankshaft resting the main journals on suitable parallels.Check that the diameter of the main journals is within specified limits.

	Measurement		Value
-	Main journal diameter (mm)	Category A	47.982 - 47.988
Category B	47.988 - 47.994
Category C	47.994 - 48.000

If the diameter of the main journals is not correct, they should be reground to the recommended undersize.

Because the crankshaft has undergone nitriding, this treatment should be repeated and the size re-checked if it is ground.

	Measurement		Value
-	Main journal undersize (mm)		0.254 - 0.508

Check that the diameter of the crankpins corresponds to the recommended figures.

	Measurement		Value
-	Crankpin diameter (mm)		41.990 ÷ 42.008

If the diameter of the crankpins is not correct, they should be reground to the recommended undersize.

Because the crankshaft has undergone nitriding, this treatment should be repeated and the size re-checked if it is ground.

	Measurement		Value
-	Crankpin undersize (mm)		0.254 / 0.508

Check the main bearings, noting that the half-bearings should not be adapted. Replace them if scoring or signs of binding are noted.Fit the main bearing halves in their seats on the upper crankcase, aligning the lubrication holes and ensuring scrupulous cleaninliness. The centre crankshaft bearing has thrust half-washers incorporated becuase it acts as a thrust carrier.If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions.1. Fit the crankshaft in its seat on the crankcase.2. Fit the calibrated wire (plastigage) for measuring the bearing clearance.

1. Fit the main journal half-bearings in the lower cylinder block/crankcase.2. Fit the lower crankcase to the upper crankcase, checking that the codes stamped on both parts of the crankcase are aligned because the crankcase components are not interchangeable.

1. Tighten bolts (1a) and bolts (1b) securing the lower crankcase. Use tool (1c) for angular tightening.

	Description	Code
1c	Torque wrench	1.860.942.000

1. Remove the lower crankcase and check the crankpin clearance. Use an appropriate gauge to measure the width of the plastigage.

Check one main journal at a time, without rotating the crankshaft.

	Measurement		Value
-	Clearance between main bearings - crankshaft journals (mm)		0.025 - 0.049

After checking all the main journals, apply sealant to the contact surfaces between the lower crankcase and upper crankcase. Then fit the lower crankcase permanently by tightening the bolts to torque in the order described previously.

Apply a 2 mm thick sealant strip continuously to the lower crankcase surface.

Op. 1028H54 PISTON WITH CONNECTING ROD - DISMANTLING AT THE BENCHClean any carbon residues carefully from the pistons.Check that the outer diameter of the pistons corresponds to the recommended figures; if not, replace the piston complete with piston rings and gudgeon pin.

	Measurement		Value
-	Outer diameter (mm)	Category A	70.760 - 70.770
Category B	70.770 - 70.780
Category C	70.780 - 70.790
	from the lower edge of the piston skirt (mm)	6

Position the piston in the cylinder liner and user a feeler gauge to measure the specified clearance.

	Measurement		Value
-	Clearance between piston - cylinder liner (mm)		0.030 ÷ 0.050

Check that the pin seat bore diameter is within specified values, otherwise replace the pin with an oversized pin.

	Measurement		Value
-	Piston pin housing diameter (mm)		17.982 ÷ 17.986

	Measurement		Value
-	Pin oversize (mm)		0.2

Check that the outer diameter of the piston pins corresponds to the recommended figures; if not, replace the worn components.

	Measurement		Value
-	Piston pin outer diameter (mm)		17.970 ÷ 17.974

User a micrometer gauge to measure the thickness of the piston sealing rings.

	Measurement		Value
-	Thickness (mm)	1st sealing ring	1.170 ÷ 1.190
2nd sealing ring	1.175 ÷ 1.190
3rd sealing ring	2.475 - 2.490

	Measurement		Value
-	Sealing ring oversize (mm)		0.4

1. Fit the sealing rings (1a) in the cylinder liner and use a feeler gauge (1b) to check the gap between the seal ends is within specified limits. Otherwise replace the sealing rings.

	Measurement		Value
-	Gap (mm)	1st sealing ring	0.200 ÷ 0.400
2nd sealing ring	0.250 ÷ 0.450
3rd sealing ring	0.200 ÷ 0.450

1. Use a feeler gauge (1a) to check the mating clearance between the retaining rings (1b) and the grooves on the piston (1c).

	Measurement		Value
-	End float (mm)	1st sealing ring	0 - 06
2nd sealing ring	0 - 0.055
3rd sealing ring	0 - 0.0055

Check that the big end and small end diameters are within specified limits.

	Measurement		Value
-	Big end diameter (mm)		45.128 ÷ 45.138

	Measurement		Value
-	Small end diameter (mm)		17.939 ÷ 17.956

Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING Op. 1028H54 PISTON WITH CONNECTING ROD - DISMANTLING AT THE BENCH Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCHPosition the tool for rotating the crankshaft.

	Description	Code
-	Flange	1.860.815.000

Turn the crankshaft using the tool fitted previously.Fit the connecting rod-piston assemblies and align in accordance with the following references.1. Piston class and arrow indicating camshaft side.2. Area where the number of the matching cylinder liner is stamped.3. Gudgeon pin offset.

Letters identifying the cylinder liner classes are shown on the crankcase.

1. Fit the connecting rod-piston assemblies (1a) with half-bearings using tool (1b) to compress the piston rings and then fit the piston into the liner.

	Description	Code
1b	Fitting tool	1.860.700.000

Rotate the engine on the overhaul stand.1. Apply the calibrated wire (plastigate) for measuring the crankpin clearance.

1. Fit the connecting rod caps (1a) complete with half-bearings (1b) and secure by tightening bolts (1c) to the specified torque using tool (1d) for angular tightening.

Fit the connecting rod caps so that the number stamped on each cap faces towards the same side as the number stamped on the big end.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	CONNECTING ROD CAP FASTENERS	M8	2 + 40°

	Description	Code
1d	Torque wrench	1.860.942.000

1. Remove the connecting rod caps and check the crankpin clearance. Use an appropriate gauge to measure the width of the plastigage.

Check one crankpin at a time, without rotating the crankshaft.

	Measurement		Value
-	Crankshaft crankpins (mm)		0.024 - 0.060

If the value measured is not within the recommended figures, replace the connecting rod bearings.Refit the connecting rod caps complete with half-bearings and secure them by tightening the bolts to the recommended torque.Remove the tool for rotating the crankshaft.

	Description	Code
-	Flange	1.860.815.000

Rotate the engine on the overhaul stand.1. Position a new oil pump gasket.2. Fit the front crankcase cover (2a) with built-in oil pump complete with intake chamber and secure by tightening bolts (2b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	ENGINE OIL PUMP	M6 X 20	1

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	ENGINE OIL PUMP	M6 X 32	1

3. Fit the engine oil filter.4. Fit the engine oil pressure sending unit and tighten it to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
4	Bolt	INSUFFICIENT ENGINE OIL PRESSURE SWITCH	M6	1

1. Fit the oil seal to the crankshaft front cover (1a) using the tool (1b).

	Description	Code
1b	Fitting tool	1.860.990.000

1. Fit the crankcase rear cover (1b) and secure by tightening bolts (1a) to the specified torque.

The crankcase rear cover comes complete with an oil seal.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	REAR COVER CRANKSHAFT	M6 X 20	1

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	REAR COVER CRANKSHAFT	M6 X 32	1

1. Fit the flywheel lock.

	Description	Code
1	Counter-torque	1.860.846.000

2. Fit engine flywheel (2a) using retaining washer (2b) and secure by tightening bolts (2c) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2c	Bolt	FLYWHEEL (MECH.)	M8	4.4

1. Position the gear on the crankshaft.2. Fit the crankshaft locking tool.

	Description	Code
2	Counter-torque	1.870.763.000

3. Secure the crankshaft gear by tightening the bolt to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	DRIVE PULLEY(PULLIES) TIMING	M12 X 1.25	2 + 90°

1. Fit the flywheel lock.

	Description	Code
1	Counter-torque	1.860.846.000

2. Fit engine flywheel (2a) using retaining washer (2b) and secure by tightening bolts (2c) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2c	Bolt	FLYWHEEL (MECH.)	M8	4.4

1. Align the driven plate to install clutch assembly (1a), using locating pin (1b).

	Description	Code
1b	Clutch locating tool	1.870.418.000

2. Tighten the bolts fixing the clutch to the engine flywheel.Remove the flywheel locking tool applied previously.

Clean the crankcase and oil sump contact surfaces, removing the silicon sealant residues.1. Apply the specified sealant continuously without any breaks over the entire perimeter of the crankcase sump as shown in the figure.

Join the end to the beginning seamlessly.

	Type	Component	Description	Qty.
1	Silicon sealant	PISTON SET	LOCTITE 5900	-

2. Fit crankcase sump (2a) and secure by tightening bolts (2b) and nuts (2c) to the specified torque.

When positioning the crankcase sump, avoid significant sideways movements that could remove the sealant.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	ENGINE OIL SUMP	M6	1

	Fastening	Component	Ø	Value(daNm)
2c	Nut	ENGINE OIL SUMP	M6	0.5

1. Because the timing is adjusted with the four pistons in line, i.e. half-way along their effective strokes, it is essential to position the crankshaft in phase with the camshafts. They can be approximately positioned by turning the crankshaft gear (1a) until the locating dowel (1b) is positioned opposite to the rpm and TDC sensor seat (1c) with the first cylinder piston in descending phase, i.e. intake.

Remove the protective cover for the rear camshaft gears.1. Unscrew the cylinder head extension side plugs.

1. Position tools (1a) in place of the plugs unscrewed previously, then turn the camshafts until the groove (1b) on the each camshaft is aligned with tool pin (1c). In ths way, the camshafts are in phase.

	Description	Code
1a	Locating pins.	1.860.985.000

Refit the protective cover for the rear camshaft gears.Fit the locating dowels in the cylinder block/crankcase.1. Position the gasket on the cylinder block/crankcase with the working "ALTO" [TOP] uppermost, taking care not to get the gasket or the surface of the cylinder block/crankcase dirty or covered in oil. The diameters of the arrowed holes decrease in order from cylinders 1 to 4 in order to distribute the coolant evenly over the entire crankcase.A = intake sideB = exhaust side.

The cylinder head gasket is ASTADUR type. The material from which the gasket is made undergoes a polymerization process during the operation of the engine so that it becomes considerably harder during usage.

In order for the polymerization process to take place, it is necessary to:

Keep the gasket in its sealed, nylon container;
only take it out shortly before fitting;
not lubricate the gasket or get oil on it, taking care to ensure that the surfaces of the cylinder block/crankcase and cylinder head are clean.

Position the cylinder head on the crankcase by aligning the locating pins.1. Tighten the cylinder head bolts (1a) to the recommended torque using tool (1b) for angular tightening.

Follow the order shown in the figure for each tightening sequence.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	CYLINDER HEAD	M9 x 1.25	3 + 90° + 90°

	Description	Code
1b	Torque wrench	1.860.942.000

1. Position the cylinder head extension gasket on the cylinder head mating surface.2. Position the tappet retaining tools beneath the cylinder head extension, then place the cylinder head extension on the cylinder head and withdraw the tools.3. Use tool (3a) to tighten camshaft housing bolts (3b) to the specified torque.4. Refit the plugs and tighten to the specified torque.

	Description	Code
2	Tappet retaining tool	1.860.988.000

	Description	Code
3a	Spanner	1.860.834.000

	Fastening	Component	Ø	Value(daNm)
3b	Hex-headed bolt	CYLINDER HEAD EXTENSION	M8 X 1	1.5

Fit the timing drive pulley by screwing in the bolt.1. Position tools (1a) in their seats on the 1st and 2nd cylinder. Tighten parts (1b) to a torque of 0.5 daNm.2. Turn the crankshaft in its normal direction of rotation until surface (2a) on the tool mobile part is aligned with surface (2b) on the part secured in the spark plug socket. When both tools positioned in the spark plug sockets are in this condition, the engine pistons will be aligned, i.e. half-away along their effective strokes.

The pistons were approximately aligned previously.

Crank the crankshaft. Proceed gradually to prevent the tool pins being expelled by compression of the pistons.

Camshaft timing was adjusted previously by applying tools (3b).

	Description	Code
1a	Bearings	1.860.992.000

	Description	Code
3b	Locating pins.	1.860.985.000

1. Fit the timing belt by fitting firstly over the crankshaft gear (1a) and then over the water pump pulley (1b), the timing drive pulley (1c) and lastly the belt tensioner fixed pulley 1(d).

Ensure that this operation is performed with the camshaft pulley (1c) slack.

1. Use suitable round-nosed pliers to turn the automatic tensioner to the position of maximum tension, i.e. with the mobile reference (1a) located as shown in the figure. Then secure nut (1b) fastening the tensioner to the mount.

1. Use tool (1a) to tighten the camshaft pulley bolts (1b) to the specified torque.

	Description	Code
1a	Support for counter-torque	1.860.831.000

	Description	Code
1a	Spanner for rotating timing pullies	1.860.831.002

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	TIMING DRIVEN PULLIES	M12 X 1.25	12

Remove the tools postioned previously to adjust the timing and lock the camshaft and turn the crankshaft through two revolutions in its direction of rotation to settle the timing drive belt.

1. Loosen the nut securing the tensioner and align the mobile pointer (1a) with the fixed reference (1b), holding the tensioner with the round-nosed pliers at all times in order not to release the tension of the belt tensioner too suddenly.2. Once both references are aligned, tighten nut (2a) securing the tensioner to the specified torque.Turn the crankshaft through two revolutions in its normal rotation direction, then reposition the tools used to adjust engine timing and check the engine is in phase.Refit the cylinder head extension side plugs.

	Fastening	Component	Ø	Value(daNm)
2a	Nut	MOBILE TIMING TENSIONER	M8	2.5

Refit the timing drive belt lower guard and upper guard.Fit the auxiliary drivebelt pulley to the crankshaft and tighten the bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CRANKSHAFT PULLEY	M8	2.2

Fit the rpm and TDC sensor and secure it using the bolt.Refit the oil dipstick.Refit the intake manifold complete with injectors and throttle body.Position the electrical wiring and connect the electrical connections.

	Description	Connector
-	Integrated throttle casing actuator	N75

	Description	Connector
-	Fuel vapour recovery solenoid valve	L10

	Description	Connector
-	Engine temperature sending unit	K36

	Description	Connector
-	Injector coupling	D81

	Description	Connector
-	Earth on engine	C40

	Description	Connector
-	Detonation sensor	K50

	Description	Connector
-	Engine oil pressure sensor (switch)	K30

	Description	Connector
-	Rpm sensor	K46

Position the relevant part of the wiring in the appropriate duct. Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE