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

Removing ( Refitting ) Rotate the crankcase through 180° on the overhaul stand.1. Undo the bolts (1a) and remove the alternator (1b).

	Description	Connector
1b	Alternator	A10

2. Undo the bolts (2a) and remove the alternator rear mounting bracket (2b).3. Undo the bolts (3a) and remove the intermediate shaft support (3b). 1. Undo the bolts (1a) and remove the air conditioner compressor (1b).2. Undo the bolts (2a) and remove the air conditioning compressor mounting (2b).3. Remove the oil filter.4. Undo the pin (4a) and remove heat exchanger (4b) complete with pipes. 1. Fit the tool.

	Description	Code
1	Counter-torque	1.860.846.000

1. Undo the bolts (1a) and remove the crankshaft pulley (1b).2. Remove the timing belt.3. Undo the bolt (left hand thread) (3a) and remove the toothed timing drive pulley (3b). 1. Undo the bolts (1a) and remove the flywheel (1b).2. Remove the tool.

	Description	Code
1	Counter-torque	1.860.846.000

1. Undo the bolts (1a) and timing side power unit support (1b).2. Undo the bolt (2a) and remove the fixed timing tensioner (2b).3. Undo the bolt (3a) and remove the auxiliary units drive belt automatic belt tensioner (3b).4. Undo the bolts (4a) and remove the support (4b) complete with timing belt tensioner. 1. Undo the bolts (1a) and remove the crankcase front cover (4b) with the oil pump incorporated (1b) complete with intake (1c).Remove the seal. Fit the tool.

	Description	Code
-	Flange	1.860.815.000

Rotate the crankcase through 180° on the overhaul stand.Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C.1. Undo the bolts (1a) and remove the connecting rod cap (1b).2. Remove the lower connecting rod half-bearing.3. Remove the connecting rod-piston assembly.4. Remove the upper connecting rod half-bearing.Carry out the same operations to remove the pistons and connecting rods for the remaining cylinders.Remove the tool.

	Description	Code
-	Flange	1.860.815.000

5. Undo the bolts (5a) and remove the crankcase rear cover (5b) with the oil seal incorporated.Check that the crankshaft endfloat corresponds to the recommended figures using a magnetic base and dial gauge.

	Measurement		Value
-	End float (mm)		0.049 - 0.211

If the value for the crankshaft endfloat does not correspond with the recommended figures, when refitting, regrind the crankcase seat and use suitable oversize thrust washers.6. Undo the bolts (6a) and remove the bearing caps (6b).7. Remove the lower main journal half-bearings.8. Remove the crankshaft.9. Remove the upper main journal half-bearings.10. Remove the thrust washers.11. Undo the bolts (11a) and remove the jets (11b) from the crankcase.12. Undo the bolt (12a) and remove the rpm and timing sensor (12b).13. Remove the engine oil minimum pressure warning light sensor. 1. Undo the bolts (1a) and remove the flange (1b) complete with oil return pipe from the turbocharger.2. Undo the connector (2a) and remove the turbocharger oil supply pipe (2b).3. Undo the bolts (3a) and remove the turbocharger mounting bracket (3b). Rotate the crankcase through 90° on the overhaul stand.Undo the bolts and remove the crankcase from the mounting brackets, then place it on a special workbench.Undo the bolts and remove the flywheel guard.    Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING.Undo the bolts and remove the intake duct from the oil pump.    Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH. Refitting ( Removing ) Wash the dismantled components.Fit the water/oil sealing plugs in the crankcase using suitable fitting tools.Lubricate all the mechanical components with engine oil.Check that the cylinder head support surface does not have cracks or superficial grooves.Check that the planarity of the cylinder head support surface corresponds to the recommended figure; if this is not the case, regrind the cylinder head support surface.

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

1. Measure the cylinder bore diameter using the diagram illustrated.

	Measurement		Value
1	Cylinder liner diameter (mm)	Category A	82.000 - 82.010
Category B	82.010 - 82.020
Category C	82.020 - 82.030

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

	Measurement		Value
-	Cylinder liner taper (mm)		< 0.005

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

	Measurement		Value
-	Cylinder liner ovality (mm)		< 0.05

If the cylinder bore 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 oversize (mm)		0.1

1. Fit the bearing caps.

The bearing caps have progressively numbered references (from zero to four starting from the front of the engine) which define the fitting position.

1. Tighten the bearing cap bolts (1a) to the recommended torque using the angular tightening tool (1b).

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	MAIN BEARING CAPS	M12	(Engine crankcase side) 2.5 +100°

	Description	Code
1b	Torque wrench	1.860.942.000

2. Check that the diameter of the main journal seats is within specified limits.

	Measurement		Value
2	Main journal seat diameter (mm)		63.691 ÷ 63.732

Check that there are no deposits or blockages in the crankshaft lubrication ducts.Check that the diameter of the main journals is within specified limits.

	Measurement		Value
-	Main journal diameter (mm)	Category A	59.994 ÷ 60.000
Category B	59.987 ÷ 59.993
Category C	59.982 ÷ 59.986

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

	Measurement		Value
-	Main journal diameter undersize (mm)		0.127

Crankpin undersizes higher than the value mentioned will adversely affect the structural resistance of the crankshaft (following contact between the tool and rolled connectors). As far as the above is concerned, if the regrinding requires undersizes greater than 0.127 mm, then the crankshaft must be replaced and a new one ordered from the Parts Dept. The half-bearings used for undersizes of more than 0.127 mm should not be ordered from the Parts Dept. (even if the number is still quoted).

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

	Measurement		Value
-	Crankpin diameter (mm)	Category A	50.799 ÷ 50.805
Category B	50.793 ÷ 50.799
Category C	50.787 ÷ 50.793

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

	Measurement		Value
-	Crankpin diameter undersize (mm)		0.127

Bearing undersizes higher than the value mentioned will adversely affect the structural resistance of the crankshaft (following contact between the tool and rolled connectors). As far as the above is concerned, if the regrinding requires undersizes greater than 0.127 mm, then the crankshaft must be replaced and a new one ordered from the Parts Dept. The half-bearings used for undersizes of more than 0.127 mm should not be ordered from the Parts Dept. (even if the number is still quoted).

Check that the small end bush internal diameter is within the recommended limits; if not, replace the worn small end bush (    1028H58 BOCCOLA PIEDE di BIELLA (una) - Sost.).

	Measurement		Value
-	Inner diameter (mm)		26.006 - 26.012

Check that the inner diameter of the piston bushes corresponds to the recommended figures; if not, replace the piston complete with piston rings, gudgeon pin and bushes.

	Measurement		Value
-	Piston bush internal diameter (mm)		25.999 - 26.004

Check that the outer diameter of the gudgeon pins is within the recommended limits; if not, replace the worn gudgeon pins.

	Measurement		Value
-	Outer diameter (mm)		25.982 - 25.988

Fit the piston rings in the cylinder liner and check that the opening between the ends is within the recommended values; if this is not the case, replace the circlips.

	Measurement		Value
-	Gap (mm)	1st Ring	0.25 - 0.40
2nd ring	0.25 - 0.50
Oil scaper ring	0.25 - 0.50

Check that the outer diameter of the pistons is within specified limits; if not, replace the piston complete with sealing rings and pin.

	Measurement		Value
-	Outer diameter (mm)	Category A	81.920 ÷ 81.930
Category B	81.930 ÷ 81.940
Category C	81.940 ÷ 81.950

Measure perpendicular to the gudgeon pin axis, 8 mm from the lower edge of the skirt.

1. Check that the axial clearance (1a) between the second ring (1b) and the housing in the piston (1c) corresponds to the recommeded figure.

	Measurement		Value
1a	End float (mm)		0.020 ÷ 0.060

Check that the axial clearance between the oil scraper ring and the housing in the piston corresponds to the recommeded figures.

	Measurement		Value
-	End float (mm)		0.030 - 0.065

1. Fit the caps (1b) on the connecting rods (1a) and secure them tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	CONNECTING ROD CAPS	M9	2.5 + 60°

Use the special tool for the angular tightening of the connecting rod cap bolts.

	Description	Code
-	Torque wrench	1.860.942.000

2. - Check that the diameter of the big end corresponds to the recommended figures; if not, replace the connecting rods.

	Measurement		Value
2	Big end diameter (mm)		53.897 ÷ 53.909

    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 BENCH.Fit the intake duct and secure it using the bolts.Check that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it.Fit the flywheel guard on the crankcase and tighten the bolts.Fit the crankcase on the overhaul stand and secure it using the bolts.Fit the turbocharger mounting bracket and secure it using the bolts.Fit the oil supply pipe to the turbocharger and tighten the connector.Fit the flange complete with oil return pipe to the sump from the turbocharger and secure it using the bolts.Fit the minimum engine oil pressure warning light sensor and tighten it to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	INSUFFICIENT ENGINE OIL PRESSURE SWITCH	-	1.9 - 2.3

Fit the rpm and timing sensor and secure it using the bolt.Fit the jets on the crankcase and secure them using the bolts.Fit the thrust washers on the third main journal.

The crankshaft supplied by the Parts Dept. comes without half-bearings and the main journals and crankpins are the "normal" size; the half-bearings to be fitted must therefore be selected identifying the class of each main journal and crankpin for the new crankshaft.

The following must be determined for the selection of main journal half-bearings:the numerical code stamped on the flywheel;the paint mark, if present, next to the main journals.Below is an example of the identification of main journal grades. 1 - Crankpin identification numerical code: the number on the left refers to the first timing side bearing; the final "N" is a code that does not matter for 4 cylinder engines; for 5 cylinder engines the numerical code for the 5th connecting rod bearing is in place of the "N"2 - Main journal identification numerical code: the first number on the left refers to the first timing side bearing; the final "N" is a code that does not matter for 4 cylinder engines; for 5 cylinder engines the numerical code for the 6th connecting rod bearing code is in place of the "N"3 - Series of numbers (if present), in groups of two digits, which indicate the dimensions (thousandth part) of the main journals: the first two numbers on the left refer to the first timing side bearing

Only use the codes that relate to the key, all other codes on the flywheel should not be used.

For the identification of the main journal grade, refer to the numerical code for reference 2.In the case of the example, the numbers 11111N indicate that all five bearings are Grade A (red) as indicated below.A further method for identifying the grade of the bearings is to read reference 3 (if present) in the diagram.In the case of the example, the number 94 (first on the left) corresponds to the dimensions 52.994 for the first timing side bearing which identifies Grade A (red); the same method should be applied for other groups of two digits for the same reference 3 (97 - 95 - 95 - 94).Main journal grade A - Normal, diameter 59.994.60.000 mm, RED paint mark, numerical code 1 (94 00)°Main journal grade B - Normal, diameter 59.987.59.993 mm, BLUE paint mark, numerical code 2 (87 93)°Main journal grade C - Normal, diameter 59.982.59.986 mm, YELLOW paint mark, numerical code 3 (82 86)°Bearing grade D - Undersize, diameter 59.867.59.873 (*) mm, BROWN paint mark, numerical code 6 (67 73)°Bearing grade E - Undersize, diameter 59.860.59.866 (*) mm, GREEN paint mark, numerical code 7 (60 66)°Bearing grade F - Undersize, diameter 55.885.59.859 (*) mm, BLACK paint mark, numerical code 8 (55 59)°(*) 0.127 mm undersize(°) Last two numbers (thousandth part) of the main journal dimensionsIn the case of the usage of a crankshaft where the maximum undersize for the bearings is 0.127 mm through grindings, the grade should be selected through the measurement of the diameter of the bearing using the above as a reference.Having defined the grade and the colour of each new or reground crankshaft bearings, it is necessary to select the thickness of the bearings that should be the same colour as the corresponding bearing; the pair of half-bearings required can be ordered from the Parts Dept. by quoting the order no.The above is designed to guarantee the optimum operational clearances for all the bearings.Lastly, we wish to point out that, generally, the clearance between the main journal and the half-bearing, obtained through the selection method indicated above, should be within the following values:Minimum: 0.025 mm - Maximum: 0.052 mm; this value can be measured, as a final check, using the calibrated wire (plastic gauge).1. Fit the jets on the crankcase and secure them using the bolts (1a).

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	PISTON COOLING NOZZLES	-	0.9 - 1.2

2. Fit the rpm and timing sensor and secure it using the bolt (2a).

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	ENGINE RPM AND TIMING SENSOR	-	0.8 ÷ 1.2

3. Fit the engine oil minimum pressure warning light sensor to the crankcase.

	Fastening	Component	Ø	Value(daNm)
3	-	INSUFFICIENT ENGINE OIL PRESSURE SWITCH	M14	2.7 ÷ 4.0

Fit the thrust washers on the third main journal. Fit the main journal half-bearings in the cylinder block/crankcase.Fit the crankshaft in the crankcase.1. Fit the main bearing caps complete with half-bearings.

The bearing caps have progressively numbered references (from zero to four starting from the pulley side) which define the fitting position.

1. Tighten the bearing cap bolts (1a) to the recommended torque using the angular tightening tool (1b).

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	MAIN BEARING CAPS	M12	2.5 + 100°

	Description	Code
1b	Torque wrench	1.860.942.000

1. Fit the tool.

	Description	Code
1	Flange	1.860.815.000

Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C.1. Fit the piston-connecting rod assembly (1a) complete with half-bearing using the tool (1b).

For the selection of the connecting rod half-bearings, follow the procedure described previously for the main journal half-bearings.

The piston-connecting rod assemblies are fitted in the cylinder block/crankcase so that the combustion chamber in the piston is facing the intake side.

2. Fit the connecting rod cap (2a) complete with half-bearing and secure it without tightening the bolts (2b).

Fit the connecting rods so that the number stamped on each rod faces toward the same side as the number stamped on the big end (inlet side).

Carry out the same operations to refit the pistons and connecting rods for the remaining cylinders. 1. Tighten the connecting rod cap bolts (1a) to the recommended torque using the angular tightening tool (1b).

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	CONNECTING ROD CAPS	M9	2.5 + 60°

	Description	Code
1b	Torque wrench	1.860.942.000

Remove the tool.

	Description	Code
-	Flange	1.820.815.000

1. Fit the crankcase rear cover (1a) with the oil seal incorporated using a suitable tool.2. Tighten the crankcase rear cover bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	REAR COVER CRANKSHAFT	M6	(Engine crankcase side) 0.8 - 1.2

Remove the tool. 1. Place the crankcase front cover with built-in oil pump (1a) in its housing complete with intake (1b) and gasket.2. Tighten the crankcase front cover bolts, complete with oil pump, to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	FRONT COVER CRANKSHAFT	M6	(Engine crankcase side) 0.9 -1.3

Apply the recommended sealant to the entire perimeter of the crankcase sump.

	Type	Component	Description	Qty.
-	Silicon sealant	ENGINE OIL SUMP	Dow Corning 7091	-

1. Fit the crankcase sump.2. Tighten the side bolts (2a) fixing the crankcase sump to the recommended torque using the tool (2b).

	Fastening	Component	Ø	Value(daNm)
2a	Side bolt	ENGINE OIL SUMP	M6	(Engine crankcase side) 0.9 - 1.2

	Description	Code
2b	Spanner	1.860.833.000

3. Tighten the front and rear bolts (3a) fixing the crankcase sump to the recommended torque using the tool (3b).

	Fastening	Component	Ø	Value(daNm)
3a	Front and rear bolt	ENGINE OIL SUMP	M8	(Engine crankcase side) 2.3 - 3.3

	Description	Code
3b	Spanner	1.860.834.000

Rotate the engine through 180° on the overhaul stand.1. Fit the tool.

	Description	Code
1	Counter-torque	1.860.846.000

2. Fit the flywheel (2a) and tighten the fixing bolts (2b) to the recommended torque using thread-locking agent.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	FLYWHEEL (MECH.)	M12	(Engine crankcase side) 14.7 -21.2

1. Fit the toothed drive pulley (1c) and tighten the bolt (left hand thread) (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Left hand bolt	DRIVE PULLEY(PULLIES) TIMING	M16	(Engine crankcase side) 33.9 -44.1

Remove the tool.

	Description	Code
1	Counter-torque	1.860.846.000

Fit the oil supply pipe to the turbocharger to the crankcase.Fit the fixed tensioner mounting bracket.Fit the fixed timing system tensioner in its housing and secure it using the bolts.Fit the timing side power unit support.Fit the auxiliary drive belt automatic tensioner and secure it with the bolt.Place the heat exchanger complete with pipes in its housing.Tighten the heat exchanger connector to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Connector	ENGINE OIL HEAT EXCHANGER	-	6.0

Place the oil filter in its housing and tighten it fully by hand after having lubricated the gasket using engine oil.Fit the air conditioning compressor support and secure it using the bolts.Fit the air conditioning compressor and secure it using the bolts without tightening them.Fit the intermediate shaft support and secure it using the bolts.Fit the bolt connecting the intermediate shaft support to the crankcase sump.Fit the alternator rear mounting bracket and secure it using the bolts without tightening them.Fit the alternator and fasten it using the bolts.Tighten the alternator rear mounting bracket bolts.Fit the mounting complete with pressure pump and secure it using the side bolts without tightening them.1. Measure the piston projection in two places at 180° on the gudgeon pin axis using the tool and take the average of the two values measured for each piston.

	Description	Code
1	Dial gauge support	1.870.404.000

Select the correct size cylinder head gasket depending on the maximum average protrusions for each individual piston.

	Measurement		Value
-	Average maximum piston projection (mm)		0.014 ÷ 0.104
	Cylinder head gasket size (no reference) (mm)	0.770 ÷ 0.870

	Measurement		Value
-	Average maximum piston projection (mm)		0.105 ÷ 0.205
	Cylinder head gasket size (one reference) (mm)	0.870 ÷ 0.970

	Measurement		Value
-	Average maximum piston projection (mm)		0.206 ÷ 0.294
	Cylinder head gasket size (two references) (mm)	0.970 ÷ 1.070

Figures for Euro 3 engines

Position the cylinder head locating bushes on the engine block.Fit the cylinder head gasket selected.

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 sealed in its container until it is fitted; do not lubricate the gasket or contact surfaces or get oil on them.

Position the cylinder head on the cylinder block/crankcase.1. Tighten the cylinder head bolts (1a) to the recommended torque using the angular tightening tool (1b).

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

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	CYLINDER HEAD	M10	(Engine crankcase side) 2.0 +4.5 + 90° + 90° + 90°

	Description	Code
1b	Torque wrench	1.860.942.000

Fit the tappet cover, complete with gasket, and secure it by tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAM COVER	M6	(Cylinder head side) 0.9 -1.2

Fit the front bolts for the pressure pump and tighten them together with the side bolts fitted previously.1. Undo the oil pump bolt shown in the diagram.Temporarily fit the toothed timing drive belt on the drive pulley.2. Fit the tool (2a) and fasten it using the calibrated screw (2b).

The crankshaft must be rotated, using small movements, to allow the locating dowel on the timing drive pulley to be inserted in the opening in the tool.

	Description	Code
2a	Template	1.860.905.000

	Description	Code
2b	Calibrated screw	1.860.905.010

1. Rotate the driven toothed pulley until the timing references are aligned.2. Fully fit the toothed timing drive belt.3. Use a screwdriver for leverage in the opening (3a) until the reference for the tensioner (3b) is aligned with the opening reference (3c) and, in this position, tighten the nut (3d) for the belt tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3d	Nut	MOBILE TIMING TENSIONER	M10	(cylinder head side) 4.2 - 5.2

Remove the tools.

	Description	Code
-	Template	1.860.905.000

	Description	Code
-	Calibrated screw	1.860.905.010

Tighten the oil pump bolt removed previously. Rotate the crankshaft through two revolutions.Recheck that the timing references and the tensioning references on the timing belt tensioner are aligned.Fit the timing belt covers and secure them using the bolts.Fit the power unit reaction rod mounting bracket.Fit the crankshaft pulley and secure it using the bolts.Fit the exhaust manifold gasket.Fit the exhaust manifold, complete with turbocharager and E.G.R. valve and secure it tightening the nuts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	EXHAUST MANIFOLD/S	M8	(Cylinder head side) 2.3 - 3.3

Connect the oil inlet pipe to the turbocharger.Connect the sump oil return pipe to the turbochager.Fit the protection for the oil return pipe to the sump from the turbocharger and secure it using the bolts.Tighten the nut fixing the exhaust manifold to the cylinder block/crankcase.Remove the seal.Connect the exhaust gas recirculation pipe and secure it to the using the nuts.Tighten the exhaust gas recirculation pipe bracket bolt.Fit the turbocharger heat shield and secure it using the bolts.Connect the water outlet hose fitting from the heat exchanger.Tighten the bolt for the water outlet pipe from the heat exchanger.Connect the water supply pipe to the heat exchanger.Fit the bracket.Fit the oil vapour separator complete with bracket and secure it using the nuts.Connect the condensation oil recovery pipe to the crankcase sump.Connect the engine oil vapour recovery pipe to the crankcase.Cconnect the fuel supply pipe to the pressure pump.Place a new pipe from the pressure pump to the single fuel manifold in its housing and secure it using the connectors without tightening them.Tighten the connector for the pipe from the pressure pump to the single fuel manifold, pump side, to the recommended torque using a spanner.

	Fastening	Component	Ø	Value(daNm)
-	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M12	(Pressure pump side) 2.2

Tighten the connector for the pipe from the pressure pump to the single fuel manifold, fuel manifold side, to the recommended torque using a suitable commercial wrench.

	Fastening	Component	Ø	Value(daNm)
-	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14	(Fuel manifold side) 2.2

Fit the oil dipstick assembly and secure it using the bolts.Fit the auxiliary drive belt pulley and secure it using the bolt.Fit the auxiliary drivebelt by using a wrench as a lever on the automatic belt tensioner.    Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE.