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 - CROMA - eLearn

194002124 - 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. Undo the bolts (1a) and remove the air conditioning compressor (1b) from the mounting.2. Undo the bolts (2a) and remove the air conditioner compressor mounting (2b).

1. Undo the bolts (1a) and remove the engine oil filter and heat exchanger mounting (1b).2. Undo the bolts (2a) and remove the alternator (2b).

1. Undo the bolts (1a) and (1b), then remove the pressure pump support assembly (1c).- Remove the locating pins.

1. Undo the bolt (1a) and remove the rpm sensor (1b).

- Undo the bolts and remove the flywheel side oil seal cover.1. Fit the tool for rotating the crankshaft.

Tool	Description	Function	Validity
1820618000	Flange	Crankshaft rotation	1.9 JTD 8V1.9 JTD 16V

1. Undo the bolts (1a) and remove the engine oil intake (1b).2. Undo the bolt (2a) and remove the timing toothed drive pulley (2b).3. Undo the bolts (3a) and remove the crankshaft oil seal front cover (3b).

1. Undo the bolts (1a) and remove the fixed timing tensioners support (1b).

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.

Tool	Description	Function	Validity
1820618000	Flange	Crankshaft rotation	1.9 JTD 8V1.9 JTD 16V

- Check that the crankshaft endfloat corresponds to the recommended figures using a magnetic base and dial gauge.

Measurement	Value	Validity
Crankshaft endfloat (mm)	0.049 ÷ 0.211	1.9 JTD 16V

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. 1. Undo the bolts (1a) and remove the connecting rod caps (1b).2. Remove the lower main journal half-bearings.3. Remove the crankshaft.4. Remove the upper main journal half-bearings.5. Remove the thrust washers.6. Undo the bolts (6a) and remove the jets (6b) from the crankcase.

- Remove the cylinder block/crankcase from the support tools, then place on a workbench. 1028H60 SERIE PISTONI, PERNI e ANELLI - Sost. a pistoni con bielle al banco - Comprende quadratura ed equilibratura 1084B18 POMPA OLIO MOTORE, staccata - Verifica al bancoDrill and remove the water/oil sealing plugs from the crankcase to allow for washing the ducts.

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	Validity
Cylinder head support surface flatness (mm)	< 0.1	1.9 JTD 16V

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

Measurement	Value	Validity
Cylinder liner inner diameter - Grade A (mm)	82.000 ÷ 82.010	1.9 JTD 16V

Measurement	Value	Validity
Cylinder liner inner diameter - Grade B (mm)	82.010 ÷ 82.020	1.9 JTD 16V

Measurement	Value	Validity
Cylinder liner inner diameter - Grade C (mm)	82.020 ÷ 82.030	1.9 JTD 16V

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

Measurement	Value	Validity
Cylinder liner taper (mm)	< 0.005	1.9 JTD 16V

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

Measurement	Value	Validity
Cylinder liner ovality (mm)	< 0.05	1.9 JTD 16V

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	Validity
Cylinder liner bore diameter oversize (mm)	0.1	1.9 JTD 16V

1. Temporarily 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).

Component	Fastening	dia	Value (daNm)	Validity
Bearing caps	Bolt	M12	1.9 ÷ 2.1 + 100°	1.9 JTD 16V

Tool	Description	Function	Validity
1860942000	Torque wrench	Tighten bolts to torque plus angle

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

Measurement	Value	Validity
Main journal seat diameter (mm)	63.705 ÷ 63.718	1.9 JTD 16V

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	Validity
Main journal diameter - Category A (mm)	59.994 ÷ 60.000	1.9 JTD 16V

Measurement	Value	Validity
Main journal diameter - Category B (mm)	59.988 ÷ 59.994	1.9 JTD 16V

Measurement	Value	Validity
Main journal diameter - Category C (mm)	59.982 ÷ 59.988	1.9 JTD 16V

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

Measurement	Value	Validity
Main journal diameter undersize (mm)	0.127	1.9 JTD 16V

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	Validity
Crankpin diameter - Category A (mm)	50.799 ÷ 50.805	1.9 JTD 16V

Measurement	Value	Validity
Crankpin diameter - Category B (mm)	50.793 ÷ 50.799	1.9 JTD 16V

Measurement	Value	Validity
Crankpin diameter - Category C (mm)	50.787 ÷ 50.793	1.9 JTD 16V

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

Measurement	Value	Validity
Crankpin diameter undersize (mm)	0.127	1.9 JTD 16V

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 half-bearings making sure they are scrupulously clean.

If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions.

Fit the crankshaft in the crankcase.1. Fit the calibrated wire (plastigage) for measuring the bearing clearance.

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

1. Fit the main bearing caps complete with half-bearings.

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).

Component	Fastening	dia	Value (daNm)	Validity
Bearing caps	Bolt	M12	1.9 ÷ 2.1 + 100°	1.9 JTD 16V

Tool	Description	Function	Validity
1860942000	Torque wrench	Tighten bolts to torque plus angle

1. Remove the bearing caps fitted previously and, using a suitable graduated measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).

Measurement	Value	Validity
Clearance between main journals - crankshaft bearings (mm)	0.011 ÷ 0.071	1.9 JTD 16V

If the figure measured is outside of the tolerance, replace the half-bearings with ones of the correct size and category.

Measure the clearance for all the bearings taking care to take the measurements one at a time without moving the crankshaft at any time.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	Validity
Small end bush inner diameter (mm)	26.006 ÷ 26.014	1.9 JTD 16V

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

Measurement	Value	Validity
Gudgeon pin housing diameter in piston (mm)	25.999 ÷ 26.004	1.9 JTD 16V

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

Measurement	Value	Validity
Gudgeon pin outer diameter (mm)	25.982 ÷ 25.987	1.9 JTD 16V

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	Validity
Cylinder compression 1st piston ring gap (mm)	0.20 ÷ 0.35	1.9 JTD 16V

Measurement	Value	Validity
Cylinder compression 2nd piston ring gap (mm)	0.60 ÷ 0.80	1.9 JTD 16V

Measurement	Value	Validity
Piston oil scraper ring gap (mm)	0.25 ÷ 0.50	1.9 JTD 16V

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	Validity
Piston outer diameter -grade A (mm)	81.920 ÷ 81.930	1.9 JTD 16V

Measurement	Value	Validity
Piston outer diameter - grade B (mm)	81.930 ÷ 81.940	1.9 JTD 16V

Measurement	Value	Validity
Piston outer diameter - grade C (mm)	81.940 ÷ 81.950	1.9 JTD 16V

Measure perpendicular to the gudgeon pin axis, 9 mm from the lower edge of the skirt.

1. Check that the backlash (1a) between the first-second ring (1b) and the seats in the piston (1c) corresponds to the recommeded figures.

Measurement	Value	Validity
Cylinder compression 1st piston ring endfloat (mm)	0.105 ÷ 0.150	1.9 JTD 16V

Measurement	Value	Validity
Cylinder compression 2nd piston ring endfloat (mm)	0.050 ÷ 0.090	1.9 JTD 16V

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

Measurement	Value	Validity
Oil scraper ring endfloat (mm)	0.030 ÷ 0.070	1.9 JTD 16V

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

Component	Fastening	dia	Value (daNm)	Validity
Connecting rod big end bearing caps	Bolt	M9	2.4 ÷ 2.6 + 60°	1.9 JTD 8V1.9 JTD 16V

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

Tool	Description	Function	Validity
1860942000	Torque wrench	Tighten bolts to torque plus angle

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

Measurement	Value	Validity
Big end inner diameter (mm)	53.897 ÷ 53.909	1.9 JTD 16V

1028H60 SERIE PISTONI, PERNI e ANELLI - Sost. a pistoni con bielle al banco - Comprende quadratura ed equilibratura 1084B18 POMPA OLIO MOTORE, staccata - Verifica al bancoCheck that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it.Place the engine block on the overhaul stand using the mounting bracket.

Tool	Description	Function	Validity
1871000000	Overhaul stand	Engine support for overhauling

Tool	Description	Function	Validity
1871000000	Bracket	Positioning engine on overhaul stand

Place the jets in their housings in the crankcase and secure them using the bolts.Place the thrust washers in their seats on the third main bearing.The main journal half-bearings fitted on the crankshaft have been selected for their optimum fitting clearance.

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 left number refers to the first timing side bearing; the final "N" is an insignificant code for 4 cylinder engines.2 - Main journal identification numerical code: the first number refers to the first timing side bearing; the final "N" is an insignificant code for 4 cylinder engines.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 key.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 IDENTIFICATIONMain journal grade A (normal), diameter 59.994.60.000 mm, RED paint mark, numerical code 1 (94 00)*Main journal grade B (normal), diameter 59.988.59.994 mm, BLUE paint mark, numerical code 2 (88 94)*Main journal grade C (normal), diameter 59.982.59.998 mm, YELLOW paint mark, numerical code 3 (82 88)*Main journal grade D (0.127 mm undersize), diameter 59.867.59.873 mm, BROWN paint mark, numerical code 6 (67 73)*Main journal grade E (0.127 mm undersize), diameter 59.861.59.867 mm, GREEN paint mark, numerical code 7 (61 67)*Main journal grade F (0.127 mm undersize), diameter 59.855.59.861 mm, BLACK paint mark, numerical code 8 (55 61)*(*): Last two numbers (thousandth part) of the main journal dimensions.- In 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: 0.011 mm - Maximum: 0.071 mm; this value can be measured, as a final check, using the calibrated wire (plastic gauge).Place the upper main bearing half-bearings in their seats in the engine block.Place the crankshaft in its housing in the crankcase.- Place the bearing caps complete with lower half-bearings in position.

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

- Tighten the connecting rod cap bolts to the recommended torque using the angular tightening tool.

Component	Fastening	dia	Value (daNm)	Validity
Bearing caps	Bolt	M12	1.9 ÷ 2.1 + 100°	1.9 JTD 16V

Tool	Description	Function	Validity
1860942000	Torque wrench	Tighten bolts to torque plus angle

- Fit the tool.

Tool	Description	Function	Validity
1820618000	Flange	Crankshaft rotation	1.9 JTD 8V1.9 JTD 16V

Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C.1. Place the piston and connecting rod assembly (1a) in its housing complete with half-bearing using a suitable 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 should be fitted in the cylinder block/crankcase so that the drain on the piston skirt is aligned with the oil jet on the engine block.

Carry out the same operations to fit the pistons and connecting rods for the remaining cylinders.

1. Test the crankpin clearance by applying plastigage to measure crankpin installation clearance.

Place the crank pin caps complete with half-bearings in their seats.

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).

- Tighten the bolts to the recommended torque, using the angular tightening tool.

Component	Fastening	dia	Value (daNm)	Validity
Connecting rod big end bearing caps	Bolt	M9	2.4 ÷ 2.6 + 60°	1.9 JTD 8V1.9 JTD 16V

Tool	Description	Function	Validity
1860942000	Torque wrench	Tighten bolts to torque plus angle

Undo the nuts and remove the connecting rod caps with the half-bearings fitted previously.1. Use an appropriate graduated measuring tool (1a) to measure the clearance indicated by the plastigage (1b).

Measurement	Value	Validity
Clearance between crankpins - crankshaft bearings (mm)	0.030 ÷ 0.056	1.9 JTD 16V

If the value measured is not within the recommended figures, replace the connecting rod bearings.Carry out this test on all the crankpins, one at a time, without ever turning the crankshaft.Fit the connecting rod cap complete with half-bearing and secure it without tightening the bolts.

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).

- Tighten the connecting rod cap bolts to the recommended torque using the angular tightening tool.

Component	Fastening	dia	Value (daNm)	Validity
Connecting rod big end bearing caps	Bolt	M9	2.4 ÷ 2.6 + 60°	1.9 JTD 8V1.9 JTD 16V

Tool	Description	Function	Validity
1860942000	Torque wrench	Tighten bolts to torque plus angle

- Remove the tool.

Tool	Description	Function	Validity
1820618000	Flange	Crankshaft rotation	1.9 JTD 8V1.9 JTD 16V

Place the crankshaft front cover in its seat complete with gasket and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Crankshaft oil seal cover	Bolt (pretreated to be replaced)	M6	(engine crankcase side) 0.8 - 1.0	1.9 JTD 16v

- Position the engine oil intake duct in its housing and secure it using the bolts. 1. Place the crankshaft front cover (1a) in its seat using the tool (1b).

Tool	Description	Function	Validity
1821247000	Fitting tool	Fitting crankshaft front oil seal	1.9 JTD 16V

Place the engine rpm sensor in its housing and secure it by tightening the bolt to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Rpm sensor	Bolt	M6	(engine crankcase side) 0.6 - 1.0	1.9 JTD 16v1.9 JTD 8v2.4 JTD 20v

- Place the timing tensioners support assembly in position and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing tensioners support	Bolt	M10x1.25	(engine crankcase side) 4.5 - 5.5	1.9 JTD 16v1.9 JTD 8v

1. Place the flywheel side cover in its housing and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Flywheel side oil seal cover	Bolt (pretreated to be replaced)	M6	(engine crankcase side) 0.8 - 1.0	1.9 JTD 16v1.9 JTD 8v2.4 JTD 20v

Place the air conditioning compressor mounting (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
ACCESSORIES SUPPORT	Bolt	M10	4,5 ÷ 5,5	1.9 jtd

- Place the air conditioning compressor in its housing and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
COMPRESSOR ON ACCESSORIES MOUNTING	Bolt	M8x1.25x90	2,25 ÷ 2,75

Apply silicon sealant to the entire perimeter of the crankcase sump.1. Place the crankcase sump in its housing.2. Tighten the side bolts securing the crankcase sump to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump	Bolt	M8	(engine crankcase side) 2.3 - 2.8	1.9 JTD 16v1.9 JTD 8v2.4 JTD 20v

3. Tighten the front and rear bolts securing the crankcase sump to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump	Bolt	M6	(side and rear) 0.8 - 1.0	1.9 JTD 16v1.9 JTD 8v2.4 JTD 20v

4. Tighten the bolts securing the air conditioning compressor mounting to the crankcase sump to the recommended torque.

- Fit the flywheel lock.

Tool	Description	Function	Validity
1860846000	Counter-torque	Flywheel lock

- Position the toothed timing drive pulley in its housing and secure it tightening the bolt to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Toothed drive pulley	Left hand bolt	M16	(crankshaft side) 32.3 - 35.7	1.9 JTD 16v1.9 JTD 8v

Remove the flywheel lock.

Tool	Description	Function	Validity
1860846000	Counter-torque	Flywheel lock

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.

Select the correct size cylinder head gasket depending on the maximum value between of the averages of the projection for each individual piston.

	Measurement		Value
-	Cylinder head gasket size (no hole) (mm)		0.82 ± 0.05
	Average - maximum piston projection (mm)	-0.020 ÷ +0.100

	Measurement		Value
-	Cylinder head gasket size (one hole) (mm)		0.92 ± 0.05
	Average - maximum piston projection (mm)	+0.101 ÷ +0.200

	Measurement		Value
-	Cylinder head gasket size (two holes) (mm)		1.02 ± 0.05
	Average - maximum piston projection (mm)	+0.201 ÷ +0.295

Position the first cylinder at T.D.C.; rotate the crankshaft a further two teeth of the toothed timing drive pulley to lower the pistons thereby preventing any interference with the valves whilst fitting the cylinder head.

- Position the cylinder head locating bushes on the crankcase as shown in the figure.

The locating bushes between the crankcase and cylinder head are shorter (12.5 mm) than the bushes between the cylinder head and the cylinder head extension. Take great care not to reverse them as this could impair engine operation.

Fit the new cylinder head gasket selected.Position the cylinder head on the cylinder block/crankcase.

Do not reuse the cylinder head bolts more than four times because they undergo permanent lengthening whenever they are tightened.Replace the bolts if the number of times that the bolts have been tightenened to the cylinder heads is unknown.

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

Component	Fastening	dia	Value (daNm)	Validity
Cylinder head	Bolt	M12	(engine crankcase side) 6.2 - 6.8 + 90° + 90° + 90°	1.9 JTD 16v

Tool	Description	Function	Validity
1860942000	Torque wrench	Tighten bolts to torque plus angle

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

- Refit the glow plugs and tighten them to the recommended torque. - Fit the pressure pump mounting complete with pressure pump back in its housing and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Pressure pump mounting	Bolt (pretreated to be replaced)	M8	(cylinder head extension side) 2.3 - 2.8	1.9 JTD 16v

Component	Fastening	dia	Value (daNm)	Validity
Pressure pump mounting	Bolt (pretreated to be replaced)	M6/M8	(engine crankcase side) 2.3 - 2.8	1.9 JTD 16v

1. If not already carried out during cylinder head overhaul, remove plugs (1a) and fit camshaft timing adjustment tools (1b) to the cylinder head extension.

Check that the tools are correctly fitted in the housings in the camshafts.

Tool	Description	Function	Validity
1870896900	Template	Engine tuning	1.9 JTD 16V

Remove the intake camshaft timing tool and tighten the plug.

- Place the camshaft housing centering bushes on the cylinder head.

The centering bushes between the cylinder head and the camshaft housing are longer (16.0) than those between the engine block and the cylinder head; take care therefore not to mix them up because this could adversely affect the operation of the engine.

- Place the valve rockers in their housings.- Place the camshaft housing gasket in position.- Position the camshaft housing and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Camshaft housing	Bolt	M8	(cylinder head side) 2.3 - 2.8	1.9 JTD 16v

If this has not already been done during the overhauling of the cylinder head, loosen the bolt fixing the exhaust side camshaft drive pulley fixing bolt.1. Undo the bolt fixing the crankcase front cover shown in the diagram.Temporarily fit the toothed timing drive belt on the drive pulley.2. Fit the tool.

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.

Tool	Description	Function	Validity
2000003000	Template	Engine tuning	1.9 JTD 16V1.9 JTD 8V

1. Fit the toothed timing belt completely taking care to ensure that the yellow references on it are aligned with the references on the toothed pullies.2. Use a screwdriver for leverage in the opening (2a) until the reference for the tensioner (2b) is in the maximum tension position and tighten the bolt (2d) for the tensioner to the recommended torque in this position.

Component	Fastening	dia	Value (daNm)	Validity
Timing moving tensioner	Nut	M8	2.3 ÷ 2.8	1.9 JTD 16v1.9 JTD 8v

Tighten the bolt fixing the exhaust side camshaft toothed pulley to the recommended torque using the tools for counter-torque.

Component	Fastening	dia	Value (daNm)	Validity
Driven toothed pulley	Bolt	M12	(camshaft side) 2.9 - 3.2 + 40°	1.9 JTD 16v1.9 JTD 8v

Tool	Description	Function	Validity
1870815000	Counter-torque	Loosen/tighten timing driven toothed pulley fixing boltLoosen/tighten nut securing front driveshaft to wheel hub	1.9 JTD 16V1.9 JTD 8V

Tool	Description	Function	Validity
1870836000	Pins	Loosen/tighten timing driven toothed pulley fixing bolt	1.9 JTD 16V1.9 JTD 8V

Remove the timing tools.

Tool	Description	Function	Validity
1870896900	Template	Engine tuning	1.9 JTD 16V

Remove the exhaust side camshaft template as the inlet side one has already been removed.

Tool	Description	Function	Validity
2000003000	Template	Engine tuning	1.9 JTD 16V1.9 JTD 8V

Rotate the crankshaft through two revolutions.- Loosen the bolt retaining the timing moving tensioner.- Use a screwdriver for leverage on the tensioner arm until the reference for the tensioner is in line with the reference opening and tighten the tensioner bolt to the recommended torque in this position.

Component	Fastening	dia	Value (daNm)	Validity
Timing moving tensioner	Nut	M8	2.3 ÷ 2.8	1.9 JTD 16v1.9 JTD 8v

Recheck the timing by refitting the timing tools.

nly fit the exhaust side camshaft template because the intake side template seat is not accessible.

Tighten the bolt fixing the crankcase front cover removed previously.Tighten the plug on the cylinder head extension for fitting the exhaust side timing tool.1. Fit the injectors (1a) in their seats complete with brackets (1b) and tighten the nuts (1c) to the recommended torque.

Start the refitting beginning with the injector for cylinder no. 4 and continue with the injectors for cylinders 3, 2, and 1.

Component	Fastening	dia	Value (daNm)	Validity
Injector brackets	Nut	M8	(cylinder head extension side) 2.3 - 2.8	1.9 JTD 16v2.4 JTD 20v

- Place the alternator in position and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
ALTERNATOR TO BRACKET	Bolt	M12	6,3 ÷ 7,6	1.9 jtd 16v1.9 jtd 8v2.4 jtd 20v

- Place the heat exchanger and engine oil filter mounting in position and secure it using the bolts.- Fit the pipe from the injectors to the fuel recovery manifold and connect to the fuel recovery manifold.- Connect the pipe from the injectors to the fuel manifold, injector side pushing it home until the clips click into place.- Place the single fuel manifold pipe in its housing and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Single fuel manifold pipe (rail)	Bolt	M8	(cylinder head extension side) 2.3 - 2.8	1.9 JTD 16v2.4 JTD 20v

- Connect the return pipe from the fuel manifold, fuel return manifold side and tighten the band.- Place the pipe from the pressure pump to the fuel manifold back in its housing and secure it tightening the connectors to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Pipe from pressure pump to fuel manifold	Connector	M14	(fuel manifold side) 2.2 - 2.4	1.9 JTD 16v2.4 JTD 20v

Component	Fastening	dia	Value (daNm)	Validity
Pipe from pressure pump to fuel manifold	Connector	M.........	(pressure pump side) .....................	1.9 JTD 16v2.4 JTD 20v

- Place the pipes from the fuel manifold to the injectors in their housings and secure them tightening the connectors to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Pipes from fuel manifold to injectors	Connector	M14	(fuel manifold side) 2.2 - 2.4	1.9 JTD 16v2.4 JTD 20v

Component	Fastening	dia	Value (daNm)	Validity
Pipes from fuel manifold to injectors	Connector	M12	(injector side) 2.4 - 2.6	1.9 JTD 16v2.4 JTD 20v

- Place the throttle control shaft valve for the inlet ducts back in its housing and secure it tightening the nuts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Throttle carrier shaft control valve for inlet ducts	Nut	M6	0.65 ÷ 0.75	1.9 JTD 16v2.4 JTD 20v

- Connect the linkage of the intake duct throttle spindle control valve.- Place the bracket complete with engine oil vapour separator and vacuum reservoir in its housing and secure it using the nuts.- Connect the engine oil vapour recovery pipes and the engine oil recovery pipe and secure them using the bands.- Place the vacuum pipes in their housings, connect them and secure them using the bolts.- Connect the engine oil vapour recovery pipe to the engine oil filler and secure it using the band.- Place the duplex engine oil heat exchanger rigid supply and return pipe back in its housing, then tighten the bands and the bolts.- Connect the pipes to the thermostat and tighten the bands.- Place the exhaust manifold gasket in its housing.- Place the turbocharger and exhaust manifold assembly complete with catalytic converter back in its housing and secure it tightening the nuts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Turbocharger and exhaust manifold assembly	Nut	M8	(cylinder head side) 1.8 - 2.2	1.9 JTD 16v

- Connect the engine oil return pipe from the turbocharger, engine crankcase side, and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil supply pipe from turbocharger	Bolt	M8	(engine crankcase side) 2.2 - 2.7	1.9 JTD 16v1.9 JTD 8v

Connect the engine oil delivery pipe to turbocharger, engine crankcase side, and tighten the connector to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil supply pipe to turbocharger	Connector	M12	(engine crankcase side) 2.2 - 2.7	1.9 JTD 16v1.9 JTD 8v

- Connect the exhaust gas intake pipe from the exhaust manifold to the E.G.R. heat exchanger, exhaust manifold side, then secure it using the collar and tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Exhaust gas/water heat exchanger for E.G.R. system	Bolt	M8	(exhaust manifold side) 2.3 - 2.8	1.9 JTD 16v2.4 JTD 20v

- Place the exhaust manifold heat shield back in its housing and secure it using the nuts.- Place the engine oil dipstick pipe back in its housing and fasten it with the bolts.- Place the turbocharger air inlet pipe complete with engine oil vapour recovery pipe in its housing, then secure it using the bands and the bolts.- Place the power unit timing side rigid support in its housing and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support	Bolt	M10	(engine crankcase side) 4.5 - 5.5	1.9 JTD 8v1.9 JTD 16v

- Position the engine components single belt fixed tensioner in its housing and secure it tightening the bolt to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine components single belt fixed tensioner	Bolt	M10x1.5	(engine crankcase side) 5.0	1.9 JTD 16v1.9 JTD 8v

- Fit the timing belt covers and secure them using the bolts.- Position the services pulley in its housing on the crankshaft and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Services pulley on crankshaft	Bolt	M8	(drive pulley side) 2.3 - 2.8	1.9 JTD 16v1.9 JTD 8v2.4 JTD 20v

- Adjust the mobile tensioner with a wrench and fit the auxiliary drive belt.- Connect the electrical connection to the thermal coupling signalling the overheating of the catalytic converter.- Connect the electrical connection to the air conditioning compressor engagement solenoid.- Tighten the bolts securing the electrical wiring.- Connect the electrical connection to the cam angle sensor.- Connect the electrical connections to the heater plugs.- Connect the electrical connections to the injectors.- Connect the electrical connection to the fuel pressure regulator on the injector single manifold.- Connect the electrical connection to the fuel pressure sensor.- Connect the electrical connection to the throttle casing.- Connect the electrical connection to the engine temperature sensor.- Connect the electrical connection to the fuel pressure regulator.- Connect the electrical connection to the air temperature and pressure sensor.- Connect the electrical connection to the E.G.R. solenoid valve.- Connect the electrical connection to the throttle control shaft valve for the inlet ducts.- Connect the electrical connection to the engine oil pressure switch.- Connect the electrical connection to the engine oil level sensor.- Connect the electrical connection to the rpm sensor.- Tighten the drain plug in the crankcase sump to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil drain plug	-	M12x1.25	(oil sump side) 2.0	1.9 JTD 16v1.9 JTD 8v2.4 JTD 20v

When the refitting of the power unit is completed, refill the engine lubrication system.

Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE