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

) Rotate the engine through 180° on the overhaul stand.1. Undo the bolts (1a) and remove the automatic engine component single belt tensioner (1b).2. Undo the fixing bolts (2a) and remove the automatic belt tensioner bracket (2b).

1. Undo and remove the engine oil filter.2. Undo the centre pin (2a) and remove the engine oil heat exchanger (2b).

1. Undo the bolt (1a) (left hand thread) and remove the toothed drive pulley (1b).

1. Undo the fixing bolts (1a) and remove the crankshaft front oil seal cover with built-in oil pump (1b).Remove the seal.

1. Undo the bolt (1a) securing the timing belt tensioner (1b) and remove it.2. Undo retaining bolts (2a) and remove the power steering pump mount, alternator and timing belt tensioner (2b).

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

	Description	Code	Function
1	Flange	1.860.815.000	Crankshaft rotation

Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C.2. Undo the bolts (2a) and remove the connecting rod cap (2b).3. Remove the lower connecting rod half-bearing.4. Remove the connecting rod-piston assembly.5. Remove the upper connecting rod half-bearing.Carry out the same operations to remove the pistons and connecting rods for the remaining cylinders.

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

	Subject	Value
.	Crankshaft	mm
-	End float	-

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.7. Undo the bolt (7a) and remove the rpm and timing sensor (7b).8. Remove the engine oil minimum pressure warning light sensor.

. Remove the engine block from the overhaul stand and place on a work bench. Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCINGUndo the bolts and remove the intake duct from the oil pump. Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCHDrill and remove the water/oil sealing plugs from the crankcase to allow for washing.

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.

	Subject	Value
.	Cylinder block/crankcase	mm
-	Cylinder head support surface flatness	< 0.1

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

	Subject	Value
1	Cylinder block/crankcase	mm
-	Cylinder liner bore	82.000 - 82.010
-	-		82.010 - 82.020
-	-		82.020 - 82.030

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

	Subject	Value
.	Cylinder block/crankcase	mm
-	Cylinder liner taper	< 0.005

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

	Subject	Value
.	Cylinder block/crankcase	mm
-	Cylinder liner ovality	< 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.

	Subject	Value
.	Cylinder block/crankcase	mm
-	Cylinder liner oversize	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).

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

	Description	Code	Function
1b	Torque wrench	1.860.942.000	Angular tightening of bearing cap bolts

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

	Subject	Value
2	Bearing caps	mm
-	Main journal seat diameter	63.705 ÷ 63.718

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.

	Subject	Value
.	Crankshaft	mm
-	Main journal diameter - Category A	59.994 ÷ 60.000
-	Category B	59.988 ÷ 59.994
-	Category C	59.982 ÷ 59.988

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

	Subject	Value
.	Crankshaft	mm
-	Main journal undersize	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.

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

	Subject	Value
.	Crankshaft	mm
-	Crankpin diameter - 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.

	Subject	Value
.	Crankshaft	mm
-	Main journal undersize	0.127

Check that the small end bush internal diameter is within the recommended limits; if not, replace the worn small end bush (Ref. op. 1028H58).

	Subject	Value
.	Small end bush	mm
-	Inner diameter	26.006 - 26.014

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.

	Subject	Value
.	Pistons	mm
-	Piston bush internal diameter	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.

	Subject	Value
.	Gudgeon pins	mm
-	Outer diameter	25.982 ÷ 25.987

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.

	Subject	Value
.	Piston rings	mm
-	1st piston ring gap	0.20 ÷ 0.35
-	2nd piston ring gap	- ÷ -

	Subject	Value
.	Oil scaper ring	mm
-	Oil scraper ring gap	- ÷ -

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

	Subject	Value
.	Pistons	mm
-	Outer diameter - 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, 9 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.

	Subject	Value
1a	Piston rings	mm
-	End float	- ÷ -

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

	Subject	Value
.	Oil scaper ring	mm
-	End float	-

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

	Value daNm	Fastening	Component	Ø
1c	2.5 + 60°	-	CONNECTING ROD CAPS	M9

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

	Description	Code	Function
.	Torque wrench	1.860.942.000	Angular tightening of bearing cap bolts

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

	Subject	Value
2	Connecting rods	mm
-	Big end diameter	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 BENCHCheck that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it.Fit the crankcase on the overhaul stand and secure it using the bolts.Fit the minimum engine oil pressure warning light sensor and tighten it to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	2.7 ÷ 4.0	-	MINIMUMM ENGINE OIL PRESSURE WARNING LIGHT SENSOR

Fit the thrust washers on the fourth bearing support.

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; for 4 cylinder engines, there is an "N" in place of the number for the 5th bearing2. - Main journal identification numerical code: the first number on the left refers to the first timing side bearing; for 4 cylinder engines, there is an "N" in place of the number for the 6th bearing3. - 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 111111 indicate that all six bearings are Grade A (red) as indicated in the Table.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 59.994 for the first timing side bearing which, as indicated in the Table, 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 - 95).Bearing grade A - Normal, diameter (mm) 59.994 - 60.000, paint mark, numerical code 1 (94 00)°Bearing grade B - Normal, diameter (mm) 59.987 - 59.993, paint mark, numerical code 2 (88 94)°Bearing grade C - Normal, diameter (mm) 59.982 - 59.986, paint mark, numerical code 3 (82 88)°Bearing grade D - Undersize, diameter (mm) 59.867 - 59.873, paint mark, numerical code 6 (67 73)°Bearing grade E - Undersize, diameter (mm) 61 - 59.866, paint mark, numerical code 7 (60 67)°Bearing grade F - Undersize, diameter (mm) 55.885 - 59.859, paint mark, numerical code 8 (55 61)°(*) 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 Table 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: - - Maximum: -; this value can be measured, as a final check, using the calibrated wire (plastic gauge).1. Fit the bolts (1a) and fasten the jets (1b) to the crankcase at the recommended torque.

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

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 five starting from the engine pulley side) which define the fitting position.

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

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

	Description	Code	Function
1b	Torque wrench	1.860.942.000	Angular tightening of bearing cap bolts

Fit the tool.

	Description	Code	Function
.	Flange	1.860.815.000	Crankshaft rotation

Rotate the crankcase through 90° on the overhaul stand.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).

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.

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

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.

Rotate the crankcase through 90° on the overhaul stand.1. Tighten the connecting rod cap bolts (1a) to the recommended torque using the angular tightening tool (1b).

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

	Description	Code	Function
1b	Torque wrench	1.860.942.000	Angular tightening of bearing cap bolts

1. Fit the crankcase rear cover (1a) with the oil seal incorporated and tighten bolts (1b) to the recommended torque.

	Value daNm	Fastening	Component	Ø
1b	0.9 - 1.2	Bolt	CRANKCASE REAR COVER	M6

Rotate the crankshaft so that cylinder no. 1 is at T.D.C.Fit the front crankcase cover with oil pump complete with gasketTighten the crankcase front cover bolts, complete with oil pump, to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	0.9 - 1.3	Bolt	FRONT COVER CRANKCASE COMPLETE WITH OIL PUMP	M6

Fit the engine oil intake complete with O-Ring and secure it using the bolts.

	Value daNm	Fastening	Component	Ø
.	0.9 - 1.3	-	OIL SECTION PUMP	-

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

	Description	Q.ty	Component	Type	Classification
.	Dow corning 7091	-	ENGINE OIL SUMP	Silicon sealant	-

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

	Value daNm	Fastening	Component	Ø
2a	(engine crankcase side) 0.9 - 1.2	Side bolts	CRANKCASE SUMP	M6

	Description	Code	Function
2b	Spanner	1.860.834.001	Loosen/Tighten crankcase sump side bolts

	Value daNm	Fastening	Component	Ø
2a	(engine crankcase side) 2.1 - 2.6	Front and rear bolts	CRANKCASE SUMP	M8

	Value daNm	Fastening	Component	Ø
2a	(engine crankcase side) 2.3 - 3.3	Front and rear bolts	CRANKCASE SUMP	M8

	Description	Code	Function
2b	Spanner	1.860.833.001	Loosen/Tighten front and rear crankcase sump bolts

Rotate the engine through 180° on the overhaul stand.Fit the flywheel lock.

	Description	Code	Function
.	Counter-torque	1.860.846.000	Flywheel lock

Fit the flywheel and tighten the bolts to the recommended torque with loctite.

	Value daNm	Fastening	Component	Ø
.	(crankshaft side) 14.7 - 21.2	Bolt with thread-locking agent	ENGINE FLYWHEEL	M12

Fit the toothed drive pulley for the timing belt and tighten the (left hand thread) bolt to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	(crankshaft side) 32.9 - 44.1	Bolt (left hand thread)	TOOTHED DRIVE PULLEY	M16

Remove the tool.

	Description	Code	Function
.	Counter-torque	1.860.846.000	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.

	Description	Code	Function
1	Dial gauge support	1.870.404.000	Piston projection from cylinder head support plane check

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

	Subject	Value
.	Cylinder head gasket	mm
-	Shim (no reference)	0.82

	Subject	Value
.	Cylinder head gasket	mm
-	Average maximum piston projection	0.201 ÷ 0.295

	Subject	Value
.	Cylinder head gasket	mm
-	Shim (two references)	1.02

	Subject	Value
.	Cylinder head gasket	mm
-	Average maximum piston projection	0.101 ÷ 0.200

	Subject	Value
.	Cylinder head gasket	mm
-	Shim (one reference)	0.92

	Subject	Value
.	Cylinder head gasket	mm
-	Average maximum piston projection	0.020 ÷ 0.100

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:

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.

	Value daNm	Fastening	Component	Ø
1a	2 + 6.5 + 90° + 90° + 90°	Bolts	CYLINDER HEAD	M12

The figure of 2 daNm in the table below is a tightening value for all the bolts following the order illustrated in the diagram.

	Description	Code	Function
1b	Torque wrench	1.860.942.000	Cylinder head bolts angular tightening

Fit the cam cover complete with gasket and secure it by tightening the bolts to torque.Fit the alternator mount, power steering pump and timing belt tensioner and tighten the bolts.Fit the fixed timing belt tensioner and tighten the retaining bolt to torque.Fit the water/oil heat exchanger and tighten the threaded fitting.Tighten the engine oil filter cartridge.Fit the single engine component drivebelt automatic tensioner bracket and tighten the bolts.Fit the automtic belt tensioner and tighten the fixing bolts.1. Remove plug (1a) and fit camshaft timing tools (1b) to the cylinder head extension.

Check the tools marked "A" are correctly fitted in the seats on the camshafts.

	Description	Code	Function
1b	Templates	1.870.986.900	Engine tuning

1. Position the cylinder head extension assembly (1a) in its housing and secure it by tightening the bolt (1b) to the recommended torque.2. Tighten the fixing bolts to the recommended torque.Loosen the bolt securing the exhaust side timing belt toothed drive pulley.Remove the intake camshaft timing tool and tighten the plug.

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 (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	Function
2a	Template	1.860.905.000	Engine tuning

	Description	Code	Function
2b	Calibrated screw	1.860.905.010	Engine tuning

Position the engine oil filler fitting metal gasket.Place the engine oil filler fitting in position and tighten the fixing bolts.Positon the vacuum pump metal gasket.Fit the vacuum pump in place and tighten the bolts.Fit the glow plugs.Fit the cooling system rigid pipe gasket.Place the rigid cooling system pipe in position and tighten the fixing bolts.Place the EGR heat exchanger in position and tighten the fixing bolts.Fit the pipes on the EGR heat exchanger and renew the fastening bands.Positon the intake manifold metal gasket.Place the intake manifold in position and tighten the fixing nuts.

	Value daNm	Fastening	Component	Ø
.	2.5	Nut	INLET MANIFOLD	M8

Place the rigid EGR pipe in position and tighten the fixing bolts.Fit the power steering pump in position.Place the pressure pump mount in position and tighten the fixing bolts.

	Value daNm	Fastening	Component	Ø
.	(Cylinder block/crankcase) 2.5	Bolt	INJECTION PRESSURE PUMP MOUNT	M8

Tighten the bolts fixing the power steering pump.

	Value daNm	Fastening	Component	Ø
.	2.5	Bolt	POWER STEERING PUMP	M8

Place the pressure pump in position and tighten the fixing nuts.

	Value daNm	Fastening	Component	Ø
.	2.5	Nut	PRESSURE PUMP	M8

Fit the pressure pump pulley.Lock the rotation of the pressure pump drive pulley using two bolts.Tighten the pressure pump drive pulley nut.

	Value daNm	Fastening	Component	Ø
.	5	Nut	PRESSURE PUMP CONTROL PULLEY	M14

Undo the two bolts for locking the rotation of the pressure pump drive pulley fitted previously.1. Fully fit the toothed timing drive belt.2. Use a screwdriver for leverage in the opening (2a) until the reference for the tensioner (2b) is aligned with the opening reference (2c) and, in this position, tighten the nut (2d) for the belt tensioner to the recommended torque.

	Value daNm	Fastening	Component	Ø
2d	2.5	Nut	MOBILE TIMING TENSIONER	M8

Tighten the bolt fixing the exhaust side camshaft toothed pulley to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	12	Bolt	TIMING DRIVEN PULLIES	M12

Remove the timing tools.

	Description	Code	Function
.	Templates	1.870.986.900	Engine tuning

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

	Description	Code	Function
.	Template	1.860.905.000	Engine tuning

	Description	Code	Function
.	Calibrated screw	1.860.905.010	Engine tuning

Rotate the crankshaft through two revolutions.Recheck the timing by refitting the timing tools.

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

Check the timing belt tensioner references are aligned.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.Fit the injectors and brackets in their seats and tighten the nuts.

Begin to fit, starting from the injector for the cylinder 5, followed by cylinders 4 , 3 , 2 , 1.

Fit the rigid fuel pipe to the pump and tighten the fastening.

	Value daNm	Fastening	Component	Ø
.	(pump side) 2.3	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14X1.5

Fit the fuel vapour recovery tank and tighten the bolts, connect the pipes to the pressure pump and injectors.Position the oil vapour recovery tank and tighten the bolt.Fit the oil vapour recovery pipes in their seats on the engine oil sump, cylinder heads and engine block and restore the fastening collars.Position the engine oil dipstick, then tighten the fastening.Place the rigid cooling system pipe in position and tighten the fixing bolts, connect the pipes and renew the fastening bands.Place the single fuel pipe in position and tighten the fixing bolts.

	Value daNm	Fastening	Component	Ø
.	2.5	Bolts	INJECTOR FUEL MANIFOLD (DIESEL)	M8

Fit new rigid fuel pipes from the single fuel pipe to the injectors and tighten the connectors.

	Value daNm	Fastening	Component	Ø
.	(injector side) 2	Connectors	INJECTOR FUEL MANIFOLD PIPE	M12X1.5

	Value daNm	Fastening	Component	Ø
.	(manifold side) 2	Connectors	PIPE FUEL MANIFOLD TO INJECTORS	M12X1.5

Clean the threaded pipe seats on the manifold and injectors with heptane.

Tighten the pressure pump rigid fuel pipe to the single fuel pipe.

	Value daNm	Fastening	Component	Ø
.	(manifold side) 2.3	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14X1.5

Fit the rigid pipe and tighten the fixing bolts.Fit the toothed drive belt protective covers and tighten the bolts.Position the flywheel retaining tool in its seat.

	Description	Code	Function
.	Flywheel lock	1.860.846.001	Prevent the rotation of the crankshaft

Fit the crankshaft pulley in position and tighten the fixing bolts.

	Value daNm	Fastening	Component	Ø
.	2.5	Bolt	CRANKSHAFT PULLEY	M8

Fit the fixed timing belt tensioner for the single engine component drive belt and tighten the retaining bolt to torque.Remove the flywheel retainer.

	Description	Code	Function
.	Flywheel lock	1.860.846.001	Prevent the rotation of the crankshaft

Fit the engine wiring with ducts and tighten the bolts.Connect the electrical connection for the timing sensor.

	Description	Connector
.	Timing sensor	K047

Connect the electrical connections for the injectors.

	Description	Connector
.	Injector	N070A

	Description	Connector
.	Injector	N070E

	Description	Connector
.	Injector	N070D

	Description	Connector
.	Injector	N070C

	Description	Connector
.	Injector	N070B

Connect the glow plug electrical connections.

	Description	Connector
.	Heater plugs	A040A

	Description	Connector
.	Heater plugs	A040E

	Description	Connector
.	Heater plugs	A040D

	Description	Connector
.	Heater plugs	A040C

	Description	Connector
.	Heater plugs	A040B

Connect the electrical connection for the turbo sensor.

	Description	Connector
.	Supercharging sensor	K082

Connect the electrical connection for the fuel pressure regulator.

	Description	Connector
.	Fuel pressure regulator	N077

Connect the electrical connection for the fuel pressure sensor.

	Description	Connector
3	Fuel pressure sensor	K083

Connect the electrical connection for the EGR solenoid valve.

	Description	Connector
.	EGR solenoid valve	L030

Connect the electrical connection for the engine rpm sensor.

	Description	Connector
.	Rpm sensor	K046

Connect the electrical connection for the coolant temperature sensor.

	Description	Connector
.	Engine coolant temperature sensor/sender unit	K036

Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE