198002007 - 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
)
1. Undo the bolts (1a) and remove the air conditioning compressor (1b) from the mounting.2. Undo bolts (2a) and remove air conditioner compressor mounting (2b).
- Undo the bolts and remove the alternator.
1. Undo the bolts (1a) and (1b), then remove pressure pump mounting assembly (1c).- Remove the locating bushes.
1. Undo bolt (1a) and remove 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 |
|---|
| 1860815000 | Flange | Crankshaft rotation | |
1. Undo the bolts (1a) and remove the engine oil intake duct (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 assembly front cover (3b).
1. Undo the bolts (1a) and remove the timing drive belt tensioner support (1b).
- Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C.1. Undo bolts (1a) and remove 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 |
|---|
| 1860815000 | Flange | Crankshaft rotation | |
- 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 |
- 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 half-washers.
1. Undo bolts (1a) and remove connecting rod caps (1b).2. Remove the lower main half-bearings.3. Remove the crankshaft.4. Remove the upper main half-bearings.5. Remove the thrust half-washers.6. Undo bolts (6a) and remove jets (6b) from the crankcase.
- Remove the crankcase from the support tools, then place on a 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 BENCH - Drill 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 coupling components with engine oil.- Check that the cylinder head support surface does not have cracks or surface grooves.- Check that the flatness of the cylinder head support surface is within the recommended limits; if this is not the case, regrind the cylinder head support surface.| Measurement | Value | Validity |
|---|
| Engine cylinder head lower surface flatness (mm) | < 0.1 | |
1. Measure the cylinder liner diameter according to the diagram shown in the figure.| Measurement | Value | Validity |
|---|
| Cylinder liner inner diameter - Grade A (mm) | 82.000 ÷ 82.010 | 1.9 JTD |
| Measurement | Value | Validity |
|---|
| Cylinder liner inner diameter - Grade B (mm) | 82.010 ÷ 82.020 | 1.9 JTD |
| Measurement | Value | Validity |
|---|
| Cylinder liner inner diameter - Grade C (mm) | 82.020 ÷ 82.030 | 1.9 JTD |
- 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 |
- 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 |
- If the cylinder liner measurements are not within the recommended limits, ream the cylinder liners following the recommended oversizes. | If reaming, ensure all the liners have the same oversize. |
| Measurement | Value | Validity |
|---|
| Cylinder liner bore oversize (mm) | 0.1 | |
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 main bearing cap bolts (1a) to the recommended torque using angle gauge tool (1b).| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Bearing caps | Bolt | M12 | 1.9 ÷ 2.1 + 100° | 1.9 JTD 16v |
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 |
- Check that there are no deposits or blockages in the crankshaft lubrication ducts.- Check that the diameter of the main journals is within the recommended limits.| Measurement | Value | Validity |
|---|
| Main journal diameter - Category A (mm) | 59.994 ÷ 60.000 | 1.9 JTD |
| Measurement | Value | Validity |
|---|
| Main journal diameter - Category B (mm) | 59.988 ÷ 59.994 | 1.9 JTD |
| Measurement | Value | Validity |
|---|
| Main journal diameter - Category C (mm) | 59.982 ÷ 59.988 | 1.9 JTD |
- If the diameter of the main journals is not correct, they should be reground to the recommended undersize.| Measurement | Value | Validity |
|---|
| Crankpin 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 is within the recommended limits.| Measurement | Value | Validity |
|---|
| Crankpin diameter - Category A (mm) | 50.799 ÷ 50.805 | 1.9 JTD |
| Measurement | Value | Validity |
|---|
| Crankpin diameter - Category B (mm) | 50.793 ÷ 50.799 | 1.9 JTD |
| Measurement | Value | Validity |
|---|
| Crankpin diameter - Category C (mm) | 50.787 ÷ 50.793 | 1.9 JTD |
- 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 | |
| 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 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 main journal 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 main bearing cap bolts (1a) to the recommended torque using angle gauge tool (1b).| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Bearing caps | Bolt | M12 | 1.9 ÷ 2.1 + 100° | 1.9 JTD 16v |
1. Remove the main bearing caps fitted previously and, using a suitable graduated measuring instrument (1a), measure the clearance shown by calibrated wire (1b).| Measurement | Value | Validity |
|---|
| Clearance between main bearings - crankshaft main journals (mm) | 0.011 ÷ 0.071 | 1.9 JTD |
 | If the figure measured is outside of the tolerance, replace the main 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 bore is within the recommended limits; if not, replace the worn small end bush. Op. 1028H58 CONNECTING ROD SMALL END BUSH (ONE) - REPLACE | Measurement | Value | Validity |
|---|
| Small end bush inner diameter (mm) | 26.006 ÷ 26.014 | 1.9 JTD |
- Check that the bore of the piston pin housing in the pistons corresponds to the recommended figures; if not, replace the piston complete with sealing rings, piston pin and bushes.| Measurement | Value | Validity |
|---|
| Piston pin housing diameter in pistons (mm) | 25.999 ÷ 26.004 | 1.9 JTD |
- Check that the outer diameter of the piston pins is within the recommended limits; if not, replace the worn piston pins.| Measurement | Value | Validity |
|---|
| Piston pin outer diameter (mm) | 25.982 ÷ 25.987 | 1.9 JTD |
- Fit the sealing 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 retaining rings.| Measurement | Value | Validity |
|---|
| Cylinder compression 1st sealing ring gap (mm) | 0.20 ÷ 0.35 | 1.9 JTD |
| Measurement | Value | Validity |
|---|
| Cylinder compression 2nd sealing ring gap (mm) | 0.20 ÷ 0.40 | 1.9 JTD 16v |
| Measurement | Value | Validity |
|---|
| Piston oil scraper ring gap (mm) | 0.25 ÷ 0.50 | 1.9 JTD |
- Check that the outer diameter of the pistons corresponds to the recommended figures; if not, replace the piston complete with sealing rings and piston pin.| Measurement | Value | Validity |
|---|
| Piston outer diameter -Grade A (mm) | 81.920 ÷ 81.930 | 1.9 JTD |
| Measurement | Value | Validity |
|---|
| Piston outer diameter - Grade B (mm) | 81.930 ÷ 81.940 | 1.9 JTD |
| Measurement | Value | Validity |
|---|
| Piston outer diameter - Grade C (mm) | 81.940 ÷ 81.950 | 1.9 JTD |
| Measure at a right angle to the piston pin axis, 9 mm from the lower edge of the skirt. |
- Check that the piston ring seats correspond to the recommended figures; if not, replace the piston complete with sealing rings and piston pins.| Measurement | Value | Validity |
|---|
| Sealing ring seat in piston - 1st groove (mm) | 2.100 ÷ 2.120 | 1.9 JTD 16v |
| Measurement | Value | Validity |
|---|
| Sealing ring seat in piston - 2nd groove (mm) | 2.040 ÷ 2.060 | 1.9 JTD 16v |
| Measurement | Value | Validity |
|---|
| Oil scraper ring seat in piston (mm) | 2.020 ÷ 2.040 | 1.9 JTD 16v |
- Check that the thickness of the piston rings is within the recommended values; if this is not the case, replace the worn rings.| Measurement | Value | Validity |
|---|
| Cylinder compression 1st sealing ring thickness (mm) | 1.970 ÷ 1.990 | 1.9 JTD 16V |
| Measurement | Value | Validity |
|---|
| Cylinder compression 2nd sealing ring thickness (mm) | 1.970 ÷ 1.995 | 1.9 JTD |
| Measurement | Value | Validity |
|---|
| Piston oil scraper ring size (mm) | 1.970 ÷ 1.995 | 1.9 JTD 16v |
1. Check that backlash (1a) between first-second ring (1b) and the seats in piston (1c) corresponds to the recommended figures.| Measurement | Value | Validity |
|---|
| Cylinder compression 1st sealing ring endfloat (mm) | 0.110 ÷ 0.150 | 1.9 JTD 16v |
| Measurement | Value | Validity |
|---|
| Cylinder compression 2nd sealing ring endfloat (mm) | 0.045 ÷ 0.090 | 1.9 JTD 16v |
| Measurement | Value | Validity |
|---|
| Oil scraper ring endfloat (mm) | 0.025 ÷ 0.070 | 1.9 JTD 16v |
1. Fit caps (1b) on connecting rods (1a) and secure them by tightening bolts (1c) to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Connecting rod caps | Bolt | M9 | 2.4 ÷ 2.6 + 60° | 1.9 JTD |
2. Check that the big end diameter is within the recommended limits; if not, replace the connecting rods.| Measurement | Value | Validity |
|---|
| Big end inner diameter (mm) | 53.897 ÷ 53.909 | 1.9 JTD |
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 - Check that there are no signs of seizing on the flywheel toothed ring gear teeth; if this is not the case, replace it.- Replace the engine block on the overhaul stand using the mounting bracket.| Tool | Description | Function | Validity |
|---|
| 1871000000 | Overhaul stand | Engine overhaul | |
| Tool | Description | Function | Validity |
|---|
| 1871000000 | Bracket | Positioning engine on overhaul stand | |
- Refit the jets in their housings in the crankcase and secure them using the bolts.- Refit the thrust half-washers in their seats on the third main bearing.The main half-bearings fitted on the crankshaft have been selected for their optimum specific 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 by identifying the class of each main journal and crankpin for the new crankshaft. |
- The following must be determined for the selection of main half-bearings: the numerical code stamped on the phonic wheel; 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 phonic wheel 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 59.994 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.- If using a crankshaft where the maximum undersize to which the journals may be ground is 0.127 mm, the grade should be selected by measuring the diameter of the journal using the above as a reference.- Having defined the grade and the colour of each new or reground crankshaft bearing, it is necessary to select the thickness of the bearings, which 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 number.- 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).- Refit 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 angle gauge tool.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Bearing caps | Bolt | M12 | 1.9 ÷ 2.1 + 100° | 1.9 JTD 16v |
- Fit the tool.| Tool | Description | Function | Validity |
|---|
| 1860815000 | Flange | Crankshaft rotation | |
- Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C.1. Place piston and connecting rod assembly (1a) in its housing complete with half-bearing, using tool (1b). | For the selection of the connecting rod half-bearings, follow the procedure described previously for the main half-bearings. |
| The piston-connecting rod assemblies should be fitted in the engine block 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 connecting rod caps complete with half-bearings in their seats. | Fit the connecting rod caps 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 angle gauge tool.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Connecting rod caps | Bolt | M9 | 2.4 ÷ 2.6 + 60° | 1.9 JTD |
- 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 plastigage (1b).| Measurement | Value | Validity |
|---|
| Clearance between connecting rod bearings - crankpin bearings (mm) | 0.030 ÷ 0.056 | 1.9 JTD |
- 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 rod caps 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 angle gauge tool.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Connecting rod caps | Bolt | M9 | 2.4 ÷ 2.6 + 60° | 1.9 JTD |
- Remove the tool.| Tool | Description | Function | Validity |
|---|
| 1860815000 | Flange | Crankshaft rotation | |
- Place the crankshaft oil seal 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 front cover | Bolt (to be replaced) | M6 | 0.8 ÷ 1.0 | 1.9 JTD |
- Position the engine oil intake duct in its housing and secure it using the bolts.
1. Place crankshaft oil seal front cover (1a) in its seat using tool (1b).| Tool | Description | Function | Validity |
|---|
| 1821247000 | Fitting tool | Fitting crankshaft front oil seal | 1.9 JTD 16v |
- Replace 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 | 0.8 ÷ 1.0 | 1.9 JTD |
- Place the timing belt tensioner mount assembly in position and secure it by tightening the bolts to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Timing belt tensioners support | Bolt | M10 | 4.5 ÷ 5.5 | 1.9 JTD |
1. Place the flywheel side cover in its housing and secure it by tightening the bolts to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Flywheel side oil seal cover | Bolt (to be replaced) | M6 | 0.8 ÷ 1.0 | 1.9 JTD 16v |
- Place the air conditioning compressor mounting in its housing and secure it by tightening the bolts to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Compressor support | Bolt | M10 | 4.5 ÷ 5.5 | |
- Place the air conditioning compressor in its housing and secure it by tightening the bolts to the recommended torque.
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Compressor | Bolt | M8 | 2.3 ÷ 2.7 | |
- Apply silicone 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 | Side bolts | M8 | 2.2 ÷ 2.7 | 1.9 JTD |
3. Tighten the front and rear bolts securing the crankcase sump to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Engine oil sump | Timing side and gearbox side bolts | M6 | 0.8 ÷ 1.0 | 1.9 JTD |
4. Tighten the bolts securing the air conditioning compressor mounting to the crankcase sump to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Compressor support | Bolt | M10 | 4.5 ÷ 5.5 | |
- Fit the flywheel lock.| Tool | Description | Function | Validity |
|---|
| 1860846000 | Counter-torque | Flywheel lock | |
- Position the toothed drive pulley in its housing and secure it by tightening the bolt to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Toothed drive pulley | Left hand bolt | M16 | 32.3 ÷ 35.7 | 1.9 JTD |
- Remove the flywheel lock.| Tool | Description | Function | Validity |
|---|
| 1860846000 | Counter-torque | Flywheel lock | |
1. Measure the piston protrusion in two places at 180° on the piston pin axis using the tool and take the average of the two values measured for each piston.
- Select the correct size cylinder head gasket, according to the maximum value of the averages for the protrusion for each individual piston.| Measurement | Value | Validity |
|---|
| Cylinder head gasket size with maximum piston projection (mm) | projection-0.020 ÷ +0.100thickness (no opening)0.82 +/- 0.05 | 1.9 JTD 16v |
| Measurement | Value | Validity |
|---|
| Cylinder head gasket size with maximum piston projection (mm) | projection+0.101 ÷ +0.200thickness (one opening)0.92 +/- 0.05 | 1.9 JTD 16v |
| Measurement | Value | Validity |
|---|
| Cylinder head gasket size with maximum piston projection (mm) | projection+0.201 +/- +0.295thickness (two openings)1.02 +/- 0.05 | 1.9 JTD 16v |
| 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 mix them up as this could impair engine operation. |
- Fit the new cylinder head gasket selected.- Position the cylinder head on the 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 tightened to the cylinder heads is unknown. |
1. Tighten the cylinder head bolts to the specified torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Cylinder head | Bolt | M12 | 6.2 ÷ 6.8 + 90° + 90° + 90° | 1.9 JTD |
| Follow the order shown in the figure for each tightening sequence. |
- Refit the glow heater plugs and tighten them to the recommended torque.
- Fit the pressure pump mounting complete with pressure pump back in its housing and secure it by tightening the bolts to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Pressure pump support | Bolt (to be replaced) | M6 | 2.3 ÷ 2.8 | 1.9 JTD |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Pressure pump support | Bolt (to be replaced) | M8 | 2.3 ÷ 2.8 | 1.9 JTD |
1. If not already done 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 | Templates | Engine tuning | 1.9 JTD 16v |
- Remove the timing tool, intake camshaft side, and tighten the plug.
- Place the cylinder head extension centring bushes on the cylinder head. | The centring bushes between the cylinder head and the cylinder head extension 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 cylinder head extension gasket in position.- Refit the cylinder head extension and secure it by tightening the bolts to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Camshaft housing | Bolt | M8 | 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 toothed 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 camshaft timing tools. | The crankshaft must be rotated, using small movements, to allow the locating dowel on the toothed timing drive pulley to be inserted in the opening in the tool. |
| Tool | Description | Function | Validity |
|---|
| 1860905000 | Template | Engine tuning | 1.9 JTD |
| Tool | Description | Function | Validity |
|---|
| 1860905010 | Calibrated screw | Engine tuning | 1.9 JTD |
1. Fit the toothed timing drive belt completely, taking care to ensure that the yellow references on it are aligned with the references on the toothed pulleys.2. Use a screwdriver for leverage in opening (2a) until the reference for tensioner (2b) is in the maximum tension position. Then tighten bolt (2d) for the tensioner to the recommended torque in this position.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Timing system moving tensioner | Nut | M8 | 2.3 ÷ 2.8 | 1.9 JTD |
- 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 timing toothed pulley | Bolt | M12 | 2.8 ÷ 3.1 + 40° | 1.9 JTD |
| Tool | Description | Function | Validity |
|---|
| 1870815000 | Counter-torque | Loosen/tighten timing driven toothed pulley bolt | 1.9 JTD |
| Tool | Description | Function | Validity |
|---|
| 1870836000 | Pins | Loosen/tighten timing driven toothed pulley bolt | 1.9 JTD |
- Remove the timing tools.| Tool | Description | Function | Validity |
|---|
| 1860905000 | Template | Engine tuning | 1.9 JTD |
| Tool | Description | Function | Validity |
|---|
| 1860905010 | Calibrated screw | Engine tuning | 1.9 JTD |
| Remove the exhaust camshaft side template as the inlet camshaft template has already been removed. |
| Tool | Description | Function | Validity |
|---|
| 1870896900 | Templates | Engine tuning | 1.9 JTD 16v |
- 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 system moving tensioner | Nut | M8 | 2.3 ÷ 2.8 | 1.9 JTD |
- Recheck the timing by refitting the timing tools. | Only fit the exhaust side camshaft template because the intake side template seat is not accessible. |
- Tighten the bolt fixing the previously removed crankcase front cover.- Tighten the plug on the cylinder head extension for fitting the exhaust side timing tool.1. Fit injectors (1a) in their seats complete with brackets (1b) and tighten 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 | 2.3 ÷ 2.8 | 1.9 JTD 16v |
- Relace the alternator in position and secure it by tightening the bolts to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Alternator | Bolt | M12 | 6.3 ÷ 7.7 | |
- 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 recovery 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 |
|---|
| Common rail | Bolt | M8 | 2.3 ÷ 2.8 | 1.9 JTD 16v |
- 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 by tightening the connectors to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Pipe from pressure pump to fuel manifold - fuel manifold side | Connector | M14 | 1.8 ÷ 2.0 | 1.9 JTD |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Pipe from pressure pump to fuel manifold - pressure pump side | Connector | M12 | 2.2 ÷ 2.4 | 1.9 JTD |
- Place the pipes from the fuel manifold to the injectors in their housings and secure them by tightening the connectors to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Pipes from fuel manifold to injectors - fuel manifold side | Connector | M14 | 1.8 ÷ 2.0 | 1.9 JTD |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Pipes from fuel manifold to injectors - injectors side | Connector | M12 | 2.2 ÷ 2.4 | 1.9 JTD |
- Place the bracket complete with engine oil vapour separator and vacuum tank in the housing and secure using the nuts.- Connect the engine oil vapour recovery pipes and the engine oil recovery pipe and secure them using the bands.- Connect the engine oil vapour recovery pipe to the engine oil filler and secure it using the band.- Connect the pipes to the thermostat and tighten the bands.- Refit the engine oil dipstick pipe assembly in its housing and fasten it with the bolts.- Position the auxiliary drive belt fixed tensioner in its housing and secure it by tightening the bolt to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Auxiliary drive belt fixed tensioner | Bolt | M8 | 2.2 ÷ 2.7 | 1.9 JTD |
- Fit the timing belt covers and secure them using the bolts.- Position the service pulley on the crankshaft in its housing and secure it by tightening the bolts to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Services pulley on crankshaft | Bolt | M8 | 2.3 ÷ 2.8 | |
- Adjust the mobile tensioner with a wrench and fit the auxiliary drive belt.- 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.- Secure the electrical connections to the glow heater plugs.- Secure the electrical connections to the injectors.- Connect the electrical connection to the fuel pressure sensor.- Secure the electrical connection to the throttle body.- 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 carrier spindle control valve for the inlet ducts.- Connect the electrical connection to the engine oil pressure switch.- 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 | Plug | M14 | 1.8 ÷ 2.2 | 1.9 JTD |
| When the refitting of the power unit is completed, refill the engine lubrication system. |
Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE
