199000406 - 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 fastenings (1a) and remove the support complete with compressor and alternator (1b).2. Remove the engine oil dipstick tube.3. Undo the bolt and remove the detonation sensor. 1. Fit the tool (1a), unscrew the bolt (1b) and remove the crankshaft gear (1c).

Tool	Description	Function	Validity
2000004500	Template	Crankshaft timing	1.2 8v1.4 8v1.4 16v

2. Undo the bolt (2a) and remove the rpm sensor (2b). 1. Undo the bolts (1a) and remove the rigid water return pipe to the pump (1b).2. Undo the bolts (2a), nuts (2b) remove the water pump (2c). 1. Remove the oil filter cartridge.2. Remove the minimum engine oil pressure switch.3. Undo the bolts (3a) and remove the engine block front cover (3b) with the built-in oil pump complete with crankshaft front oil seal (3c) and intake chamber (3d).4. Remove the engine block front cover gasket. 1. Undo the bolts (1a) and remove the crankshaft rear cover (1b). 1. Undo the bolts (1a) and remove the connecting rod cap (1b).2. Remove the lower crankpin half-bearings.3. Remove the connecting rod - piston assemblies.4. Remove the upper connecting rod half-bearings.- Carry out the same operations for removing the remaining pistons. 1. Check that the crankshaft endfloat is within specified limits.

Measurement	Value	Validity
Crankshaft endfloat (mm)	0.055 ÷ 0.265	1.2 8v1.4 8v1.3 Multijet

- If the value for the crankshaft endfloat does not correspond with the recommended figures, when refitting, regrind the crankcase seat and use suitable thrust washers (fastened to the central main bearing half) oversized by 0.127 mm.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.

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

    Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH - Unscrew the coolant chamber plugs from the crankcase.- Remove the lubrication duct plug from the crankcase.- Check the condition of the piston cooling oil sprays.1. If oil sprays (1a) are blocked, remove them using tool (1b).

Insert the drift guide hole on the nozzle surface to prevent the drift from slipping and damaging the cylinder liner during the removal operation.

Tool	Description	Function	Validity
1860395000	Striker	Engine oil jet removal	1.2 8v1.4 8v1.4 16v

Refitting ( Removing ) - Wash and check the appearance of all compents removed.- Tighten the water/oil sealing plugs to the upper crankcase.1. Use the tool (1a) to fit new oil sprays (1b).

Tool	Description	Function	Validity
1860313000	Fitting tool	Engine oil jet fitting	1.2 8v1.4 8v1.4 16v

- 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	1.2 8v1.4 8v1.4 16v1.9 Multijet

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

Measurement	Value	Validity
Cylinder liner diameter - Grade A (mm)	72.000 ÷ 72.010	1.4 8v1.4 16v

Measurement	Value	Validity
Cylinder liner diameter - Grade B (mm)	72.010 ÷ 72.020	1.4 8v1.4 16v

Measurement	Value	Validity
Cylinder liner diameter - Grade C (mm)	72.020 ÷ 72.030	1.4 8v1.4 16v

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

Measurement	Value	Validity
Cylinder liner ovality (mm)	+/- 0.05	1.2 8v1.4 8v1.4 16v

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

Measurement	Value	Validity
Cylinder liner taper (mm)	+/- 0.005	1.2 8v1.4 8v1.4 16v

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

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

Measurement	Value	Validity
Cylinder liner diameter oversize (mm)	0.1	1.2 8v1.4 8v1.4 16v1.3 Multijet1.9 Multijet

- Check that the diameter of the main journals corresponds to the recommended figures.

Measurement	Value	Validity
Main journal diameter - Category A (mm)	47.997 ÷ 48.003	1.4 8v1.4 16v

Measurement	Value	Validity
Main journal diameter - Category B (mm)	47.988 ÷ 47.994	1.4 8v1.4 16v

Measurement	Value	Validity
Main journal diameter - Category C (mm)	47.982 ÷ 47.988	1.4 8v1.4 16v

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

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

Measurement	Value	Validity
Main journal diameter undersize (mm)	0.127	1.2 8v1.4 8v1.4 16v1.3 Multijet

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

Measurement	Value	Validity
Crankpin diameter (mm)	41.990 ÷ 42.008	1.2 8v1.4 8v1.4 16v

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

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

Measurement	Value	Validity
Crankpin diameter undersize (mm)	0.127	1.2 8v1.4 8v1.4 16v1.3 Multijet1.9 Multijet

- Fit the crankshaft into its seat on the crankcase.- Fit the calibrated wire (plastigage) for measuring the main journal backlash.- Refit the connecting rod caps complete with half-bearings and secure them by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Main bearing caps	Bolt	M10	1.9 ÷ 2.1 + 90° +/- 3°	1.2 8v1.4 8v

- Check that the diameter of the main journals corresponds to the recommended figures.

Measurement	Value	Validity
Main journal seat diameter - Category 1 (mm)	51.705 ÷ 51.709	1.2 8v1.4 8v

Measurement	Value	Validity
Main journal seat diameter - Category 2 (mm)	51.709 ÷ 51.713	1.2 8v1.4 8v

Measurement	Value	Validity
Main journal seat diameter - Category 3 (mm)	51.713 ÷ 51.717	1.2 8v1.4 8v

- The size of the main journal half-bearings is given.

Measurement	Value	Validity
Main half-bearings - Category 1 (Red) (mm)	1.836 ÷ 1.840	1.2 8v1.4 8v1.4 16v

Measurement	Value	Validity
Main half-bearings - Category 2 (Blue) (mm)	1.843 ÷ 1.847	1.2 8v1.4 8v1.4 16v

Measurement	Value	Validity
Main half-bearings - Category 3 (Yellow) (mm)	1.848 ÷ 1.852	1.2 8v1.4 8v1.4 16v

Measurement	Value	Validity
Main journal half-bearing thickness oversize (mm)	0.254 ÷ 0.508	1.2 8v1.4 8v

- Remove the main bearing caps and check the main journal backlash. Use an appropriate gauge to measure the width of the plastigage.

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

Measurement	Value	Validity
Clearance between main bearings - crankshaft main journals (mm)	0.025 ÷ 0.040	1.2 8v1.4 8v1.4 16v

- After checking all the main journals, refit the main bearing caps with half-bearings and secure by tightening the bolts to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Main bearing caps	Bolt	M10	1.9 ÷ 2.1 + 90° +/- 3°	1.2 8v1.4 8v

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

Measurement	Value	Validity
Piston outer diameter -Grade A (mm)	71.960 ÷ 71.970	1.4 8v1.4 16v

Measurement	Value	Validity
Piston outer diameter - Grade B (mm)	71.970 ÷ 71.980	1.4 8v1.4 16v

Measurement	Value	Validity
Piston outer diameter - Grade C (mm)	71.980 ÷ 71.990	1.4 8v1.4 16v

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

- Position the piston in the cylinder liner and use a feeler gauge to measure the specified clearance.- Check that the pin seat bore diameter is within specified values, otherwise replace the pin with an oversized pin.

Measurement	Value	Validity
Piston pin housing diameter in pistons (mm)	17.982 ÷ 17.986	1.2 8v1.4 8v

Measurement	Value	Validity
Piston gudgeon pin diameter oversize (mm)		1.2 8v1.4 8v

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

Measurement	Value	Validity
Piston pin outer diameter (mm)	17.970 ÷ 17.974	1.2 8v1.4 8v1.4 16v

- Check that the piston ring seats are within the recommended values.

Measurement	Value	Validity
Sealing ring seat in piston - 1st groove (mm)	1.020 ÷ 1.040	1.4 8v1.4 16v

Measurement	Value	Validity
Sealing ring seat in piston - 2nd groove (mm)	1.210 ÷ 1.230	1.4 8v1.4 16v

Measurement	Value	Validity
Sealing ring seat in piston - 3rd groove (mm)	2.010 ÷ 2.030	1.4 8v1.4 16v

- Check that the thickness of the piston rings is within the recommended limits.

Measurement	Value	Validity
Cylinder compression 1st sealing ring thickness (mm)	0.970 ÷ 0.990	1.4 8v1.4 16v

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- Fit the connecting rod-piston assemblies with half-bearings using the tool to compress the piston rings and then fit the piston into the liner.- Rotate the engine through 180° on the overhaul stand.- Apply the calibrated wire (plastigate) for measuring the crankpin clearance.- Refit the connecting rod caps complete with half-bearings and secure them by tightening the bolts to the recommended torque.

The connecting rod caps are fracture type. If replaced, they are supplied pre-fractured by the manufacturer.Check that the parts are free of burrs, blisters, scratches or any other surface defect. Before installation, parts must be thorougly washed, cleaned and dried. Fit the connecting rod caps so that the number stamped on each cap faces towards the same side as the number stamped on the big end.

Each connecting rod must be paired with its cap, respecting the numerical references stamped on the parts. Connecting rods and connecting rod caps are not interchangeable.

Component	Fastening	dia	Value (daNm)	Validity
Connecting rod caps	Bolt	M8	1.9 ÷ 2.1 + 40° +/- 2°	1.2 8v1.4 8v1.4 16v1.3 Multijet

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

Measurement	Value	Validity
Crankpin seat diameter (mm)	45.128 ÷ 45.138	1.2 8v1.4 8v

- The size of the connecting rod half-bearings is given.

Measurement	Value	Validity
Connecting rod half-bearing thickness (mm)	1.544 ÷ 1.548	1.2 8v1.4 8v1.4 16v

Measurement	Value	Validity
Connecting rod half-bearing thickness oversize (mm)	0.254 ÷ 0.508	1.2 8v1.4 8v

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

Measurement	Value	Validity
Clearance between connecting rod bearings - crankpin bearings (mm)	0.021 ÷ 0.060	1.2 8v1.4 8v

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

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

Component	Fastening	dia	Value (daNm)	Validity
Connecting rod caps	Bolt	M8	1.9 ÷ 2.1 + 40° +/- 2°	1.2 8v1.4 8v1.4 16v1.3 Multijet

- Position a new oil pump gasket.- Fit the front crankcase cover with built-in oil pump complete with intake chamber and secure by tightening bolts to the specified torque.- Fit the engine oil filter.- Fit the minimum engine oil pressure switch.- Fit the oil seal to the crankshaft front cover using the tool.

Tool	Description	Function	Validity
1860903000	Fitting tool	Fitting crankshaft front oil seal	1.2 8v1.4 8v

- Fit the crankcase rear cover and secure by tightening the bolts to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Crankshaft to crankcase rear cover	Bolt	M6	0.8 ÷ 1.0	1.2 8v1.4 8v1.4 16v

- Fit a new rear camshaft oil seal using the tools.

Tool	Description	Function	Validity
1860879000	Grip	Fitting crankshaft rear oil seal	1.2 8v1.4 8v

Tool	Description	Function	Validity
1860881000	Fitting tool	Fitting crankshaft rear oil seal	1.2 8v1.4 8v

- Fit the water pump and secure with the bolts and nut.- Fit the rigid coolant return pipe to the pump and secure to the crankcase with the bolt.- Fit the crankshaft gear.- Position the tool and tighten the crankshaft gear bolt to the specified torque.

Tool	Description	Function	Validity
2000004500	Template	Crankshaft timing	1.2 8v1.4 8v1.4 16v

Component	Fastening	dia	Value (daNm)	Validity
Crankshaft gear	Bolt	M11	1.9 ÷ 2.1 + 90° +/- 3°	1.2 8v1.4 8v

- Remove the tool fitted previously.- Rotate the engine on the overhaul stand.- Clean the crankcase and oil sump contact surfaces, removing the silicon sealant residues.- Apply the silicone sealant continuously without any breaks over the entire perimeter of the crankcase sump.

Join the end to the beginning seamlessly.

- Fit the crankcase sump and secure it by tightening the bolts and the nuts to the specified torque.

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

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump - crankcase side	Bolt	M8	2.2 ÷ 2.7	1.2 8v1.4 8v

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump - rear cover side and oil pump side	Nut	M6	0.8 ÷ 1.0	1.2 8v1.4 8v

- Clean the contact surfaces between the cylinder head and engine block.- Fit the locating bushes for the cylinder block/crankcase.- Position the cylinder head gasket on the cylinder block/crankcase.1. Fit the cylinder head and tighten the fixing bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Cylinder head	Bolt	M9	2.9 ÷ 3.1 + 90° + 90° +/- 3°	1.2 8v1.4 8v

Follow the order illustrated below for the tightening of the cylinder head bolts.

- Fit the intake chamber and tighten the nuts to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Intake manifold	Nut	M8	2.3 ÷ 2.8	1.2 8v1.4 8v1.9 Multijet

1. Fit the template to the camshaft rear shank.

Tool	Description	Function	Validity
2000004400	Template	Camshaft timing	1.2 8v1.4 8v

1. Fit the timing belt. 1. Fit the crankshaft timing template to the drive pulley.

Tool	Description	Function	Validity
2000004500	Template	Crankshaft timing	1.2 8v1.4 8v1.4 16v

1. Proceed as shown in the figure to adjust the automatic tensioner reference fork until it is in contact. 1. Fit the reaction tool (1a) and tighten the variable valve timing bolt (1b) to the specified torque.

Tool	Description	Function	Validity
2000004200	Counter-torque	Timing driven pulley lock	1.4 8v

Component	Fastening	dia	Value (daNm)	Validity
Variable valve timing	Bolt	M12	1.9 ÷ 2.1 + 55° +/- 2°	1.4 8v

- Fit the variable valve timing bolt plug and secure to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Variable valve timing sealing plug	Plug	M27	2.4 ÷ 3.0	1.4 8v

- Remove both templates and the reaction tool fitted previously and turn the engine through a couple of revolutions to settle the timing belt.- Loosen the belt tensioner nut and adjust the front fork until it is aligned with the rear fork.- Tighten the belt tensioner nut to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Moving timing system tensioner	Nut	M8	2.5 ÷ 3.1	1.2 8v1.4 8v

- Fit the templates removed previously to check the engine timing adjustment.1. Position cam cover (1a) on the cylinder head and tighten bolts (1b).2. Fit the tappet cover locating tool.

Tool	Description	Function	Validity
2000004300	Template	Tappet cover centering	1.4 8v

- Tighten the previously screwed in cam cover bolts to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Tappet cover	Bolt	M6	0.8 ÷ 1.0	1.2 8v1.4 8v1.3 Multijet1.9 Multijet

- Remove the tappet cover locating tool fitted previously.1. Fit the timing sensor.2. Fit the injection control unit mount. - Fit the rpm sensor and tighten the bolt.- Fit the knock sensor and tighten the bolt to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Knock sensor	Bolt (to be replaced)	M8	2.2 ÷ 2.7	1.2 8v1.4 8v1.4 16v

- Fit the engine oil dipstick tube.- Fit the mount with compressor and alternator and secure the fastenings.

Component	Fastening	dia	Value (daNm)	Validity
Compressor support	Bolt	M10x1.25	4.5 ÷ 5.5	1.2 8v1.4 8v1.4 16v1.4 16v TJet

Component	Fastening	dia	Value (daNm)	Validity
Compressor support	Nut	M8x1.25	2.3 ÷ 2.7	1.2 8v1.4 8v1.4 16v1.4 16v TJet

Component	Fastening	dia	Value (daNm)	Validity
Compressor support	Nut	M10x1.25	4.5 ÷ 5.5	1.2 8v1.4 8v 1.4 16v1.4 16v TJet

- Fit the timing belt protective covers and secure them using the bolts.- Fit the crankshaft pulley and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Services pulley on crankshaft	Bolt	M8	2.3 ÷ 2.8

- Fit the auxiliary drivebelt by adjusting the automatic belt tensioner.- Fit the timing side rigid power unit mount and tighten the bolts to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support	Bolt	M10	5.4 ÷ 6.6	1.2 8v1.4 8v1.4 16v

- Connect the electrical connection for the coolant temperature sensor.- Connect the electrical connection for the timing sensor.- Connect the electrical connection of the ignition coil module.- Connect the electrical connection for the throttle casing.- Connect the electrical connection for the knock sensor.- Connect the air conditioning compressor electrical connection.- Connect the earth lead to the crankcase.- Connect the electrical connection for the absolute pressure sensor.- Connect the electrical connection for the air pressure/temperature sensor.- Connect the electrical connection for the variable valve timing electromagnet.- Remove the engine from the overhaul stand.