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 bolts (1a) and the nut (1b) securing the water pump to the crankcase.2. Remove the sealant using the tool (2a) and remove the water pump (2b).

Tool	Description	Function	Validity
1870718000	Blade	Cut sealant

- Clean thoroughly between the crankcase and water pump mating surfaces.3. Remove the minimum engine oil pressure switch. 1. Fit the tool (1a) and undo the bolt (1b) securing the crankshaft gear.

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

- Remove the template fitted previously.2. Remove the crankshaft gear.3. Undo the bolt (3a) and remove the rpm sensor (3b). 1. Undo the bolts (1a) and remove the crankcase front cover (1b) with the oil pump incorporated, complete with gasket (1c) and intake duct (1d). 1. Undo bolts (1a) and remove crankshaft rear cover (1b) with built-in oil seal. - Rotate the engine block through 180°.1. Fit the tool for rotating the crankshaft.

Tool	Description	Function	Validity
1860815000	Flange	Crankshaft rotation	1.4 16v1.3 Multijet

1. Undo the bolts (1a) and remove the connecting rod caps (1b).2. Remove the lower connecting rod half-bearings.3. Remove the connecting rod - piston assemblies.4. Remove the upper connecting rod half-bearings.

The arrow on the piston crown facing the timing side indicates the fitting direction.The matching of the connecting rod-cap is the "BREAKING" type therefore the position is compulsory and the number corresponding to the position of the cylinder must be present.

- Remove the flange for rotating the crankshaft fitted previously.1. Using a dial gauge, check that the crankshaft endfloat is within specified limits.

Measurement	Value	Validity
Crankshaft endfloat (mm)	0.155 ÷ 0.355	1.4 16v

- Remove the dial gauge.

If the value for the crankshaft endfloat does not correspond with the recommended figures, when refitting, regrind the crankcase seat and use the central main bearing half incorporating appropriately oversized crankshaft thrust half-washers.

1. Undo the bolts (1a) and remove the lower crankcase (1b) complete with lower half-bearings from the engine block. 1. Remove the lower main half bearings from the engine block.2. Remove the crankshaft.3. Remove the upper main half-bearings. 1. Undo the bolt and remove the knock sensor. - Remove the bushes used to locate the engine block base on the engine block.- Raise the engine block using a hydraulic lift and place it on a suitable 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 1. Remove the coolant chamber plugs from the crankcase using a steel striker.2. Remove the lubrication duct plug from the crankcase using a steel striker. 1. Remove the oil jets (1a) using the tool (1b).

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

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

Use new oil jets when refitting.

Refitting ( Removing ) - Wash and check the appearance of all components removed.- Place the crankcase on the overhaul stand.- Fit the water/oil sealing plugs in the crankcase using suitable fitting tools and sealant.- Fit the locating bushes for the crankcase.1. Use the tool (1a) and a plastic mallet to fit the new oil jets (1b).

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

1. Using a calibrated metal rule (1a) and a feeler gauge (1b), check the flatness of the cylinder head - cylinder block support surface.2. If the measurement does not correspond to the recommended values, 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 liners 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/bores 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 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 liners 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 is within the recommended limits.

Measurement	Value	Validity
Main journal diameter - Category A (mm)	47.994 ÷ 48.000	1.4 16v TJet

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 does not fall within the recommended values, 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 is within the recommended limits.

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

- 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 main bearing halves in their seats on the upper crankcase, aligning the lubrication ports and ensuring scrupulous cleanliness. The central main bearing half incorporates thrust half-washers because it performs a load-bearing function and also acts as a thrust bearing.- If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions.1. Fit the crankshaft in the special housing in the engine block with the upper half-bearings.2. Fit the calibrated wire (plastigage) for measuring the main journal clearance. 1. Fit the main half-bearings in the lower crankcase.2. Fit the lower crankcase on the engine block, checking that the codes stamped on both parts of the crankcase correspond, because the crankcase components are not interchangeable. - The size of the main 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 bearing half undersize (mm)	0.127	1.4 16v

- Tighten the bolts securing the lower crankcase to the engine block to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Crankcase	Central bolt	M10	1.9 ÷ 2.1 + 87° ÷ 93°	1.4 16v

Component	Fastening	dia	Value (daNm)	Validity
Crankcase	Side bolt	M10	2.8 ÷ 3.2	1.4 16v

1. Remove the lower crankcase and check the main journal clearance. Use an appropriate measuring device 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, apply sealant to the contact surfaces between the lower crankcase and upper crankcase. Then fit the lower crankcase permanently by tightening the bolts to torque in the order described previously.

Apply a 2-mm thick continuous sealant strip to the lower crankcase surface.

- Check that the outer diameter of the pistons corresponds to the recommended figures; if not, replace the pistons complete with sealing rings and gudgeon pins.

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 pistons in the cylinder liners and use a feeler gauge to measure the specified clearance.

Measurement	Value	Validity
Clearance between piston - cylinder liner (mm)	0.030 ÷ 0.050	1.4 16v

- Check that the inner bore of the gudgeon pin housings is within the recommended limits; if not, replace the pistons.

Measurement	Value	Validity
Piston pin housing diameter (mm)	17.978 ÷ 17.982	1.4 16v TJet

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

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

- Use a micrometer gauge to measure the thickness of the piston sealing rings.

Measurement	Value	Validity
Cylinder compression 1st sealing ring thickness (mm)	1.170 ÷ 1.195	1.4 16v TJet

Measurement	Value	Validity
Cylinder compression 2nd sealing ring thickness (mm)	1.170 ÷ 1.190	1.4 8v1.4 16v

Measurement	Value	Validity
Cylinder compression 3rd sealing ring thickness (mm)	1.970 ÷ 1.990	1.4 16v TJet

Measurement	Value	Validity
Sealing ring oversize (mm)	0.1	1.2 8v1.4 8v1.4 16v

1. Fit the sealing rings (1a) in the cylinder liners/bores and use a feeler gauge (1b) to check the gap between the seal ends is within specified limits. Otherwise replace the sealing rings.

Measurement	Value	Validity
Cylinder compression 1st sealing ring gap (mm)	0.20 ÷ 0.35	1.4 16v TJet

Measurement	Value	Validity
Cylinder compression 2nd sealing ring gap (mm)	0.40 ÷ 0.60	1.4 16v TJet

Measurement	Value	Validity
Cylinder compression 3rd sealing ring gap (mm)	0.20 ÷ 0.40	1.4 16v

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

Measurement	Value	Validity
Sealing ring seat in piston - 1st groove (mm)	1.220 ÷ 1.240	1.4 16v TJet

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

1. Use a feeler gauge (1a) to check mating clearance between retaining rings (1b) and grooves on pistons (1c).

Measurement	Value	Validity
Cylinder compression 1st sealing ring endfloat (mm)	0.025 ÷ 0.070	1.4 16v TJet

Measurement	Value	Validity
Cylinder compression 2nd sealing ring endfloat (mm)	0.020 ÷ 0.060	1.4 8v1.4 16v

Measurement	Value	Validity
Cylinder compression 3rd sealing ring endfloat (mm)	0.020 ÷ 0.060	1.4 16v TJet

- Check that the diameter of the big ends and the small ends are within the recommended values.

Measurement	Value	Validity
Big end diameter (mm)	45.138 ÷ 45.148	1.4 16v TJet

Measurement	Value	Validity
Small end diameter with bush (mm)	17.993 ÷ 18.000	1.4 16v TJet

The small end bush cannot be separaated from the actual connecting rod.Therefore the bush is handled together with the connecting rod by the Parts Dept.

    Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING     Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH - Fit the tool for rotating the crankshaft.

Tool	Description	Function	Validity
1860815000	Flange	Crankshaft rotation	1.4 16v1.3 Multijet

- Fit the connecting rod-piston assemblies and align in accordance with the following references.1. Piston class and arrow indicating timing side.2. On on inlet side where the number indicating the cylinder to which the connecting rod belongs is stamped.3. Gudgeon pin offset

The matching of the connecting rod-cap is the "BREAKING" type therefore the position is compulsory and the number corresponding to the position of the cylinder must be present.

Letters identifying the cylinder liner classes are shown on the crankcase.

1. Fit connecting rod/piston assemblies (1a) with half-bearings, using tool (1b) to compress retaining rings and then fit the piston into the liner. - Rotate the engine on the overhaul stand.1. Apply the calibrated wire (plastigage) for measuring the crankpin clearance. - The size of the connecting rod half-bearings is given.

Measurement	Value	Validity
Standard connecting rod half-bearing thickness (mm)	1.544 ÷ 1.548	1.4 16v TJet

Measurement	Value	Validity
Connecting rod half-bearing 1 oversize (mm)	0.127	1.4 16v TJet

Measurement	Value	Validity
Connecting rod half-bearing 2 oversize (mm)	0.254	1.4 16v TJet

Measurement	Value	Validity
Connecting rod half-bearing 3 oversize (mm)	0.508	1.4 16v TJet

- 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 thoroughly 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

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

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

Measurement	Value	Validity
Clearance between connecting rod bearings - crankpin bearings (mm)	0.024 ÷ 0.060	1.4 16v TJet

- 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 torque given previously.- Rotate the engine on the overhaul stand.- 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.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil pump	Bolt	M6	0.9 ÷ 1.1	1.4 16v

- Place the minimum engine oil pressure switch in position and tighten it to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Switch for engine oil pressure warning light	-	M14	2.9 ÷ 3.5

- Fit the oil seal on the crankshaft front cover using the tool.

Tool	Description	Function	Validity
1860990000	Fitting tool	Fitting crankshaft front cover oil sealFitting oil seal on exhaust camshaft	1.2 8v1.4 8v1.4 16v

- Remove the flange for rotating the crankshaft fitted previously.- Place a new crankcase rear cover with integrated oil seal in position and secure it by tightening the bolts to the recommended 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

- Place the crankshaft gear in its housing.1. Because the timing is adjusted with the four pistons in line, i.e. half-way along their effective strokes, it is essential to position the crankshaft in phase with the camshafts. They can be approximately positioned by turning the crankshaft gear (1a) until the locating dowel (1b) is positioned opposite to the rpm sensor seat (1c) with the first cylinder piston in descending phase, i.e. intake. 1. Position the counter-torque tool.

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

2. Secure the crankshaft gear (2a) by tightening the bolt (2b) to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Crankshaft gear	Bolt	M12	1.9 ÷ 2.1 + 107° ÷ 113°	1.4 16v

3. Position the rpm sensor (3a) in its housing and secure it by tightening the bolt (3b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Rpm sensor	Bolt	M6	0.8 ÷ 1.0	1.2 8v1.4 8v1.4 16v

- Apply silicon sealant to the splining on the flange securing the water pump to the cylinder block/crankcase.- Position the water pump in its housing and secure it, tightening the bolts and the nut to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Water pump	Bolt	M6	0.9 ÷ 1.1	1.4 16v

Component	Fastening	dia	Value (daNm)	Validity
Water pump	Nut	M6	0.9 ÷ 1.1	1.4 16v

- Rotate the engine through 180° on the overhaul stand.- Clean the lower crankcase and oil sump contact surfaces, removing the silicon sealant residues.- Apply the sealant without a break to the entire perimeter of the oil sump.- Position the oil sump in its housing and secure it, tightening the bolts and the nuts to the recommended torque.

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

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump	Bolt	M6	0.8 ÷ 1.0	1.4 16v

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump	Nut	M6	0.8 ÷ 1.0	1.4 16v

- Rotate the engine through 180° on the overhaul stand.- Fit the locating bushes for the cylinder block/crankcase.- Fit a new cylinder head gasket on the cylinder block.- Position the cylinder head on the crankcase aligning the locating dowels.1. Tighten the bolts securing the cylinder head to the recommended torque.

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

Component	Fastening	dia	Value (daNm)	Validity
Cylinder head	Bolt	M9	3 + 90° + 90°	1.4 16v

- Fit the locating bushes and position the camshaft housing on the cylinder head support plane.- Position the tappet retaining tools beneath the camshaft housing, then place the camshaft housing on the cylinder head and withdraw the tools.- Use the tool to tighten the camshaft housing bolts to the specified torque.

Tool	Description	Function	Validity
1860834000	Spanner	Loosen/tighten the cylinder head extension bolts	1.4 16v

Component	Fastening	dia	Value (daNm)	Validity
Engine cylinder head extension	Bolt	M8	1.3 ÷ 1.6	1.4 16v

- Refit the plugs complete with new O-rings and tighten them to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine cylinder head extension plugs	-	M16	1.3 ÷ 1.6	1.4 16v

- Place the camshaft driven pulley in its housing without tightening the bolt.- Fit the camshaft driven pulley locking tool.

Tool	Description	Function	Validity
2000015800	Counter-torque	Camshaft driven pulley lock	1.4 16v

- Tighten the camshaft driven pulley bolt to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Driven timing pulley	Bolt	M12	10.8 ÷ 13.2	1.4 16v

- Tighten the retaining bolts for the camshaft idler gears to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Camshaft gears	Bolt	M12	12.0	1.4 16v

- Loosen the bolt securing the camshaft driven pulley and remove the locking tool.- Remove the tool used previously for counter-torque for tightening the bolt securing the crankshaft gear.1. Position the tools (1a) in the seats for the spark plug for 1st and 2nd cylinder, tightening the pins (1b) to a torque of 0.5 daNm.

Tool	Description	Function	Validity
1860992000	Bearings	Crankshaft timing	1.4 16v

2. Rotate the crankshaft in its normal direction of rotation until the tool moving pins fitted previously are aligned with one another.

Rotate the crankshaft proceeding gradually to prevent the tool pins being expelled by the compression of the pistons.

3. The camshaft timing was adjusted previously by fitting the tools illustrated.

Tool	Description	Function	Validity
1860985000	Locating pins	Camshaft timing	1.4 16v

- Proceed with fitting the timing drive belt, firstly fitting it on the crankshaft gear, the water pump pulley, the camshaft driven pulley and lastly on the mobile tensioner.

Ensure that this operation is performed with the camshaft driven pulley slack.

1. Tension the timing belt by turning it anticlockwise with the tool (1a) and the moving tensioner (1b) and then secure it when the reference fork (1c) is in contact (1d).

Tool	Description	Function	Validity
1860987000	Spanner	Tensioning toothed timing drive belt	1.2 8v1.4 8v1.4 16v

- Fit the camshaft driven pulley locking tool.

Tool	Description	Function	Validity
2000015800	Counter-torque	Camshaft driven pulley lock	1.4 16v

- Tighten the camshaft driven pulley bolt to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Driven timing pulley	Bolt	M12	10.8 ÷ 13.2	1.4 16v

- Remove the tools positioned previously for the timing and locking of the camshafts and rotate the crankshaft through two revolutions.1. Loosen the moving tensioner nut and adjust the front fork using the tool (1a) until it is aligned with the rear fork (1b).2. Tighten the nut fixing the moving tensioner to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Moving timing system tensioner	Nut	M8	2.2 ÷ 2.7	1.4 16v

- Turn the crankshaft through two revolutions in its normal rotation direction, then reposition the tools used to adjust engine timing and check the engine is in phase.- Remove the tools used for timing the engine.- Place the side plugs in their seats in the cylinder head extension and tighten them to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine cylinder head extension plugs	-	M16	1.3 ÷ 1.6	1.4 16v

- Place the flywheel side camshaft rear cover in its housing and secure it using the nuts.- Place the water pump rigid inlet pipe, complete with a new gasket, in position and secure it tightening the bolts to the cylinder block/crankcase and to the cylinder head to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Water pump rigid inlet pipe	Bolt	M6	0.9 ÷ 1.1	1.4 16v

- Fit the ignition coils and tighten them to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Ignition coils	Bolt	M6	0.8 ÷ 1.0	1.2 8v1.4 8v1.4 16v

- Position the timing sensor in its housing and secure it using the bolt.- Place the timing side rigid engine support in position and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Rigid engine support, timing side	Bolt	M8	2.2 ÷ 2.7	1.4 16v

- Fit the upper and lower timing belt covers and secure them using the bolts.- Position the crankshaft pulley 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

- Place the oil filter mounting and engine oil heat exchanger in position and tighten the connector, crankshaft oil seal front cover side, to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Heat exchanger and oil filter mounting - crankshaft front oil seal cover side	Connector	M20	4.1 ÷ 4.9	1.4 16v TJet

- Tighten the bolt fixing the engine oil heat exchanger and oil filter mounting assembly, crankcase side, to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Heat exchanger and oil filter mounting - engine block side	Bolt	M10	4.5 ÷ 5.5	1.4 16v TJet

- Place the exhaust manifold-turbocharger assembly, complete with new gasket, back in its housing and secure it tightening the new nuts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Exhaust manifold	Nut (to be replaced)	M8	1.4 ÷ 1.6 + 30° +/- 3°	1.2 8v1.4 8v1.4 16v1.3 Multijet

- Place the exhaust manifold heat shield in its housing and tighten the nuts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Exhaust manifold heat shield	Nut	M6	0.8 ÷ 1.0	1.4 16v TJet

- Place the turbocharger coolant return pipe, complete with new gasket, in position and tighten the connectors.

The connectors should be tightened keeping the pipe still. Any movement of the pipe of more than 3° will adversely affect the seal of the connectors.

- Place the turbocharger lubrication oil supply pipe, complete with new gasket, back in its housing and tighten the connectors to the recommended torque.

The connectors should be tightened keeping the pipe still. Any movement of the pipe of more than 3° will adversely affect the seal of the connectors.

Component	Fastening	dia	Value (daNm)	Validity
Turbocharger lubrication oil supply pipe - heat exchanger side	Connector	M6	0.8 ÷ 1.0	1.4 16v TJet

Component	Fastening	dia	Value (daNm)	Validity
Turbocharger lubrication oil supply pipe - turbocharger side	Connector	M12	1.8 ÷ 2.2	1.4 16v TJet

- Tighten the bolt fixing the turbocharger lubrication oil supply pipe intermediate mounting bracket.- Place the engine oil heat exchanger water return pipe, complete with new gaskets, in position and tighten the connectors.

The connectors should be tightened keeping the pipe still. Any movement of the pipe of more than 3° will adversely affect the seal of the connectors.

- Place the engine oil heat exchanger water return pipe, complete with new gaskets, in position and tighten the connectors to the recommended torque.

The connectors should be tightened keeping the pipe still. Any movement of the pipe of more than 3° will adversely affect the seal of the connectors.

Component	Fastening	dia	Value (daNm)	Validity
Water supply pipe to engine oil heat exchanger	Connector	M16	3.0 ÷ 3.6	1.4 16v TJet

- Tighten the bolts securing the coolant delivery pipe to the engine oil heat exchanger, crankcase side and heat exchanger side.- Place the turbocharger lubrication oil return, complete with new gasket, back in its housing and tighten the bolts to the recommended torque.

Tighten the "slotted bolt" first when connecting the pipe to the turbocharger.

The connectors should be tightened keeping the pipe still. Any movement of the pipe of more than 3° will adversely affect the seal of the connectors.

Component	Fastening	dia	Value (daNm)	Validity
Lubrication oil return pipe from turbocharger	Bolt	M6	0.8 ÷ 1.0	1.4 16v TJet

- Tighten the intermediate connector securing the turbocharger lubrication oil return pipe to the engine block, engine oil heat exchanger side, to the recommended torque.

The connector should be tightened keeping the pipe still. Any movement of the pipe of more than 3° will adversely affect the seal of the connector.

Component	Fastening	dia	Value (daNm)	Validity
Turbocharger lubrication oil return pipe in sump - engine oil heat exchanger side	Connector	M16	3.0 ÷ 3.6	1.4 16v TJet

- Place the water-engine oil heat exchanger heat shield in its housing and tighten the bolts to the recommended torque.- Place the engine oil filter heat shield in its housing and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil filter heat shield	Bolt	M6	0.8 ÷ 1.0	1.4 16v TJet

- Refit the bracket complete with pressurized air by-pass solenoid and tighten the fastenings.- Refit the oil vapour separator and tighten the bolts.- Refit the air chamber in its seat and tighten the new bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Air chamber	Bolt (to be replaced)	M7	1.3 ÷ 1.7	1.4 16v TJet

- Connect the oil vapour supply pipe to the air chamber and tighten the band.- Place the air chamber mounting bracket in position and tighten the bolts.- Place the engine oil dipstick pipe back in its housing and fasten it with the bolt.- Place the intermediate shaft bearing support in position and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Intermediate driveshaft bearing support	Bolt	M8	2.3 ÷ 2.8	1.4 16v TJet

- Fit the alternator and air conditioning compressor mounting in position and tighten the fastenings to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Air conditioning compressor/alternator mounting	Bolt	M10	4.5 ÷ 5.5	1.4 16v

- Place the alternator in position and tighten the bolts.- Place the air conditioning compressor in position and tighten the bolts.- Fit the auxiliary units single belt, adjust the moving tensioner and then remove the locking pin.- Place the engine wiring back in position and tighten the bolt fixing the ignition coil wiring duct.- Connect the electrical connections for the ignition coils.- Secure the electrical connection for the timing sensor.- Connect the earth lead and tighten the bolt.- Connect the electrical connection for the engine coolant temperature sensor.- Connect the electrical connection for the pressurized air by-pass solenoid valve.- Connect the electrical connection for the throttle body.- Connect the wiring duct to the air chamber using the retaining clips.- Connect the electrical connection for the fuel vapour solenoid valve.- Connect the electrical connection for the detonation sensor.- Connect the injector wiring junction.- Connect the electrical connection for the air conditioning compressor.- Connect the alternator earth lead and tighten the nut.- Place the timing belt inner guard in its housing and secure it using the bolts.- Connect the earth lead to the auxiliary support and tighten the bolt.- Connect the electrical connection for the air temperature and pressure sensor.- Connect the electrical connection for the exhaust gas temperature sensor.- Connect the electrical connection for the minimum engine oil pressure switch.- Connect the electrical connection for the engine rpm sensor.