1004E20 ENGINE - DISMANTLE AND RE-BUILD FOLLOWING OPERATION 1004E10 - WASH AND CHECK DISMANTLED PARTS - RE-FIT CYLINDER HEAD AND OIL SUMP - DOES NOT INCLUDE REPAIRS TO CYLINDER HEAD AND AUXILIARY UNIT - Fiat - DOBLO - eLearn

2585282 - 1004E20 engine - dismantle and re-build following operation 1004e10 - wash and check dismantled parts - re-fit cylinder head and oil sump - does not include repairs to cylinder head and auxiliary unit

Remove the electrical components before washing to prevent damaging them through the chemical compounds used for washing.

Removing ( Refitting

) 1. Undo the bolt (1a) and remove the rpm sensor (1b).2. Undo the bolt (2a) and remove the rigid coolant inlet pipe to the water pump (2b) complete with O-Ring (2c).

1. Undo the bolts (1a) and remove the engine oil filter mount (1b) complete with engine oil filter (1c), engine oil heat exchanger (1d) and engine oil filler fitting (1e).Remove the gasket.2. Undo bolts (2a) and remove the air conditioner compressor (2b).

1. Undo the bolts (1a) and remove the air conditioner compressor mount (1b).

1. Undo the connectors (1a) and remove the engine pipe (1b).

1. Undo bolts (1a) and remove alternator (1b).

1. Undo the bolts (1a) and remove the alternator mounting (1b).

1. Undo the bolts (1a) and remove the engine oil recovery manifold (1b).2. Undo the bolts (2a) and remove the starter motor (2b).

Rotate the engine through 180° on the overhaul stand.1. Undo the lower crankcase retaining bolts.2. Cut the lower crankcase sealant using the tool.

	Description	Code
2	Blade	1.870.718.000

3. Remove the lower crankcase.Remove the lower main journal half-bearings.

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

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

	Measurement		Value
1	End float (mm)		0.055 ÷ 0.265

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. Remove the crankshaft (1a) complete with rear oil seal (1b).2. Remove the upper main journal half-bearings.

The central main bearing half is joined to the thrust half-rings. Press the ends of the half-bearing to separate.

1. Undo the bolts (1a) and remove the engine oil jets (1b).2. Remove the lower engine block locating bushes.

Use an appropriate tool to support the upper engine block.Unscrew the retaining bolts and separate the upper crankcase from the overhaul stand plate.Position the upper crankcase on a suitable workbench.Proceed with the removal Op. 1028H60 PISTON SET, GUDGEON PINS AND SEALS - REPLACE WITH PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING.Proceed with the removal 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

) Clean sealant residues off the mating surfaces between: cylinder head extension/lower cylinder head, upper crankcase/lower crankcase and lower crankcase/crankcase sump.Clean the parts removed thoroughly and check their condition visually.Fit the water/oil sealing plugs in the crankcase using suitable fitting tools.Lubricate all the mechanical components with engine oil.1. Measure the cylinder bore diameter using the diagram illustrated.

	Measurement		Value
1	Cylinder liner diameter (mm)	Category A	69.600 ÷ 69.610
Category B	69.610 ÷ 69.620
Category C	69.620 ÷ 69.630

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

	Measurement		Value
-	Cylinder liner taper (mm)		< 0.010

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

	Measurement		Value
-	Cylinder liner ovality (mm)		± 0.005

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

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

	Measurement		Value
-	Cylinder liner oversize (mm)		0.1

Use an appropriate support tool to replace the upper crankcase on the overhaul stand.Refit the lower crankcase locating bushes in their seats.Fit the lower crankcase to the upper crankcase provisionally.1. Tighten the central bolts (1a) securing the lower crankcase to the specified torque, following the order shown in the figure. Use tool (1b) for angular tightening.

	Fastening	Component	dia	Value(daNm)
1a	Central bolt	ENGINE CRANKCASE	M10	(Engine crankcase side) 1.9 - 2.1 + 80 ± 3?

	Description	Code
1b	Torque wrench	1.860.942.000

2. Tighten the lower crankcase side bolts to the specified torque, following the order shown in the figure.

	Fastening	Component	dia	Value(daNm)
2	Central bolt	ENGINE CRANKCASE	M8	(Engine crankcase side) 2.9 - 3.2

3. Check that the diameter of the main journal seats is within specified limits (without fitting the half-bearings).

	Measurement		Value
3	Main journal seat diameter (mm)	Category A	54.710 ÷ 54.714
Category B	54.714 ÷ 54.718
Category C	54.718 ÷ 54.722

Check that there are no deposits or blockages in the crankshaft lubrication ducts.Check that the diameter of the main journals is within specified limits.

	Measurement		Value
-	Main journal diameter (mm)	Category A	50.994 ÷ 51.000
Category B	50.988 ÷ 50.994
Category C	50.982 ÷ 50.988

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

	Measurement		Value
-	Main journal 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 corresponds to the recommended figures.

	Measurement		Value
-	Crankpin diameter (mm)	Category A	42.591 ÷ 42.600
Category B	42.582 ÷ 42.591

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

	Measurement		Value
-	Crankpin undersize (mm)		0.127

Check the crankshaft and connecting rod bearings bearing in mind that no adjustment operations should be carried out on the half-bearings. Replace them if scoring or signs of binding are noted.The size of the main journal half-bearings is given.

	Measurement		Value
-	Main bearing half thickness (mm)	Category A	1.836 ÷ 1.841
Category B	1.841 ÷ 1.846
Category C	1.846 ÷ 1.851

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

	Measurement		Value
-	Connecting rod half-bearing thickness (mm)	Category A	1.546 ÷ 1.552
Category B	1.550 ÷ 1.556

Place the upper main bearing halves in their seats taking great care over cleanliness.

Half-bearings of different categories may be fitted to the same journal to reduce the clearance. In the above case, observe the following installation requirements. Fit the thickest half-bearing to the main bearing cap and the thinnest to the crankcase.

If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions. The thrust half-rings are built into the central main bearing half.

The thrust half-ring thickness is given.

	Measurement		Value
-	Thrust half-washer thickness (mm)		2.310 ÷ 2.360

The thrust half-washer undersize is 0.127 mm.

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

1. Refit the lower crankase with lower main bearing halves in its seat.2. Tighten the central bolts (2a) securing the lower crankcase to the specified torque, following the order shown in the figure. Use tool (2b) for angular tightening.

	Fastening	Component	dia	Value(daNm)
2a	Central bolt	ENGINE CRANKCASE	M10	(Engine crankcase side) 1.9 - 2.1 + 80 ± 3?

	Description	Code
2b	Torque wrench	1.860.942.000

3. Tighten the lower crankcase side bolts to the specified torque, following the order shown in the figure.

	Fastening	Component	dia	Value(daNm)
3	Central bolt	ENGINE CRANKCASE	M8	(Engine crankcase side) 2.9 - 3.2

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

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

	Measurement		Value
1b	Clearance between main bearings - crankshaft main journals (mm)		0.028 ÷ 0.048

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

1. After checking all the main journals, apply a strip of specified silicon sealant to the contact surfaces between the lower crankcase and the upper crankcase as shown in the diagram in the figure.

The sealant strip must be unbroken. The sealant strip diameter must be 2.5 - 3.5 mm

	Type	Component	Description	Qty.
1	Silicon sealant	ENGINE CRANKCASE	Loctite 5900	-

After applying the sealant clean the crankshaft lower oil seal seat.

Fit the lower crankcase to the upper crankcase permanently by tightening the bolts as shown previously.Check that the small end bush bore diameter is within the recommended limits; if not, replace the connecting rod assemblies.

	Measurement		Value
-	Inner diameter (mm)		23.006 ÷ 23.012

Check that the diameter of the gudgeon pin housing in the piston is within the recommended values.

	Measurement		Value
-	Piston pin housing diameter (mm)		22.990 ÷ 22.996

If the piston pin bore diameter is not within specified values, replace the piston complete with its piston pin and rings.Check that the outer diameter of the piston pins is within the recommended limits; if not, replace the worn piston pins.

	Measurement		Value
-	Outer diameter (mm)		22.982 ÷ 22.987

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.

	Measurement		Value
-	Gap (mm)	1st sealing ring	0.20 ÷ 0.30
2nd sealing ring	1.0 ÷ 1.5

	Measurement		Value
-	Gap (mm)	Oil scaper ring	0.25 - 0.50

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
-	Outer diameter (mm)	Category A	69.520 ÷ 69.530
Category B	69.530 ÷ 69.540
Category C	69.540 ÷ 69.550

Measure perpendicular to the gudgeon pin axis, 12 mm from the lower edge of the skirt.

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

	Measurement		Value
-	Backlash, first ring (mm)		0.09 ÷ 0.13

1. Check that the backlash (1a) between the second ring (1b) and the housing in the piston (1c) corresponds to the recommeded figure.

	Measurement		Value
1a	Backlash, 2nd ring (mm)		0.04 ÷ 0.08

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

	Measurement		Value
-	End float (mm)		0.030 ÷ 0.070

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

The connecting rods are pre-set fracture type and are supplied already fractured by Parts together with the cap bolts. The connecting rod caps are not interchangeable because the fracture profile differs from part to part.

	Fastening	Component	dia	Value(daNm)
1c	Bolt	CONNECTING ROD CAPS	M8	1.9 ÷ 2.1 + 40? ± 2?

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

	Description	Code
-	Torque wrench	1.860.942.000

2. Check that the big end diameter (without fitting the half-bearings) is within the recommended limits; if not, replace the connecting rods.

	Measurement		Value
2	Big end diameter (mm)		45.734 ÷ 45.744

Proceed with the refitting Op. 1028H60 PISTON SET, GUDGEON PINS AND SEALS - REPLACE WITH PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING.Proceed with the refitting Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH.Check that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it.Refit the engine oil sprays in their seats and secure by tightening the bolts to the specified torque.

The engine oil spray bolts are pretreated with locking compound and should be replaced whenever they are refitted.

	Fastening	Component	dia	Value(daNm)
-	Bolt	PISTON COOLING NOZZLES	M6	(Engine crankcase side) 0.8 - 1.0

1. Fit the tool.

	Description	Code
1	Flange	1.860.815.000

Turn the crankshaft using the tool fitted previously.Fit the connecting rod-piston assemblies and align in accordance with the following references.1. Piston class (1a) and arrow (1b) indicating camshaft side.2. Area where the number of the matching cylinder liner is stamped.3. Exhaust (3a) on the piston skirt to be aligned with oil spray (3b).

1. Refit the piston-connecting rod assemblies (1a) in their seats with upper connecting rod bearing halves using tool (1b).

The connecting rod bearing halves may be identified as follows:upper connecting rod bearing half, connecting rod side, trimetallic and dark in colour;lower connecting rod bearing half, cap side bimetallic, light coloured with a hole.Never reverse the positioning of the connecting rod bearing halves under any circumstances.

Rotate the engine through 180° on the overhaul stand.1. Fit the calibrated wire (plastigage) for measuring the bearing clearance.

1. Refit the connecting rod cap assemblies (1a) in their seats with upper connecting rod bearing halves using tool (1b).

2. Tighten the connecting rod cap bolts (2a) to the recommended torque using the angular tightening tool (2b).

	Fastening	Component	dia	Value(daNm)
2a	Bolt	CONNECTING ROD CAPS	M8	1.9 ÷ 2.1 + 40? ± 2?

	Description	Code
2b	Torque wrench	1.860.942.000

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

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

	Measurement		Value
1b	Crankshaft crankpins (mm)		0.030 ÷ 0.062

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

Fit the connecting rod caps permanently by tightening the bolts as shown previously.Remove the tool.

	Description	Code
-	Flange	1.860.815.000

1. Fit the crankshaft rear oil seal (1a) using the tool (1b).

	Description	Code
1b	Fitting tool	1.870.900.200

Rotate the engine through 180° on the overhaul stand.1. Place the starter motor (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1b	-	STARTER MOTOR	M8	(Engine crankcase side) 2.3 - 2.8

2. Place the separator condensed oil manifold (2a) in its housing and secure it by tightening the bolts (2b) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
2b	Bolt	ENGINE OIL RECOVERY MANIFOLD	M6	(Engine crankcase side) 0.8 - 1.0

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

	Fastening	Component	dia	Value(daNm)
1b	Bolt	ALTERNATOR SUPPORT	M8	(Engine crankcase side) 2.3 - 2.8

1. Place the alternator (1a) in its housing and fasten it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1b	Bolt	ALTERNATOR ASSEMBLY	M8	(Mount side) 2.3 - 2.8

Refit the engine oil pipe in its seat on the crankcase and secure with connectors.1. Place the air conditioner compressor mounting (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1b	Bolt	COMPRESSOR MOUNT (AC)	M8	(Upper and lower engine crankcase side) 2.3 - 2.8

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

	Fastening	Component	dia	Value(daNm)
1b	Bolt	AIR CONDITIONER ASSEMBLY COMPRESSOR	M8	(Mount side) 2.3 - 2.8

2. Replace the engine oil filter mount (2a) with the engine oil filter (2b), engine oil filler fitting (2c) and secure by tightening bolts (2d) to the specified torque.

Ensure the gasket is present, undamaged and correctly positioned.

	Fastening	Component	dia	Value(daNm)
2d	Bolt	OIL FILTER MOUNT	M6	(Engine crankcase side) 0.8 - 1.0

1. Refit the rigid coolant inlet pipe to the water pump (1a) complete with O-ring (1b) and secure with bolt (1c).

Fit the rigid pipe in the crankcase very carefuly to ensure the o-ring is correctly positioned.

2. Place the rpm sensor (2a) in its housing and secure it by tightening the bolt (2b) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
2b	Bolt	ENGINE RPM AND TIMING SENSOR	M6	(Engine crankcase side) 0.8 - 1.0

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
1	Dial gauge support	1.870.404.001

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

	Measurement		Value
-	Cylinder head gasket size (no hole) (mm)		0.67 ÷ 0.77
	Average - maximum piston projection (mm)	0.028 ÷ 0.127

	Measurement		Value
-	Cylinder head gasket size (one hole) (mm)		0.77 ÷ 0.87
	Average - maximum piston projection (mm)	0.128 ÷ 0.227

	Measurement		Value
-	Cylinder head gasket size (two holes) (mm)		0.87 ÷ 0.97
	Average - maximum piston projection (mm)	0.228 ÷ 0.327

1. Fit the camshaft timing adjustment tool.

	Description	Code
1	Template	1.870.900.300

1. Ensure the lower cylinder head locating bushes are present in the engine block.2. Fit the new cylinder head gasket selected.3. Position the cylinder head on the cylinder block/crankcase.4. Tighten the cylinder head bolts to the recommended torque using the angular tightening tool.

Follow the order shown in the figure for each tightening sequence. The nominal tightening of 4.0 daNm is performed in two stages: a pretightening to 2.0 daNm followed by an additional tightening of 2.0 daNm.

	Fastening	Component	dia	Value(daNm)
4	Bolt	CYLINDER HEAD	M10	(Engine crankcase side) 3.8 - 4.2 +90 + 90?

	Description	Code
4	Torque wrench	1.860.942.000

Check the cylinder head - crankcase misalignment.

It is only possible for the cylinder head to protrude from the crankcase.

	Measurement		Value
-	Cylinder head - crankcase misalignment (mm)		0.1

Connect the condensed engine oil recovery pipe, oil vapour separator side, and tighten the collar.Tighten the bolt securing the water/exhaust gas heat exchanger for the EGR to the crankcase.1. If not already carried out during cylinder head overhaul, remove plugs (1a) and fit camshaft timing adjustment tools (1b) to the cylinder head extension.

Fit the tools and position with their millings horizontal. Ensure they fit into the seats on the camshafts.

	Description	Code
1b	Templates	1.870.896.900

Remove the intake camshaft timing tool and tighten the plug.

1. Refit the cylinder head extension (1a) with gasket (1b) in its seat.

1. Tighten the single cylinder head extension bolt M8 (1a) to a pretorque of 1.5 daNm and M7 (1b) to a pretorque of 1.2 daNm2. Tighten bolts (2a) and (2b) securing the single cylinder head extension to the specified torque.

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

	Fastening	Component	dia	Value(daNm)
2a	Bolt	CYLINDER HEAD EXTENSION	M8	(Lower cylinder head side) 2.5

	Fastening	Component	dia	Value(daNm)
2b	Bolt	CYLINDER HEAD EXTENSION	M7	(Lower cylinder head side) 1.8

Check the misalignment between the cylinder head extension - cylinder head.

It is only possible for the cylinder head extension to protrude from the cylinder head.

	Measurement		Value
-	Misalignment between cylinder head extension - cylinder head (mm)		0.1

Refit new injector dust rings into their seats on the cylinder head extension.1. Refit the injectors (1a) complete with brackets (1b) in their seats.

Before refitting, replace the copper ring on the injectors.

2. Refit the tapered washer (2a) and washer (2b) in their seats.3. Tighten the nut securing the injector bracket to the specified torque.

	Fastening	Component	dia	Value(daNm)
3	Nut	INJECTORS(DIESEL)	M8	(Cylinder head side) 1.8 - 2.2

Use a suitable tool (e.g. vice) to set the chain tensioner and hold it fully back with a retaining pin.1. Place the chain tensioner (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1b	Bolt	MOBILE TIMING TENSIONER	M6	(Cylinder head side) 0.8 - 1.0

1. Place the timing chain fixed pad (1a) back in its housing and secure it using the bolts (1b).2. Refit the exhaust side camshaft toothed drive pulley (2a) together with chain (2b) and toothed drive pulley (2c).

Fit the exhaust side camshaft toothed drive pulley and the toothed drive pulley according to the position marked on disassembly. If the pulleys are replaced, fit with the wording facing outwards.

3. Place the timing chain mobile pad (3a) back in its housing and secure it using the pin (3b).

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

	Fastening	Component	dia	Value(daNm)
1	Bolt	TIMING DRIVEN PULLEY	M12	(Exhaust camshaft side) 10.8 - 13.2

Remove the chain tensioner retaining pin and check that the piston is in contact with the mobile pad.1. Refit the support bracket (1a) complete with single fuel manifold pipe (1b), fuel pressure regulator (1c), fuel pressure sensor (1d) and secure with bolts (1e).2. Connect the return pipe from the pressure pump to the fuel manifold, pressure pump side, and tighten the collar.3. Fit new pipes from the fuel manifold to the injectors and secure with connectors without tightening.4. Tighten the connectors for the pipes from the fuel manifold to the injector side injectors to the recommended torque using an appropriate commercial wrench.

	Fastening	Component	dia	Value(daNm)
4	Connector	PIPE FUEL MANIFOLD TO INJECTORS	M12	(Injector side) 2.3 - 2.5

5. Tighten the connectors for the pipes from the fuel manifold to the fuel manifold side injectors to the recommended torque using an appropriate commercial wrench.

	Fastening	Component	dia	Value(daNm)
5	Connector	PIPE FUEL MANIFOLD TO INJECTORS	M14	(Fuel manifold side) 2.7 - 2.9

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

6. Place a new pipe from the pressure pump to the single fuel manifold in its housing and secure it using the connectors without tightening them.7. Tighten the connector for the pipe from the pressure pump to the single fuel manifold, pump side, to the recommended torque using a spanner.

	Fastening	Component	dia	Value(daNm)
7	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M12	(Pressure pump side) 2.3 - 2.5

8. Tighten the connector for the pipe from the pressure pump to the single fuel manifold, fuel manifold side, to the recommended torque using a suitable commercial wrench.

	Fastening	Component	dia	Value(daNm)
8	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14	(Fuel manifold side) 2.7 - 2.9

9. Connect the fuel outlet pipe from injectors (9a), injector side and push in until the clip clicks into place (9b).

Place the camshaft cover gasket back in its housing.1. Fit the tool to the camshaft cover.

	Description	Code
1	Hose	1.870.900.600

2. Place the timing cover (2a) in its housing complete with engine oil draught (2b) and engine oil pump, then tighten the bolts (2c) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
2c	Bolt	FRONT COVER CRANKSHAFT	M6	0.8 ÷ 1.0

Connect the engine oil vapour recirculation pipe fitting to the timing cover and tighten the bolts.

Ensure the o-ring is present and correctly positioned.

Rotate the engine through 180° on the overhaul stand.Place the crankcase oil sump partition back in its housing and secure it using the bolts.Apply a strip of recommended silicon sealant to the contact surfaces between the crankcase sump and lower crankcase as shown in the diagram in the figure.

The sealant strip must be unbroken. The sealant strip diameter must be 3.5 0.5 mm

	Type	Component	Description	Qty.
-	Sealant	ENGINE OIL SUMP	LOCTITE 5900	-

1. Position the crankcase sump (1a) in its housing and secure it tightening the bolts (1b) and the nuts (1c) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1b	Bolt	ENGINE OIL SUMP	M6	(Lower engine crankcase side) 0.8 - 1.0

	Fastening	Component	dia	Value(daNm)
1c	Nut	ENGINE OIL SUMP	M6	(Cam cover side) 0.8 ÷ 1.0

2. Place the bracket (2a) in its housing and secure it by tightening the bolts (2b) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
2b	Bolt	GEARBOX/ENGINE COUPLING BRACKET	M8	(Lower engine crankcase side) 2.7 - 3.3

Rotate the engine through 180° on the overhaul stand.Place the engine oil dipstick pipe back in its housing and fasten it with the bolt.Place the intermediate driveshaft mount in position and secure it tightening the bolts to the recommended torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	FRONT DRIVE SHAFT BEARING MOUNT	M8	(Lower engine crankcase side) 2.0 - 2.4

Remove the tool.

	Description	Code
-	Hose	1.870.900.600

1. Position the crankcase pulley support flange (1a) in its housing and secure it with the left-threaded bolt without tightening it (1b) to the recommended torque.

1. Place the water pump (1a), complete with gasket in position, then tighten the bolts (1b) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1b	Nut	COOLANT PUMP	M6	(Engine upper crankcase side) 0.8 - 1.0

2. Position the crankshaft pulley (2a) in its housing and secure it tightening the nuts (2b) to the recommended torque.3. Position the auxiliary drivebelt mobile tensioner (3a) in its housing and secure it tightening the bolt (3b) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
3b	Bolt	SINGLE BELT MOVING TENSIONER VARIOUS	M10	(Engine upper crankcase side) 4.5 - 5.5

Adjust the mobile tensioner with a wrench and fit the auxiliary drive belt.1. Place the timing side rigid engine support (1a) in its housing with the engine lift bracket (1b) and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1c	Bolt	RIGID ENGINE MOUNT, TIMING SIDE	M10	(Engine upper crankcase side) 5.7 - 6.3

1. Place the turbocharger (1a) in its housing complete with catalytic converter (1b) and fasten it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1c	Nut	TURBOCHARGER	M8	(Exhaust manifold side) 2.3 - 2.8

Replace the pipe carrying coolant to the engine oil heat exchanger complete with gasket, then tighten the collar and bolts.

Fold over the gasket safety tabs.

Tighten the bolt securing the pipe carrying coolant to the engine oil heat exchanger to the crankcase.Refit the exhaust manifold heat shield with the engine lift bracket and secure with the nut and bolts.1. Position the pipe carrying engine oil to the turbocharger (1a) in its housing and secure it tightening connectors (1b) to the recommended torque.

Replace the copper washers on the connectors.

	Fastening	Component	dia	Value(daNm)
1b	Connector	OIL DELIVERY PIPE TO TURBO	M10	(Turbocharger/oil filter mount side) 1.1 - 1.3

Position a new gasket between the crankcase and the engine oil return pipe to the turbocharger.2. Tighten the bolts securing the engine oil return pipe from the turbocharger, crankcase side, to the specified torque.

	Fastening	Component	dia	Value(daNm)
2	Bolt	OIL RETURN PIPE FROM TURBO	M6	(Turbocharger/ngine crankcase side) 0.8 - 1.0

Fit the protective strips to the oil filter and the engine oil heat exchanger.

Place the electrical wiring in position and fasten it to the bands on the air capacity chamber.Connect the electrical connection for the E.G.R. solenoid valve.Connect the electrical connection to the fuel pressure regulator.Connect the electrical connection for the pressure relief sensor.Connect the electrical connection to the fuel pressure sensor.Refit the engine wiring and secure.Tighten the bolts securing the wiring duct to the cylinder head.Connect the electrical connection to the air conditioning compressor engagement electromagnet.Connect the electrical connection for the cam angle sensor.Connect the electrical connections to the injectors.Connect the glow plug electrical connections.Connect the electrical connection to the engine oil pressure warning light switch.Connect the electrical connection for the engine rpm sensor.Connect the electrical connection to the engine coolant temperature sensor.Remove the engine from the overhaul stand.