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.

1. Position the flywheel lock.

	Description	Code
1	Counter-torque	1.860.846.000

2. Undo the bolts (2a) and remove the clutch plate (2b).

1. Position crankshaft gear locking tool as shown in the figure.

	Description	Code
1	Counter-torque	1.870.744.000

Work with flywheel retaining tool 1860846000 fitted.

2. Undo the bolt securing the crankshaft gear and remove it.

1. Undo the bolts fixing the engine flywheel.2. Remove the engine flywheel (2a) together with washer (2b) and the flywheel retainer positioned previously.

1. Undo the fixing bolts (1a) and remove the crankshaft rear cover (1b).

1. Undo bolt (1a) and remove the rigid engine coolant pump inlet pipe (1b) with sealing ring.2. Undo the bolts (2a) and nut (2b) remove the water pump (2c).

1. Remove the engine oil filter using a suitable tool.2. Remove the oil pressure sending unit.3. Undo 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. Using the service bolts, fit the tool for rotating the crankshaft.

	Description	Code
1	Flange	1.860.815.000

Rotate the crankshaft using the tool fitted previously until cylinders 1 and 4 are at T.D.C.1. Undo the bolts (1a) and remove the connecting rod cap (1b) for cylinders 1 and 4 complete with half-bearings (1c).2. Remove the piston-connecting rod assemblies (2a) for cylinders 1 and 4 complete with half-bearings (2b)Carry out the same operations to remove the pistons and connecting rods for cylinders 2 and 3.Remove the tool for rotating the crankshaft.

	Description	Code
-	Flange	1.860.815.000

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.

Hoist the crankcase using a hydraulic hoist with chains and remove the crankcase from the support brackets. Place on a suitable workbench. Op. 1028H60 PISTON SET, GUDGEON PINS AND SEALS - REPLACE WITH PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH1. Remove the coolant chamber plugs from the crankcase using a steel drift.2. Remove the lubrication duct plug from the crankcase using a steel drift.

Check the condition of the piston cooling oil sprays.1. If they are blocked, remove the oil sprays (1a) using a steel drift (1b). Insert the drift guide hole on on the nozzle surface to prevent the drift from slipping during the extraction operation and removing the cylinder liner.

	Description	Code
1b	Drift	1.860.395.000

Whenever the oil sprays are removed, they must not be reused but must be replaced.

Wash and check the appearance of all compents removed.Before fitting the water/oil sealing plugs in the crankcase, apply suitable sealant to the plug seats.

	Type	Component	Description	Qty.
-	Aerobic sealant	ENGINE CRANKCASE	Loktite 648	-

Apply suitable sealant to the plugs and fit the plugs in their seats using an ordinary drift.

	Type	Component	Description	Qty.
-	Sealant	CRANKCASE PLUGS	Loktite 510	-

1. Use the tool (1a) and a mallet to fit the new oil jets (1b).

	Description	Code
1a	Fitting tool	1.860.313.000

1. Using a calibrated metal rule (1a) and a feeler gauge (1b), check the planarity of the cylinder head - cylinder block/crankcase support surface.2. If the measurement does not correspond to the recommended values, regrind the cylinder head support surface.

	Measurement		Value
2	Cylinder head support surface flatness (mm)		< 0.1

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

	Measurement		Value
-	Cylinder liner diameter (mm)	Category A	70.800 - 70.810
Category B	70.810 - 70.820
Category C	70.820 - 70.830

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

	Measurement		Value
-	Cylinder liner ovality (mm)		< 0.05

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

	Measurement		Value
-	Cylinder liner taper (mm)		± 0.005

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
-	Cylinder liner bore diameter oversize (mm)		0.4

If the 0.4 mm oversize involves altering the cylinder bore diameter grade, the piston grade will be altered; for oversizes above grade C, replace the cylinder block/crankcase.

Clean the lubrication ports in the crankshaft using an air jet.Check that the diameter of the main journals is within specified limits.

	Measurement		Value
-	Main journal diameter (mm)	Category A	47.994 - 48.000
Category B	47.988 - 47.994
Category C	47.982 - 47.988

If the diameter of the main journals is not correct, they should be reground to the recommended undersize (0.270 mm).

Because the crankshaft has undergone nitriding, this treatment should be repeated and the size re-checked if it is ground. If the result of this check is less than the figures for grade A, replace the crankshaft.

	Measurement		Value
-	Main journal undersize (mm)	Category A	47.867 - 47.873
Category B	47.861 - 47.867
Category C	47.855 - 47.861

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

	Measurement		Value
-	Crankpin diameter (mm)		41.990 ÷ 42.008

- If the diameter of the crankpins is not correct, they should be reground to the recommended undersize (0.127 mm).

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

	Measurement		Value
-	Crankpin undersize (mm)		41.863 - 41.881

Check the main bearings, noting that the half-bearings should not be adapted. Replace them if scoring or signs of wear are noted.Fit the main bearing halves in their seats on the crankcase, aligning the lubrication holes and ensuring scrupulous cleaninliness. The centre crankshaft bearing has thrust half-washers incorporated becuase it acts as a thrust carrier.If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions.1. Use a dial gauge on a magnetic base to check that the crankshaft end float is within specified values.

	Measurement		Value
-	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 thrust washers (fastened to the central main bearing half) oversized by 0.270 mm.1. Fit the crankshaft in the crankcase.2. Fit the calibrated wire (plastigage) for measuring the bearing clearance.

1. Fit the main bearing caps (1a) complete with half-bearings (1b) and secure by tightening bolts (1c) to the specified torque using tool (1d) for angular tightening.

	Fastening	Component	dia	Value(daNm)
1c	Bolt	MAIN BEARING CAPS	M10 X 1.25	2 + 90°

	Description	Code
1d	Torque wrench	1.860.942.000

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

Thoroughly clean any residues of the calibrated wire (Plastigage) from the crankshaft.

	Measurement		Value
-	Clearance between main bearings - crankshaft journals (mm)		0.025 - 0.049

After checking all the main journals, refit the main bearing caps with half-bearings and secure by tightening the bolts to the specified torque. Op. 1028H54 PISTON WITH CONNECTING ROD - SEPRATION AT THE BENCHCheck that the outer diameter of the pistons corresponds to the recommended figures; if not, replace the piston complete with piston rings and gudgeon pin.If the outer diameter is within the tolerance, clean any carbon residues from the pistons.

	Measurement		Value
-	Outer diameter (mm)	Category A	70.760 ÷ 70.770
Category B	70.770 ÷ 70.780
Category C	70.780 ÷ 70.790
	from the lower edge of the piston skirt (mm)	8.5

Check that the pin seat bore diameter is within specified values, otherwise replace the pin with an oversized pin.

	Measurement		Value
-	Piston pin housing diameter (mm)		17.982 ÷ 17.986

	Measurement		Value
-	Pin oversize (mm)		0.2

Check that the outer diameter of the gudgeon pins corresponds to the recommended figures; if not, replace the worn components.

	Measurement		Value
-	Piston pin outer diameter (mm)		17.970 ÷ 17.974

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

	Measurement		Value
-	Thickness (mm)	1st sealing ring	1.175 - 1.190
2nd sealing ring	1.175 - 1.190
3rd sealing ring	2.475 - 2.490

	Measurement		Value
-	Sealing ring oversize (mm)		0.4

1. Fit the sealing rings (1a) in the cylinder liner 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
-	Gap (mm)	1st sealing ring	0.200 ÷ 0.400
2nd sealing ring	0.250 ÷ 0.450
3rd sealing ring	0.200 ÷ 0.450

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

	Measurement		Value
-	End float (mm)	1st sealing ring	0.040 ÷ 0.080
2nd sealing ring	0.020 ÷ 0.055
3rd sealing ring	0.020 ÷ 0.055

Check that the big end and small end diameters are within specified limits.

	Measurement		Value
-	Big end diameter (mm)		45.128 ÷ 45.138

	Measurement		Value
-	Small end diameter (mm)		17.939 ÷ 17.956

Op. 1028H60 PISTON SET, GUDGEON PINS AND SEALS - REPLACE WITH PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING Op. 1028H54 PISTON WITH CONNECTING ROD - SEPRATION AT THE BENCH Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCHPosition the tool for rotating the crankshaft.

	Description	Code
-	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 and arrow indicating camshaft side.2. Area where the number of the matching cylinder liner is stamped.3. Gudgeon pin offset.

1. Fit the connecting rod-piston assemblies (1a) with half-bearings using tool (1b) to compress the piston rings and then fit the piston into the liner.

	Description	Code
1b	Fitting tool	1.860.700.000

Rotate the engine on the overhaul stand.1. Apply the calibrated wire (plastigate) for measuring the crankpin clearance.

1. Place the connecting rod caps (1a) in their seats complete with half-bearings (1b) and secure them by tightening the bolts (1c) to the recommended torque.

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.

	Fastening	Component	dia	Value(daNm)
1c	Bolt	CONNECTING ROD CAP FASTENERS	M8	2 + 40°

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

Thoroughly clean any residues of the calibrated wire (Plastigage) from the crankshaft.

	Measurement		Value
-	Clearance between connecting rod bearings - crankpins (mm)		0.024 - 0.062

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.Remove the tool for rotating the crankshaft.

	Description	Code
-	Flange	1.860.815.000

1. Position a new oil pump gasket.2. Fit the front crankcase cover (2a) with built-in oil pump complete with intake chamber and secure by tightening bolts (2b) to the specified torque.

	Fastening	Component	dia	Value(daNm)
2b	Bolt	ENGINE OIL PUMP	M6	1

3. Fit the engine oil filter.4. Fit the engine oil pressure sending unit and tighten it to the recommended torque.

	Fastening	Component	dia	Value(daNm)
4	Bolt	INSUFFICIENT ENGINE OIL PRESSURE SWITCH	M14 X 1.5	3.2

1. Fit the oil seal to the crankshaft front cover (1a) using the tool (1b).

	Description	Code
1b	Fitting tool	1.860.903.000

1. Using the tools (1a) and (1b), fit the crankcase rear cover complete with oil seal and secure it using the bolts (1c).

	Description	Code
1a	Grip	1.860.879.000

	Description	Code
1b	Fitting tool	1.860.881.000

Tighten the bolts securing the cover to the cylinder block/crankcase to the recommended torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	REAR COVER CRANKSHAFT	M6	1

1. Fit the flywheel lock.

	Description	Code
1	Counter-torque	1.860.846.000

2. Fit engine flywheel (2a) using retaining washer (2b) and secure by tightening bolts (2c) to the specified torque.

	Fastening	Component	dia	Value(daNm)
2c	Bolt	FLYWHEEL (MECH.)	M8 X 1.25	4.4

1. Position the gear on the crankshaft.2. Fit the crankshaft locking tool.

	Description	Code
2	Counter-torque	1.870.744.000

3. Secure the crankshaft gear by tightening the bolt to the specified torque.

	Fastening	Component	dia	Value(daNm)
3	Bolt	DRIVE PULLEY(PULLIES) TIMING	M11	2 + 90°

Apply a continuous, unbroken strip of the specified sealant around the outer edge of the water pump.

Join the end to the beginning seamlessly.

	Type	Component	Description	Qty.
-	Silicon sealant	COOLANT PUMP	-	-

1. Fit water pump (1a) and secure by tightening bolts (1a) and nut (1c) to the specified torque.

	Fastening	Component	dia	Value(daNm)
1b	Bolt	COOLANT PUMP	M6	1

	Fastening	Component	dia	Value(daNm)
1c	Nut	COOLANT PUMP	M6 X 1	0.7

2. Fit the engine coolant pump rigid inlet pipe (2a) complete with O-ring and secure with bolt (2b).

	Fastening	Component	dia	Value(daNm)
2b	Bolt	COOLANT PUMP RIGID INLET PIPE	M6	1

1. Align the driven plate to install clutch assembly (1a), using locating pin (1b).

	Description	Code
1b	Clutch locating tool	1.870.418.000

2. Tighten the bolts fixing the clutch to the engine flywheel.Remove the flywheel locking tool applied previously.

Rotate the engine on the overhaul stand.1. Apply the specified sealant continuously without any breaks over the entire perimeter of the crankcase sump as shown in the figure.

Join the end to the beginning seamlessly.

	Type	Component	Description	Qty.
1	Silicon sealant	ENGINE OIL SUMP	Arexon RHODORSIL 5552	-

2. Fit crankcase sump (2a) and secure by tightening bolts (2b) and nuts (2c) to the specified torque.

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

	Fastening	Component	dia	Value(daNm)
2b	Bolt	ENGINE OIL SUMP	M6	1

	Fastening	Component	dia	Value(daNm)
2c	Nut	ENGINE OIL SUMP	M6	0.7

Turn the engine on the overhaul stand.Fit the locating dowels in the cylinder block/crankcase.Position the gasket on the cylinder block/crankcase with the working "ALTO" [TOP] uppermost, taking care not to get the gasket or the surface of the cylinder block/crankcase dirty or covered in oil.

The cylinder head gasket is ASTADUR type. The material from which the gasket is made undergoes a polymerization process during the operation of the engine so that it becomes considerably harder during usage.

In order for the polymerization process to take place, it is necessary to:

Keep the gasket in its sealed, nylon container;
only take it out shortly before fitting;
not lubricate the gasket or get oil on it, taking care to ensure that the surfaces of the cylinder block/crankcase and cylinder head are clean.

Position the cylinder head on the cylinder block/crankcase.1. Tighten the cylinder head bolts (1a) to the recommended torque using tool (1b) for angular tightening.

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

	Fastening	Component	dia	Value(daNm)
1a	Bolt	CYLINDER HEAD	M9 x 1.25	3 + 90° + 90°

	Description	Code
1b	Torque wrench	1.860.942.000

Fit the tappet cover, complete with gasket, and secure it by tightening the bolts to the recommended torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	CAM COVER	M6	1

Adjust engine timing as follows:1. Rotate the driven toothed timing pulley until the timing references are aligned.2. Rotate the driven toothed pulley until the timing references are aligned.3. Fit the timing drive belt.

1. Fit tools (1a) and (1b) to the timing belt mobile tensioner.

The weight of tool (1b) must be without the knurled part and positioned 65 mm along the graduated rod. The graduated rod must be aligned horizontally by adjusting the tool joint.

	Description	Code
1a	Belt tensioner	1.860.745.300

	Description	Code
1b	Belt tensioner	1.860.745.100

Settle the timing drive belt by turning the crankshaft through two revolutions in its direction of rotation.

During this stage, the graduated rod may move away from the horizontal. In this case, adjust the tool joint and repeat the operation.

2. Keeping the belt taut, tighten the nut fixing the moving timing belt tensioner to the recommended torque.

	Fastening	Component	dia	Value(daNm)
2	Nut	MOBILE TIMING TENSIONER	M8 X 1.25	2.8