1004E40 ENGINE REMOVED, GENERAL OVERHAUL - Fiat - DUCATO - eLearn

244000624 - 1004E40 ENGINE REMOVED, GENERAL OVERHAUL

) - Disconnect the electrical connections.

	Description	Connector
.	Injector	N070A

	Description	Connector
.	Injector	N070B

	Description	Connector
.	Injector	N070C

	Description	Connector
.	Injector	N070D

	Description	Connector
.	Timing sensor	K047

	Description	Connector
.	Heater plugs	A040A

	Description	Connector
.	Air conditioning compressor engagement electro-magnet	L020

	Description	Connector
.	Injection pump third piston deactivation solenoid valve	L005

	Description	Connector
.	Fuel pressure regulator	N077

	Description	Connector
.	Engine coolant temperature sensor/sender unit	K036

	Description	Connector
.	Heater plugs	A040B

	Description	Connector
.	Heater plugs	A040C

	Description	Connector
.	Heater plugs	A040D

	Description	Connector
.	Fuel pressure sensor	K083

	Description	Connector
.	Engine oil pressure sensor	K028

1. Undo bolts (1a), release from the bands and remove duct (1b) with wiring.

- Remove the pneumatic connection pipe from the EGR valve and wastegate.1. Remove oil vapour intake pipe (1a), undo bolt (1b), remove the turbocharger connection bands and remove intake sleeve (1d).

1. Remove the engine oil return pipe from the turbo.

1. Undo lower mount nut (1a) and the four flange nuts (1b) while supporting the turbocharger.

1. Lower turbocharger (1a), undo oil delivery connector (1b) and remove the turbocharger assembly.

1. Undo the bolts securing the EGR pipe.2. Undo bolts (2a) and remove exhaust manifold (2b) complete with EGR valve and pipe, spacers and gaskets.

1. Undo bolts (1a) and nuts (1b) and remove intake manifold (1c) complete with plastic sleeve and gaskets.

1. Unscrew bolts (1a), remove band (1b) connecting the thermostat pipe and remove the rigid coolant intake pipe to pump (1c) complete with flexible hose (1d).

1. Disconnect the heat exchanger pipe from the thermostat.2. Disconnect the supplementary heater pipe from the thermostat.3. Undo the oil dipstick tube retaining bolt.

1. Undo bolts (1a) and nuts (1b) and remove thermostat (1c) complete with coolant connection pipe.

1. Remove the oil filter.2. Undo bolt (2a) and remove oil-water exchanger (2b) complete with gasket.

1. Undo bolts (1a) and remove power steering mount (1b) with pump and pipe.

1. Undo front bolt (1a) and rear bolt (1b) and remove compressor (1c), recovering the profiled shims and nuts.

- Unscrew the retaining bolts and remove both cable and pipe brackets.1. Fit the tool.

	Description	Code	Function
1	Counter-torque	1.860.846.000	Flywheel lock

1. Unscrew bolt (1a) and remove auxiliary driveblet pulley (1b).

1. Unscrew the bolts and remove the clutch assembly.

1. Undo the eight bolts (1a) and remove engine flywheel (1b).

Support the flywheel because it is very heavy.

2. Remove the tool.

	Description	Code	Function
2	Counter-torque	1.860.846.000	Flywheel lock

1. Remove timing belt front cover (1a), upper cover (1b) and lower cover (1c) in order by unscrewing retaining bolts (1d).

1. Undo bolts (1a) and remove the timing side engine support (1b).

1. Loosen bolt (1a) and use a ¼" box wrench (1b) to loosen the belt, then tighten the bolt again and remove timing belt (1c).

- Disconnect the vapour recirculation pipe from the cylinder head cover.1. Undo bolt (1a) and remove the fuel temperature sensor (1b).

1. Fit the tools.

	Description	Code	Function
1	Counter-torque	1.860.831.000	Timing pulley lock

	Description	Code	Function
1	Counter-torque	1.860.831.001	Timing pulley lock

2. Undo the pulley bolt.

1. Fit the tools.

	Description	Code	Function
1	Extractor	1.860.954.001	Pressure pump control pulley removal

	Description	Code	Function
1	Reaction pins	1.860.954.002	Pressure pump control pulley removal

2. Remove the pulley.

1. Use a wrench and counterwrench to loosen the pump side high pressure pipe connector.2. Loosen the manifold side high pressure pipe connector (2a) and remove pipe (2b).

1. Undo the bolts (1a) and remove the rear bracket (1b).

1. Undo nuts (1a) and remove high pressure pump (1b).

1. Use a wrench and counterwrench to loosen the injector side high pressure pipe connector.2. Loosen the fuel manifold side high pressure pipe connector.3. Remove the pipe.

- Repeat the operations for all injectors.1. Undo bolts (1a) and remove manifold (1b).

1. Undo bolts (1a) and remove the high pressure pump mount (1b).

1. Undo bolts (1a) and remove the fuel filter mount (1b).

1. Undo bolt (1a) and remove the oil dipstick (1b).

- Remove the coolant pipes from the engine block.1. Remove the timing belt pulley (1a) and recover both tabs (1b).2. Undo bolt (2a) and remove the timing belt mobile tensioner (2b).3. Undo bolt (3a) and remove the fixed timing belt mobile tensioner (2b).

1. Undo the bolts (1a) and remove the coolant pump (1b).

1. Undo the retaining bolt and remove the engine timing sensor.2. Undo the ten bolts (2a) and remove the cylinder head cover (2b).- Undo the bolts in the order indicated.

1. Undo the retaining bolts.- Undo the bolts in the order indicated.2. Remove the cylinder head.- Remove the cylinder head gasket.- Remove the locating pins.

- Rotate the crankcase through 180° on the overhaul stand.1. Unscrew the retaining bolts and remove the oil sump using the tool at the points indicated.

	Description	Code	Function
.	Blade	1.870.718.000	Engine oil sump removal

Do not use the tool at the point indicated due to the presence of a locating pin that could become damaged.

1. Undo bolts (1a) and remove the engine block front cover (1b).

1. Undo bolt (1a) and remove the engine oil dipstick tube.2. Undo bolts (2a) and remove oil pump (2b) complete with chain (2c), pinion (2d) and tab (2e).

1. Undo nuts (1a) and remove the connecting rod caps (1b) with bearing.2. Remove the piston-connecting rod-bolt-bearing assembly by withdrawing from below.- Repeat the operations for all pistons.

Mark each connecting rod-cap pair to allow correct assembly.

1. Undo bolts (1a) and remove the main bearing caps (1b) with bearings, except no. 1.

The main bearing caps are marked by an increasing number from the flywheel end (no. 1) to the timing end (no. 5).Cap no. 1 (flywheel end) also acts as a rear engine block cover.

2. Remove the lower thrust rings.3. Remove cap no. 1 (3a) using tools (3b) as shown.

	Description	Code	Function
3a	Extractor	1.860.854.000	Removing rear bearing cap

	Description	Code	Function
3a	Mallet	1.846.011.000	Removing rear bearing cap

4. Remove crankshaft (4a) complete with bearings (4b).5. Remove the upper thrust rings.

Mark the upper and lower bearings and the thrust rings to allow correct refitting.

1. Undo the bolt (1a) and remove the oil sprays (1b).

- Rotate the crankcase through 180° on the overhaul stand.1. Unscrew the oil channel sealing plugs.2. Remove oil pressure sensor (2a) and oil temperature sensor (2b).3. Remove the water sealing plugs from the engine block using a drift.

- Remove any damaged or broken studs.- Undo the bolts and remove the crankcase from the mounting brackets, then place it on a special workbench.

Refitting ( Removing

) - Wash the dismantled components.- Clean all parts very thoroughly before installing.- Clean the oil sump contact surface thoroughly.1. Clean the coolant channels between the cylinders thoroughly using a steel scourer.

- Lubricate all the mechanical components with engine oil.- Check that the cylinder head support surface does not have cracks or superficial grooves.1. - Check that cylinder head support surface flatness is within specified limits.

	Subject	Value
1	CRANKCASE AND COMPONENTS	mm
-	Cylinder head support surface flatness	0,03

1. Check that crankcase height is within specified limits.

	Subject	Value
1	CRANKCASE AND COMPONENTS	mm
-	Engine block height	234,95 - 235,05

- If engine block flatness and/or height are not within specified limits, grind the cylinder head support surface without exceeding the minimum permitted height.

	Subject	Value
.	CRANKCASE AND COMPONENTS	mm
-	Minimum permitted crankcase height	234,75 - 234,85

If the height is lower than the permitted minimum, replace the crankcase.

1. Measure the cylinder bore/liner diameter.

	Subject	Value
1	CRANKCASE AND COMPONENTS	mm
-	Cylinder liner bore	85,000 - 85,018

The measurements should be taken for each cylinder at three different heights for the bore/liner (1, 2, 3) and at two perpendicular planes (a, b).

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

	Subject	Value
.	CRANKCASE AND COMPONENTS	mm
-	Cylinder liner taper	< 0,009

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

	Subject	Value
.	CRANKCASE AND COMPONENTS	mm
-	Cylinder liner straightness	< 0,0055

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

	Subject	Value
.	CRANKCASE AND COMPONENTS	mm
-	Cylinder liner oversize	0,60

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

1. Fit oil sprays (1b), tighening bolt (1a) to the specified torque.

	Value - daNm	Fastening	Component	Ø
1a	1,0	Bolt	PISTON COOLING NOZZLES	-

1. Fit the oil channel plugs, tightening to the specified torque.

	Value - daNm	Fastening	Component	Ø
1	4,0	Plug	CRANKCASE AND COMPONENTS	-

2. Fit oil pressure sensor (2a) and oil level sensor (2b) and tighten to the specified torque.

	Value - daNm	Fastening	Component	Ø
2a	3,0	Oil pressure sensor	CRANKCASE AND COMPONENTS	-

	Value - daNm	Fastening	Component	Ø
2b	2,7	Oil level sensor	CRANKCASE AND COMPONENTS	-

3. Fit the water sealing plugs in the crankcase using suitable fitting tools.

- Check that there are no deposits or blockages in the crankshaft lubrication ducts.- Check the static balance of the crankshaft resting the main journals on suitable parallels.1. Check that the diameter of the main journals is within specified limits.

	Subject	Value
1	CRANKSHAFT	mm
-	Main journal diameter	59,977 - 60,000

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

	Subject	Value
.	CRANKSHAFT	mm
-	Main journal undersize	0,300

The main journals should all be reground to the same undersize.

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

	Subject	Value
2	CRANKSHAFT	mm
-	Crankpin diameter	49,980 - 50,000

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

	Subject	Value
.	CRANKSHAFT	mm
-	Main journal undersize	0,300

The crankpins should all be reground to the same undersize.

3. Check that the width of main bearing no. 2 is within specified limits.

	Subject	Value
3	CRANKSHAFT	mm
-	Width of main bearing no. 2	26,630 - 26,650

- If the width of main bearing no.2 is not correct, it should be reground to the recommended undersize.

	Subject	Value
.	CRANKSHAFT