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 - DUCATO - eLearn

244000626 - 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

) 1. Use the tool (1a) with special adaptors and, using an ordinary spanner (1b), undo the nut fixing the pressure pump toothed drive pulley.

	Description	Code	Function
1a	Counter-torque	1.870.815.000	Timing pulley lock

	Description	Code	Function
1a	Pins for counter-torque	1.870.836.000	Timing pulley lock

2. Position the tool (2a), tighten the bolt (2b) and remove the pressure pump toothed drive pulley (2c).

	Description	Code	Function
2a	Extractor	1.870.855.000	Pressure pump control pulley removal

1. Undo the bolts (1a) and remove the pressure regulator (1b).

1. Undo the bolts (1a) and remove the pressure pump (1b) complete with fuel pipes and return manifold (1c).

1. Undo the bolts (1a) and remove the support for the pressure pump (1b) with the water pump incorporated.2. Remove the seal from the water pump.

1. Undo the bolts (1a) and remove the rigid power unit support (1b).

1. Using an ordinary tool (1a), undo the cartridge engine oil filter (1b) and remove it.

1. Undo the engine oil filter connector (1a) and remove the engine oil heat exchanger (1b).

1. Undo the bolt (1a) and remove the rpm sensor (1b) and seal (1c).

1. Undo and remove the engine oil pressure switch.

1. Undo the bolt (1a) and remove the automatic timing belt tensioner (1b).

1. Undo the bolt (1a) and remove the timing belt toothed drive wheel (1b).

1. Use the tool described below to fit the oil sealing ring.2. Position the extraction jaws for the tool in the oil seal splining.3. Secure the extraction pincers in position using retaining bolts.4. Tighten the tool pin (4a) to remove the oil sealing ring(4b) from its seat.

Because the oil seal must always be replaced, it may be destroyed when it is removed.

	Description	Code	Function
1	Extractor	99340057	Extracting timig side crankshaft element

1. Undo the bolts (1a) and remove the crankshaft front cover (1b) with vacuum unit, oil pump and gasket (1c) incorporated.

1. Undo the bolts (1a) and remove the clutch (1b).2. Undo the flywheel fixing bolts.3. Remove the tool.

	Description	Code	Function
3	Counter-torque	1.860.846.000	Flywheel lock

4. Remove the flywheel.5. Remove the protective cover.

1. Use the tool described below to extract the flywheel side oil seal.2. Position the tool extraction pincers (2a) into oil sealing ring grooves (2b).3. Secure the extraction pincers in position using retaining bolts.4. Tighten the tool pin to remove the oil sealing ring from its seat.

Because the oil seal must always be replaced, it may be destroyed when it is removed.

	Description	Code	Function
1	Extractor	99340058	Extracting flywheel end crankshaft seal

1. Undo the bolts (1a) and remove the oil intake duct (1b).2. Undo the bolt (2a) and remove the pipe (2b).

1. Fit the tool for rotating the engine.

	Description	Code	Function
1	Flange	1.860.815.000	Crankshaft rotation

Rotate the crankshaft using the tool fitted previously until the piston concerned is at B.D.C.2. Undo the bolts (2a) and remove the connecting rod cap (2b).3. Remove the lower connecting rod half-bearing.4. Remove the connecting rod-piston assembly.5. Remove the upper connecting rod half-bearing.Carry out the same operations to remove the pistons and connecting rods for the remaining cylinders.Remove the tool.

	Description	Code	Function
.	Flange	1.860.815.000	Crankshaft rotation

1. Undo the bolts (1a) and remove the lower crankcase (1b).2. Remove the lower main journal half-bearings.3. Remove the crankshaft.4. Remove the upper main journal half-bearings.

1. Undo the bolts (1a) and remove the flywheel (1c) from the crankshaft (1b).

1. Undo the bolts (1a) and remove the piston lubrication jets (1b) from the crankcase.

Remove the cylinder head centering pins.Remove any damaged or broken studs.Drill and remove the water/oil sealing plugs from the crankcase to allow for washing.Undo the bolts and remove the crankcase from the mounting brackets, then place it on a special workbench.Characteristic of working principle

Refitting ( Removing

) Wash the dismantled components.Fit the water/oil sealing plugs in the crankcase and tighten them to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	2.5	Filler	ENGINE CRANKCASE	-

	Value daNm	Fastening	Component	Ø
.	1.7	Tapered plug	ENGINE CRANKCASE	3/8" X 10

	Value daNm	Fastening	Component	Ø
.	4.2	Male plug	ENGINE CRANKCASE	M14 X 1.5

	Value daNm	Fastening	Component	Ø
.	(Draining water) 2.0	Plug	ENGINE CRANKCASE	M14 X 1.5

	Value daNm	Fastening	Component	Ø
.	(Level sensor) 1.0	Plug	ENGINE CRANKCASE	M12 X 1.25

Lubricate all the mechanical components with engine oil.Check that the cylinder head support surface does not have cracks or superficial grooves.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.

	Subject	Value
.	Crankcase and components	mm
-	Cylinder support surface flatness	< 0,10

1. Measure the cylinder bore/liner diameter.

	Subject	Value
1	CRANKCASE AND COMPONENTS	mm
-	Cylinder liner bore	88.002 - 88.022

The measurements should be taken for each cylinder at three different heights for the bore/liner and at two perpendicular planes.

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

	Subject	Value
.	Crankcase and components	mm
-	Cylinder liner taper	< 0,05

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

	Subject	Value
.	Crankcase and components	mm
-	Cylinder liner ovality	< 0,05

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.

Position the jets on the crankcase and secure them using the fixing bolts.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.Check that the diameter of the main journals is within specified limits.

	Subject	Value
.	CRANKSHAFT	mm
-	Main journal diameter	71.182 - 71.202
-(76.182 - 76.208*)	-

(*) main journal n°5

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	0,254 - 0,508

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

The undersize should be marked by a special stamp on the side of the no. 1 crank arm.For undersize main journals: the letter M.For undersize main journals and crankpins: the letters MB.Check that the diameter of the crankpins corresponds to the recommended figures.

	Subject	Value
.	CRANKSHAFT	mm
-	Crankpin diameter	59.015 - 59.038

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

	Subject	Value
.	Crankshaft	mm
-	Crankpin undersize	0,254 - 0,508

The crankpins should all be reground to the same undersize.

The undersize should be marked by a special stamp on the side of the no. 1 crank arm.For undersize crankpins: the letter B.For undersize main journals and crankpins: the letters MB.

	Subject	Value
.	Crankshaft	mm
-	Ovality	0,005
-	Taper	0,005

	Subject	Value
.	Crankshaft	mm
-	Main journal misalignment	0,05
-	Crankpin misalignment	0,125

Regrind the shaft following the recommended figures.Check that the thickness of the half-bearings corresponds to the recommended figures; if not, replace them.

	Subject	Value
.	MAIN BEARINGS
-	Main bearing half thickness	mm
-	Category A	2.155 - 2.164
-	Category B	2.165 - 2.174

	Subject	Value
.	MAIN BEARINGS
-	Main bearing half thickness	mm
-	Category C	2.175 - 2.184
-	Category D	2.185 - 2.194

Check that the thickness of the connecting rod half-bearings is within specified limits; if not, replace them.

	Subject	Value
.	BIG END BEARINGS
-	Connecting rod side big end half-bearing size	mm
-	Category A	1.875 - 1.884
-	Category B	1.883 - 1.892

	Subject	Value
.	BIG END BEARINGS
-	Connecting rod side big end half-bearing size	mm
-	Category C	1.891 - 1.900

	Subject	Value
.	BIG END BEARINGS
-	Cap side big end half-bearing size	mm
-	Category A	1.877 - 1.883
-	Category B	1.885 - 1.891

	Subject	Value
.	BIG END BEARINGS
-	Cap side big end half-bearing size	mm
-	Category C	1.893 - 1.899

Position the flywheel on the crankshaft and secure it by tightening the fixing bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	1.5	Bolt	PHONIC WHEEL ON CRANKSHAFT	M6 X 1

Fit the upper main journal half-bearings in the cylinder block/crankcase.Fit the crankshaft in the crankcase.1. Fit the calibrated wire (plastigate) for measuring the bearing clearance.

Position the gaskets and the lower main journal half-bearings on the lower crankcase.Fit the lower crankcase.1. Using the special tool and a torque wrench, tighten the lower crankcase fixing bolts to the recommended torque in the order given.

	Description	Code	Function
1	Torque wrench	1.860.942.000	Angular tightening of lower crankcase bolts

	Value daNm	Fastening	Component	Ø
1	(Inner side) 5 + 60° + 60°	Bolt	ENGINE CRANKCASE	-

	Value daNm	Fastening	Component	Ø
1	(Outer side) 3	Bolt	ENGINE CRANKCASE	-

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

	Subject	Value
.	CRANKSHAFT	mm
-	End float	0.010 - 0.240

If the crankshaft endfloat does not correspond to the recommended figure, the crankshaft must be reground and the crankshaft half-bearings replaced as a result.

The centre crankshaft bearing has thrust washers incorporated. It is only available as spares with normal size thrust washers.

1. Remove the lower crankcase and the half-bearings and measure the bearing clearance using the special gauge.

	Subject	Value
.	MAIN BEARINGS	mm
-	Radial clearance	0.044 - 0.075

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

Check that the internal diameter of the piston bushes is within the recommended limits; if not, replace the piston.

	Subject	Value
.	PISTON SET	mm
-	Piston bush internal diameter	31.003 - 31.009

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

	Subject	Value
.	GUDGEON PIN	mm
-	Outer diameter	30.990 - 30,996

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.

	Subject	Value
.	PISTON SET	mm
-	Outer diameter	87.903 - 87.937

Take the measurement perpendicular to the gudgeon pin axis.

1. If the bore has to be reamed, fit the piston rings (1a) and the oil scraper ring in the cylinder bore and using a feeler gauge (1b) check that the gap between the end of each ring corresponds to the recommended figures; if not, replace the piston rings.

	Subject	Value
1	PISTON RING SET	mm
-	First ring gap	0.200 - 0.350
-	Second ring gap	0.600 - 0.800
-	Oil scraper ring gap