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.

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	0.250 - 0.500

Check that the thickness of the piston rings and the oil scraper ring is within the recommended limits.

	Subject	Value
	PISTON RING SET	mm
-	First ring size	2.068 - 2.097 (*)
-	Second ring size	1.970 - 1.990
-	Oil scraper ring size	2.470 - 2.490

(*) measured 1.5 mm from the outside edge.The piston rings are available as spares in 0.4 mm oversizes.

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

	Subject	Value
1a	PISTON RING SET	mm
-	First ring end float	-
-	Second ring clearance	0.015 - 0.037
-	Oil scraper ring clearance	0.050 - 0.090

	Description	Q.ty	Component	Type	Classification
1	LOCTITE 5205	-	ENGINE CRANKCASE	Sealant	-

The surfaces to be stuck should be clean and free from any residues.

The components should be fitted within ten minutes of applying the sealant.

Fit the lower crankcase.Tighten the bolts fixing the lower crankcase to torque in the order given.

	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	-

Fit the tool for rotating the crankshaft.

	Description	Code	Function
.	Flange	1.860.815.000	Crankshaft rotation

Rotate the crankcase through 90° on the overhaul stand.Rotate the crankshaft until the cylinder concerned is at B.D.C.1. Fit the piston-connecting rod assembly (1a) complete with half-bearing using the tool (1b).

	Description	Code	Function
.	Fitting tool	1.860.700.000	Fitting tool

The piston-connecting rod assemblies are fitted in the crankcase with the reference stamped on the piston facing the flywheel side and the reference on the skirt in line with the oil jets.

Rotate the crankcase through 90° on the overhaul stand.Fit the connecting rod cap complete with half-bearing and secure it without tightening the bolts.

It is impossible to confuse the fitting positions on account of the particular shape of the cap-connecting rod.

Proceed in the same way for the remaining pistons and connecting rods.Tighten the connecting rod cap bolts to the recommended torque using the angular tightening tool.

	Value daNm	Fastening	Component	Ø
.	4 + 60°	Bolt	CONNECTING ROD CAP FASTENERS	-

	Description	Code	Function
1	Torque wrench	1.860.942.000	Connecting rod cap bolt angular tightening

Position the engine oil intake and the pipe and secure them using the bolts.

	Value daNm	Fastening	Component	Ø
.	1.0	Bolt	OIL SECTION PUMP	M6 X 1

Position the oil sump with the gasket and ring gear and secure it tightening the bolts to the recommended torque.

Check the condition of the seal and replace it if necessary.

	Value daNm	Fastening	Component	Ø
.	2.5	Bolt	ENGINE OIL SUMP	M8 X 1.25

	Value daNm	Fastening	Component	Ø
.	1.0	Bolt	ENGINE OIL SUMP	M6 X 1

Fit a new front crankshaft cover gasket.Position the crankshaft front cover with the vacuum unit and oil pump incorporated and screw in the fixing bolts without tightening them.1. Centre the crankshaft front cover with the vacuum unit and oil pump (1a) incorporated using the tool (1b).

	Description	Code	Function
1b	Locator	99396037	Tool for locating front crankshaft cover

1. Tighten the crankshaft front cover fixing bolts in the order given.

	Value daNm	Fastening	Component	Ø
.	1.0	Bolt	ENGINE OIL PUMP	M6 X 1

1. Use the tool described below to fit the timing side oil seal.

	Description	Code	Function
1	Fitting tool	99346254	Front cover gasket fitting

2. Tighten the threaded tool pin until it comes into contact with the crankshaft drive gear seat.3. Position a new oil seal in its seat.4. Position the fitting tool (4a) in contact with the oil sealing ring and tighten the nut (4b) to fully fit the oil sealing ring into its seat on the front cover.

Position the rigid power unit support and tighten the fixing bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	5	Bolt	RIGID ENGINE MOUNT, TIMING SIDE	M10X1.5

Position the water pump with a new seal.Tighten the fixing bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	2.5	Bolt	COOLANT PUMP	M8 X 1.25

	Value daNm	Fastening	Component	Ø
.	1.0	Bolt	COOLANT PUMP	M6 X 1

Position the engine coolant inlet pipe and tighten the bolt fixing it ot the crankcase.Position the engine oil heat exchanger with a new gasket and tighten the engine oil filter connector to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	8.0	Connector	ENGINE OIL HEAT EXCHANGER	M22 X 1.5

Position the engine oil filter and tighten it by hand to the torque given in the table.

	Value daNm	Fastening	Component	Ø
.	2.5	-	CARTRIDGE OIL FILTER	M22 X 1.5

Position the rpm sensor with a new seal and secure it using the special bolt.Position the pressure pump complete with fuel pipes and secure it tightening the special bolt to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	2.5	Bolt	INJECTION PUMP TIMING	M8 X 1.25

Check the condition of the fuel pipes and replace them if necessary.

Position the pressure regulator and tighten the fixing bolts.Position the pressure pump toothed drive pulley.1. Use the tool (1a) with special adaptors and, using an ordinary spanner (1b), tighten the nut fixing the pressure pump toothed drive pulley (1c) to the recommended torque.

	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

	Value daNm	Fastening	Component	Ø
.	7.0	Nut	PRESSURE PUMP CONTROL PULLEY	M14 X 1.5

Remove the tool.

	Description	Code	Function
.	Flange	1.860.815.000	Crankshaft rotation

Tilt the engine 90° on the overhaul stand.Fit the protective cover.1. Use the tool described below to fit the flywheel side oil seal.2. Apply plate (2a) to the crankshaft and secure using retaining bolts (2b).Position a new oil seal in its seat.3. Position the fitting tool (3) in contact with the oil sealing ring and tighten the nut (3b) to fully fit the oil seal into its seat on the crankshaft.

	Description	Code	Function
1	Fitting tool	99346255	Flywheel end crankshaft seal fitting

Position the flywheel and secure it tightening the bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	3.0	Bolt	FLYWHEEL (MECH.)	M12 X 1.25

Return the engine to its original position.1. Rotate the crankshaft and measure the projection of the pistons at two points 180° on the gudgeon pin axis using the tool.

	Description	Code	Function
1	Dial gauge support	1.870.404.000	Piston projection from cylinder head support plane check

	Subject	Value
.	ENGINE PISTON	mm
-	Piston projection	0.300-0,600

Measure the piston projection or recess.

The difference between the maximum projection measurement and the minimum measurement for the four pistons should not exceed 0.15 mm.

	Subject	Value
.	CYLINDER HEAD GASKET	mm
-	Size	1.100
-	Maximum piston projection	0.300 - 0.400

	Subject	Value
.	CYLINDER HEAD GASKET	mm
-	Size	1.200
-	Maximum piston projection	0.400 - 0.500

	Subject	Value
.	CYLINDER HEAD GASKET	mm
-	Size	1.300
-	Maximum piston projection	0.500 - 0.600

Position the first and fourth pistons close to T.D.C.1. Undo the plug in the crankcase and, rotating the crankshaft using small movements, position the tool for detecting T.D.C. in the housing for the plug.

	Description	Code	Function
1	Pin	99360615	TDC positioning

1. Fit the clutch (1a) using the tool (1b).

	Description	Code	Function
1b	Clutch locating tool	1.875.029.000	Driven plate locating

2. Tighten the fixing bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
2	2.7	Bolt	CLUTCH ASSEMBLY	M8 X 1.25

3. Fit the tool.

	Description	Code	Function
3	Counter-torque	1.860.846.000	Flywheel lock

Fit the toothed drive pulley and tighten the fixing bolt to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	35	Bolt	ENGINE ASSEMBLY	M18 X 1.5

Position the cylinder head locating bushes on the engine block.1. Fit the cylinder head gasket with the word "ALTO" facing the flywheel side.

the arrow shows where the word "ALTO" is stamped.

The cylinder head gasket is metal and the old gasket should be replaced with one of the same type.

Position the cylinder head on the cylinder block/crankcase.1. Tighten the centre fixing bolts (1a) and the side fixing bolts (1b) to the recommended torque using the angular tightening tool (1c).

	Value daNm	Fastening	Component	Ø
1a	(Centre fastening) 10 + 90° + 90°	Bolt	CYLINDER HEAD	-

	Value daNm	Fastening	Component	Ø
1b	(Side fastening) 5 +60° +60°	Bolt	CYLINDER HEAD	-

	Description	Code	Function
1c	Torque wrench	1.860.942.000	Tightening cylinder head bolts to cylinder block

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

1. Position the tappets and the rocker arms in their housings.

The inlet tappets and the exhaust tappets are the same.

Position the camshaft housing locating dowels.2. Position the upper cylinder head gasket on the locating dowels.

1. Position the camshaft housing (1a) on the cylinder head and tighten the bolts (1b) to the recommended torque.

	Value daNm	Fastening	Component	Ø
1b	11,5	Bolt	CYLINDER HEAD EXTENSION	M12X1.25

Fit the fixed timing belt tensioner and tighten the retaining bolt to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	2.5	Bolt	FIXED TENSIONER	M8 X 1.25

Fit the moving timing belt tensioner and screw in the retaining bolt without tightening it.1. Rotate the moving tensioner to the position illustrated to facilitate the fitting of the timing belt.

1. Fit the timing belt onto the pulleys and gears.

If the mileage of the belt is more than 25,000 km, it must be replaced irrespective of its appearance or wear. If it is not being replaced, it should be remembered that the replacement interval for timing belt and automatic tensioner set out in the maintenance programme is every 240,000 km or 5 years.

Remove the timing pin for the timing pulley in relation to the timing sensor.

	Description	Code	Function
.	Pin for timing adjustment	1.860.617.000	Positioning of timing pulley with timing sensor

This operation allows the timing belt to bed in on the pulley.

1. Using the reaction tool (1a) fitted with pins, tighten the bolt fixing the timing drive pulley (1b) to torque.

	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

1. Acting on the hexagonal bolt (1a), rotate the semi-automatic tensioner in an anti-clockwise direction, placing the tensioner (1b) moving reference in the position illustrated, i.e. about 20°-22° to the right of the position indicated by the reference (1c), then lock the fixing nut (1d).

Tighten the bolt fixing the automatic tensioner.Remove the tools used for timing the camshafts and for positioning the crankshaft close to T.D.C.

	Description	Code	Function
.	Templates	99360614	Camshaft timing adjustment

	Description	Code	Function
.	Pin	99360615	TDC positioning

Rotate the crankshaft through eight revolutions in its direction of rotation.1. Loosen the bolt fixing the tensioner and, working carefully, position the tensioner (1a) reference in line with the reference opening (1b), then tighten the nut (1c) fixing the belt tensioner to torque.

	Value daNm	Fastening	Component	Ø
1c	3.6	Bolt	MOBILE TIMING TENSIONER	M8

Rotate the crankshaft through two further revolutions in its direction of rotation.Check that the position of the references remains unchanged, then temporarily refit the tools for timing the camshafts and the crankshaft for a final check.If the tools do not fit perfectly in the housings or the references on the tensioner have moved, carry out the belt tension adjustment procedure again.Fit the studs on the camshaft housing for the timing tools.Fit the mounting bracket on the camshaft housing and tighten the fixing bolt and nut.Fit the thermostat and tighten the fixing bolts.Position the oil dipstick pipe.Position the intake manifold and tighten the fixing bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	2.5	Bolt	INLET MANIFOLD	M8 X 1.25

Fasten the engine coolant filler pipe and the engine oil dipstick to the intake manifold.

Tighten the heater plugs.Position the injectors and the seals and tighten the fixing bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	2.5	Bolt	INJECTORS(DIESEL)	M8 X 1.25

Check the condition of the seals and replace them if necessary.

Position the fuel manifold and tighten the fixing bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	2.5	Bolt	INJECTOR FUEL MANIFOLD (DIESEL)	M8 X 1.25

Position the pipes from the fuel manifold to the injectors and tighten the connectors to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	2.3	Connector	PIPE FUEL MANIFOLD TO INJECTORS	M12 X 1.5

Position the pipe from the fuel manifold to the pressure pump and tighten the connectors to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	2.3	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14X1.5

Position the fuel return pipe connector and tighten it to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	4	Connector	INJECTOR FUEL MANIFOLD (DIESEL)	M16

Position the fuel return pipe from the injectors and secure it using the special springs.

Each time work is carried out on the fuel pipes they have to be replaced with new pipes to prevent leaks of fuel from the connectors.

The fuel pipes are supplied as spares in kits with four pipes from the fuel manifold to the injectors and one from the fuel manifold to the pressure pump.

Position the engine oil pressure sensor and tighten it.Position the pipe from the thermostat to the radiator and the pipe from the engine oil heat exchanger to the radiator and secure them using the bolts and the retaining bands.Position the timing sensor in its housing and secure it using the bolts.Position the oil vapour separator and tighten the fixing bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	1.0	Bolt	ENGINE OIL VAPOUR SEPARATOR	M6 X 1

Position the timing cover and tighten the fixing bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	1.0	Bolt	TIMING BELT PROTECTIVE COVER(S)	M6 X 1

Position the crankshaft pulley and tighten the fixing bolts to the recommended torque.Position the injection wiring and the heater plugs wiring.Connect the heater plug connections.

	Description	Connector
.	Heater plugs	A040A

	Description	Connector
.	Heater plugs	A040B

	Description	Connector
.	Heater plugs	A040C

	Description	Connector
.	Heater plugs	A040D

Connect the electrical connections for the injection wiring.

	Description	Connector
.	Injector	N070A

	Description	Connector
.	Injector	N070B

	Description	Connector
.	Injector	N070C

	Description	Connector
.	Fuel pressure sensor	K083

	Description	Connector
.	Timing sensor	K047

	Description	Connector
.	Injector	N070D

	Description	Connector
.	Coolant temperature sending unit (for instrument panel)	K035

	Description	Connector
.	Engine coolant temperature sensor/sender unit	K036

	Description	Connector
.	Rpm sensor	K046

	Description	Connector
.

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Proceed with the dismantling.1. Fit the tool.

	Description	Code	Function
1	Counter-torque	1.860.741.000	Tool for preventing crankshaft rotation

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

1. Undo the flywheel fixing bolts.2. Remove the tool.

	Description	Code	Function
2	Counter-torque	1.860.741.000	Tool for preventing crankshaft rotation

3. Remove the flywheel.

1. Remove the protective cover.2. Undo the bolts (2a) and remove the crankcase rear cover (2b) with the oil seal incorporated.

1. Undo the bolts (1a) and remove the crankcase front cover (1b) with the oil seal incorporated.

1. Undo the bolts (1a) and remove the engine oil intake duct (1b) releasing it from its housing.2. Undo the fixing bolts (2a) and remove the front manifold side bracket (2b).3. Undo the fixing bolts (3a) and remove the pressure pump side front bracket (3b) complete with engine rpm sensor.4. Undo the fixing bolts (4a) and remove the intermediate driveshaft mounting bracket (4b).5. Undo the fixing bolts (5a) and remove the pressure pump side rear bracket (5b).6. Undo the fixing bolts (6a) and remove the rear manifold side bracket (6b).

1. Fit the tool.

	Description	Code	Function
1	Flange	1.860.815.000	Crankshaft rotation

Rotate the crankshaft using the tool fitted previously until the cylinder 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) and the gasket (1c).2. Remove the lower main journal half-bearings.3. Remove the crankshaft.4. Remove the upper main journal half-bearings.

1. Lower the non-slip fins, undo the bolts and remove the jets from the crankcase.

Rotate the crankcase through 180° on the overhaul stand.1. Undo the bolts (1a) and remove the fixed timing belt tensioner (1b).2. Undo the bolts (2a) and remove the front engine support complete with water pump (2b).3. Undo the bolts (3a) and remove the auxiliary unit (3b).

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 Proceed with the reassembly.Wash the dismantled components.Fit the water/oil sealing plugs in the crankcase using suitable fitting tools.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	Cylinder liner bore	mm
-	Category A	94,402 - 94,412
-	Category B	94,413 - 94,422
-	Category C,	94,423 - 94,432

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 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.

	Subject	Value
.	Crankcase and components	mm
-	Cylinder liner oversize	0,40

1. Extract the gearbox input shaft centering ring using the tool.

	Description	Code	Function
1	Mallet	1.840.206.001	Gearbox drive input shaft locating ring

	Description	Code	Function
1	Extractor	1.840.207.814	Gearbox drive input shaft locating ring

1. Make two millings in the timing gear (1a), then extract it using a special extractor (1b).

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	80,182 - 80,208
-	Main journal diameter	86,182- 86,208 (*)

(*) main journal n°5If 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	56,515 - 56,538

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

	Subject	Value
.	Crankshaft	mm
-	Main journal undersize	0,254 - 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

1. Regrind the shaft following the recommended figures.

Since for crankpin undersizes of 0.508 mm and main journal undersizes of 0.254 and 0.508 mm the rolled part of the half-bearings may be damaged, if necessary, replace them.

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

	Subject	Value
.	Main bearing half thickness	mm
-	Category A	2,165 - 2,174
-	Category B	2,319 - 2,428
-	Category C	2,573 - 2,682

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

	Subject	Value
.	Connecting rod bearing half thickness	mm
-	Category A	1,875 - 1,884
-	Category B	2,129 - 2,138
-	Category C	2,483 - 2,492

Fit the upper main journal half-bearings in the cylinder block/crankcase.Fit the crankshaft in the crankcase1. Fit the calibrated wire (plastigate) for measuring the bearing clearance.

Do not move the crankshaft during the checking operations.

Position the gaskets and the lower main journal half-bearings on the lower crankcase.Fit the lower crankcase.1. Tighten the bolts fixing the lower crankcase to the recommended torque in the order given.

	Value daNm	Fastening	Component	Ø
1	(engine crankcase side) 4.5 -5.5	Bolt	LOWER CRANKCASE	M14

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

	Subject	Value
.	Crankshaft	mm
-	End float	0,049 - 0,211

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 flywheel side 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
.	Crankshaft bearings	mm
-	Radial clearance	0,032 - 0,102

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

Characteristic of working principle Op. 1028H58 CONNECTING ROD SMALL END BUSH - REPLACECheck that the internal diameter of the piston bushes is within the recommended limits; if not, replace the piston.

	Subject	Value
.	Engine piston set
-	Piston bush internal diameter	32,003 - 32,009

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	31,996 - 31,999

Check that the outer diameter of the pistons is within specified limits; if not, replace the piston complete with sealing rings and pin.

	Subject	Value
1	Outer diameter	mm
-	Category A	94,310 - 94,320
-	Category B	94,320 - 94,330
-	Category C	94,330 - 94,340

Measure perpendicular to the gudgeon pin axis, 10 mm from the lower edge of the skirt.

1. If the bore has to be reamed, fit the piston rings (1a) and the oil scraper ring in the cylinder bore and check that the gap (1b) 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	0,20 - 0,35
-	Second ring gap	0,30 - 0,50
-	Oil scraper ring gap	0,30 - 0,55

Check that the thickness of the piston rings and the oil scraper ring is within the recommended limits.

	Subject	Value
.	Piston ring set	mm
-	First ring size	2,068 - 2,097 (*)
-	Second ring size	1,970 - 1,995
-	Oil scraper ring size	2.470 - 2.490, mm

(*) measured at the 91.4 mm diameter

piston rings are available as spares in 0.4 mm oversizes.

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

	Subject	Value
1a	Piston ring set	mm
-	First ring end float	0,103 - 0,162
-	Second ring end float	0,055 - 0,100
-	Oil scraper ring end float	0,050 - 0,090

Characteristic of working principle Fit the crankcase on the overhaul stand and secure it using the bolts.Fit the upper main journal half-bearings in the cylinder block/crankcase.Fit the crankshaft in the crankcase.Position the gaskets and the lower main journal half-bearings on the lower crankcase.Fit the lower crankcase.Tighten the bolts fixing the lower crankcase to the recommended torque in the order given.

	Value daNm	Fastening	Component	Ø
.	(engine crankcase side) 4.5 -5.5	Bolt	LOWER CRANKCASE	M14

1. Fit the tool.

	Description	Code	Function
1	Flange	1.860.815.000	Crankshaft rotation

	Description	Code	Function
1b	Fitting tool	1.860.700.000	Piston ring fitting

The piston-connecting rod assemblies are fitted in the crankcase with the reference stamped on the piston facing the flywheel side and the reference on the skirt in line with the oil jets.

Rotate the crankcase through 90° on the overhaul stand.1. Fit the connecting rod cap (1a) complete with half-bearing (1b) and secure it without tightening the bolts (1c).

Fit the connecting rods so that the number stamped on each rod faces towardt he same side as the number stamped on the big end (pressure pump side).

Carry out the same operations to refit the pistons and connecting rods for the remaining cylinders.

1. Tighten the connecting rod cap bolts (1a) to the recommended torque using the angular tightening tool (1b).

	Value daNm	Fastening	Component	Ø
1a	4,5 - 5,5 + 63°	Bolt	CONNECTING ROD CAPS	M12

	Description	Code	Function
1b	Torque wrench	1.860.942.000	Connecting rod cap bolt tightening

Fit the engine oil intake and tighten the fixing bolts.Fit the brackets on the lower crankcase securing them using the bolts.Apply sealant to the entire perimeter of the crankcase sump.

	Description	Q.ty	Component	Type	Classification
.	Dow Corning 7091	-	ENGINE OIL SUMP	Silicon sealant	-

Fit the crankcase sump.Tighten the bolts securing the crankcase sump to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	1,8	Bolt	ENGINE OIL SUMP	M8

Fit the auxiliary unit and screw in the bolts without tightening them to torque.

The auxiliary units support is also fastened using four M12 bolts which secure the compressor at the same time. All the bolts are tightened to torque when the compressor is fitted (see OP 1004D40).

Fit the front engine support complete with water pump after having applied the sealant and tighten the bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	(injector side) 5.0	Bolt	COOLANT PUMP	M10

	Description	Q.ty	Component	Type	Classification
.	Dow Corning 7091	-	COOLANT PUMP	Silicon sealant	-

Fit the lower fixed tensioner and secure it tightening the fixing bolt to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	2.5	Bolt	FIXED TENSIONER	M8

Fit the guard and the upper fixed tensioner tightening the fixing bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	2.5	Bolt	FIXED TENSIONER	M8

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	Function
1	Dial gauge support	1.870.404.000	Piston projection from cylinder head support plane check

at the end of the measuring operations ensure that the piston for cylinder no. 1 is at TDC (the reference made on the timing gear should be vertical).

Remove the tool.

	Description	Code	Function
.	Flange	1.860.815.000	Crankshaft rotation

Select the correct size cylinder head gasket depending on the maximum average protrusions for each individual piston.

the difference between the minimum and maximum values should not be more than 0.20 mm.

	Subject	Value
.	Cylinder head gasket	mm
-	Size	1,20
-	Average maximum piston projection	0,40 - 0,50

	Subject	Value
.	Cylinder head gasket	mm
-	Size	1,30
-	Average maximum piston projection	0,51 - 0,60

	Subject	Value
.	Cylinder head gasket	mm
-	Size	1,40
-	Average maximum piston projection	0,61 - 0,70

	Subject	Value
.	Cylinder head gasket	mm
-	Size	1,50
-	Average maximum piston projection	0,71 - 0,80

Position the cylinder head locating bushes on the engine block.Fit the cylinder head gasket with the word "ALTO" facing the mechanic.

the arrow indicates where the gasket size is stamped.

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:

Position the cylinder head on the cylinder block/crankcase.

before fitting the cylinder head, rotate the camshaft so that the valves for cylinder no. 1 are closed and those for cylinder no. 4 are in the crossover stage (the references on the gear and the cylinder head should be aligned).

1. Tighten the cylinder head bolts (1a) to the recommended torque using the angular tightening tool (1b).

	Value daNm	Fastening	Component	Ø
1a	6,0 + 6,0 + 180°	Bolt	CYLINDER HEAD	M12

	Description	Code	Function
1b	Torque wrench	1.860.942.000	Tightening cylinder head bolts to cylinder block

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

Fit the protective cover.Fit the crankcase rear cover with the oil seal incorporated and tighten the fixing bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	(engine crankcase side) 2.5	Bolt	REAR COVER CRANKSHAFT	M8

1. Fit the tool.

	Description	Code	Function
1	Counter-torque	1.860.741.000	Tool for preventing crankshaft rotation

2. Fit the flywheel (2a), apply thread-locking agent to the bolts (2b) and tighten them to the recommended torque using the angular tightening tool (2c).

	Description	Q.ty	Component	Type	Classification
2b	LOCTITE 573		FLYWHEEL (MECH.)	Thread locking agent

	Value daNm	Fastening	Component	Ø
2b	(crankshaft side) 3 +90°	Bolt	FLYWHEEL (MECH.)	M12 X 1.25

	Description	Code	Function
2c	Torque wrench	1.895.897.001	Flwheel retaining bolt tightening

1. Fit the clutch (1a) using the tool (1b)

	Description	Code	Function
1b	Clutch locating tool	1.870.402.000	Clutch installation

2. Tighten the fixing bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
2	(Engine crankshaft side) 13.6 -16.8	Bolt	CLUTCH ASSEMBLY	M12

3. Remove the tool.

	Description	Code	Function
3	Counter-torque	1.860.741.000	Tool for preventing crankshaft rotation

the fixing bolts come in two different lengths: positions 1,2,9,10,11,12,19,20,21,22 are occupied by long bolts, the other positions by short bolts.

Fit the crankcase front cover with the oil seal incorporated and tighten the fixing bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	(engine crankcase side) 2.3	Bolt	FRONT COVER CRANKSHAFT	M8

Rotate the engine through 180° on the overhaul stand.1. Check that the reference on the timing gear is in a vertical position.2. Check that the camshaft references are aligned.3. Fit the tool.

	Description	Code	Function
3	Calibrated shim	1.860.638.000	Timing belt tensioning

1. Fully fit the toothed timing drive belt.Remove the tool.

	Description	Code	Function
.	Calibrated shim	1.860.638.000	Timing belt tensioning

Rotate the crankshaft through two revolutions.Check once again that the timing references on the crankshaft and the camshaft are aligned.2. Tighten the belt tensioner nut to the recommended torque.

	Value daNm	Fastening	Component	Ø
2	(cylinder head side) 2.5	Nut	MOBILE TIMING TENSIONER	M8

Remove the tool.

	Description	Code	Function
.	Flange	1.860.815.000	Crankshaft rotation

Fit the timing belt covers and secure them using the bolts.Fit the oil filler plug.Fit the tool.

	Description	Code	Function
.	Counter-torque	1.860.741.000	Tool for preventing crankshaft rotation

Fit the crankshaft pulley and tighten the bolt to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	(crankshaft side) 20	Bolt	CRANKSHAFT PULLEY	M20

Remove the tool.

	Description	Code	Function
.	Counter-torque	1.860.741.000	Tool for preventing crankshaft rotation

Fit the camshaft cover and the gasket underneath and tighten the fixing bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
.	1,0	Bolt	CAM COVER	M6

1. Fit the injector bracket support pads.2. Fit the injectors (2a) complete with gasket (2b).3. Fit the injector brackets (3a) and tighten the bolts (3b) to the recommended torque.

	Value daNm	Fastening	Component	Ø
3b	2,6 - 3,2	Nut	INJECTORS(DIESEL)	M6

1. Position the connectors for the pipe from the injectors to the fuel recovery manifold in the injector housings and connect the pipe to the fuel manifold.2. Fit the pipes from the fuel manifold to the injectors.3. Tighten the connectors for the pipes from the fuel manifold to the manifold side injectors to the recommended torque.

always replace the pipes complete with connectors.

	Value daNm	Fastening	Component	Ø
3	(Manifold end) 2.6 - 3.2	Connector	PIPE FUEL MANIFOLD TO INJECTORS	M14

4. Tighten the connectors for the pipes from the fuel manifold to the injector side injectors to the recommended torque.

	Value daNm	Fastening	Component	Ø
4	(Injector end) 1.9 -2.3	Connector	PIPE FUEL MANIFOLD TO INJECTORS	M12

1. Fit the oil dipstick assembly and secure it using the bolt.2. Place the pipe from the pressure pump to the single fuel manifold back in its housing, then tighten the connector for the pipe from the pressure pump to the fuel manifold, pump side, to the recommended torque.

always replace the pipes complete with connectors.

	Value daNm	Fastening	Component	Ø
2	(Pressure pump end) 1.9 - 2.3	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M12

3. Tighten the connector for the pipe from the pressure pump to the fuel manifold, fuel manifold side, to the recommended torque.

	Value daNm	Fastening	Component	Ø
3	(Fuel manifold end) 2.6 - 3.2	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14

4. Fit the pipe from the fuel supply connector to the pressure pump.

Fit the intake manifold and the gasket underneath and tighten the fixing bolts to the recommended torque.

	Value daNm	Fastening	Component	Ø
3	2,5	Nut	INLET MANIFOLD	M8

Connect the thermal starter fuel pipe connector to the fuel manifold.Connect the electrical connectors for the wiring to the sensors/actuators.Fit the wiring mounting brackets and secure them using the bolts.Fit the injector cover.Characteristic of working principle