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

244000624 - 1004E40 ENGINE REMOVED, GENERAL OVERHAUL

) 1. Remove the spark plug leads and bracket.2. Remove the oil vapour separator complete with pipes.3. Remove the intake manifold with throttle body and fuel manifold.4. Remove the engine coolant intake manifold.5. Remove the ignition coil.

1. Remove the engine mounting brackets.2. Remove cam cover (2a) and gasket (2b).3. Remove the exhaust manifold heat shield.4. Remove exhaust manifold (4a) and gaskets (4b).

- Remove the oil dipstick.- Remove the oil filter.1. Fit the tool.

	Description	Code	Function
1	Counter-torque	1.860.161.001	Tool for preventing crankshaft rotation

1. Undo bolt (1a) and remomve washer (1b) and accessory drivebelt pulley (1c).2. Remove both toothed timing belt covers.

1. Unscrew the bolts and remove the clutch assembly.

1. Undo retaining bolts (1a) and remove flywheel (1b).2. Remove the tool.

	Description	Code	Function
2	Counter-torque	1.860.161.001	Tool for preventing crankshaft rotation

Suppport the flyhwheel because it is very heavy.

1. Loosen the tensioner roller retaining screw and remove the toothed belt.2. Remove the tensioner roller.3. Remove timing pinion (3a) and tab (2b).4. Remove the coil mount with thermostat.

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

1. Turn the camshaft until the gear-cylinder head locating holes are aligned and introduce the 10 mm diameter reference pin.2. Unscrew the ten cylinder head retaining bolts.3. Remove the cylinder head.4. Remove the cylinder head gasket.- Remove the locating pins from the engine block.

- Rotate the crankcase through 180° on the overhaul stand.1. Loosen the hex-heated retaining bolts.2. Unscrew the short (2a) and long (2b) hex-heated socket bolts.3. Remove the oil sump.

1. Undo the bolts (1a) and remove the engine block front cover (1b).2. Remove spacer (2a) with key (2b).

1. Undo bolts (1a) and remove oil pump (1b) complete with chain (1c), pinion (1d) and tab (1e).2. Remove the spacer washer.

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

Mark each connecting rod-cap pair to ensure effective assembly.

1. Undo bolts (1a) and remove the connecting rod caps (1b) with bearings, except for no.1.

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

2. Remove the lower thrust washers (2a).3. Remove cap no. 1 (3a) using tools (3b), as described.

	Description	Code	Function
3b	Extractor	1.860.854.000	Removing rear bearing cap

	Description	Code	Function
3b	Mallet	1.846.011.000	Removing rear bearing cap

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

Mark the upper and lower bearings and the thrust washers to ensure correct refitting.

1. Undo the oil duct sealing plugs.2. Remove the oil pressure sensor.3. Remove the water/oil sealing plugs from the engine block using a mallet.4. Remove the cover plate.

- 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 refitting.- Clean the oil sump support surface thoroughly1. Clean the coolant ducts 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 the flatness of the cylinder head plane corresponds to the recommended values.

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

- Check that engine block height is within the recommended 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.1. Measure the cylinder bore/liner diameter.

	Subject	Value
1	CRANKCASE AND COMPONENTS	mm
-	Cylinder liner bore	86,000 - 86,018

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).

- 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
-	1st cylinder liner oversize	0,25

	Subject	Value
.	CRANKCASE AND COMPONENTS	mm
-	2nd cylinder liner oversize	0,60

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

1. Fit oil duct plugs (1a) and (1b) and tighten to the specified torque.

	Value - daNm	Fastening	Component	Ø
1a	2,5	Plug	CRANKCASE AND COMPONENTS	-

	Value - daNm	Fastening	Component	Ø
1b	3,5	Plug	CRANKCASE AND COMPONENTS	-

	Value - daNm	Fastening	Component	Ø
1b	2,5	Plug	CRANKCASE AND COMPONENTS	-

2. Fit the engine oil pressure sensor and tighten it to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2	6,0	Oil pressure sensor	CRANKCASE AND COMPONENTS	-

3. Fit the water sealing plugs in the crankcase using suitable fitting tools.4. Fit the cover plate on the engine block and tighten the bolts to the specified torque.

	Value - daNm	Fastening	Component	Ø
4	0,5	Bolts	CRANKCASE AND COMPONENTS

- 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	59,975 - 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.

The undersize should be marked by a special stamp on the side of the no. 1 crank arm.

2. Check that the diameter of the crankpins is within specified limits.

	Subject	Value
2	CRANKSHAFT	mm
-	Crankpin diameter	49,984 - 50,000

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

	Subject	Value
.	CRANKSHAFT	mm
-	Crankpin undersize	0,300

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. 4 crank arm.

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	25,70 - 25,75

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

	Subject	Value
.	CRANKSHAFT	mm
-	1st oversize on width of main journal bearing no. 2	0,20
-	2nd oversize on width of main journal bearing no. 2	0,30
-	3rd oversize on width of main journal bearing no. 2	0,40

- If the crankshaft has been ground, fit new oversize bearings to restore the original clearance.

Because the crankshaft is heat-treated, it must be heat-treated again and then undergo a dimension check if it is ground.

- Check main bearing half condition by sight and replace if necessary. Do not attempt to adjust bearings.

The lower main bearings (mounting end) are divided into four thickness categories, whereas upper main bearings (engine block end) come on a single thickness category.

1. Check that the thickness of lower (1a) and upper (1b) half-bearings corresponds to specified limits; if not, replace them.

	Subject	Value
1a	Lower main bearing half thickness	mm
-	Category A	1,844
-	Category B	1,857

	Subject	Value
1a	Lower main bearing half thickness	mm
-	Category C	1,866
-	Category D	1,877

	Subject	Value
1b	MAIN BEARINGS	mm
-	Upper main bearing half thickness	1,847

- If the crankshaft has been ground, fit new oversize bearings to restore the original clearance as described below.

	Subject	Value
.	MAIN BEARINGS
-	Oversize lower main bearing half thickness	mm
-	Category A	1,994
-	Category B	2,007

	Subject	Value
.	MAIN BEARINGS
-	Oversize lower main bearing half thickness	mm
-	Category C	2,016
-	Category D	2,027

	Subject	Value
.	MAIN BEARINGS	mm
-	Oversize upper main bearing half thickness	1,997

2. Check that the thickness of the thrust half-rings corresponds to specified limits; if not, replace them.

	Subject	Value
2	MAIN BEARINGS	mm
-	Thrust half-ring thickness	1,850

- Fit the upper main journal half-bearings in the cylinder block/crankcase.

If the bearings are reused, ensure the bearing halves are positioned correctly in their original seats.The upper main bearing halves are grooved to help distribute the lubricant.The lower main bearing halves lack grooves.

- Fit the crankshaft.1. Fit the calibrated wire (plastigate) for measuring the bearing clearance.

- Fit the main journal caps complete with half-bearings.

Fit cap no. 1 (flywheel end) without gaskets.Fit cap no. 2 with thrust rings.See the procedure on the following pages to fit main bearing caps nos 1 and 2.Do not move the crankshaft during the checking operations.

1. Tighten the main bearing caps to the specified torque.

	Value - daNm	Fastening	Component	Ø
1	7,0	Bolt	MAIN BEARINGS	-

1. Remove the main bearing caps and the half-bearings and measure the journal clearance using the special graduated gauge.

	Subject	Value
1	MAIN BEARINGS	mm
-	Radial clearance	0,039 - 0,080

- Choose the bearing category lower than the measured clerance to obtain the specified operating clearance of 0.038 - 0.069 mm.

	Subject	Value
.	MAIN BEARINGS
-	Lower main bearing halves	mm
-	Category A	0,039 - 0,052
-	Category B	0,053 - 0,062

	Subject	Value
.	MAIN BEARINGS
-	Lower main bearing halves	mm
-	Category C	0,063 - 0,074
-	Category D	0,075 - 0,080

The lower bearing categories are identified by a colour: category A, blue, category B, black, category C, green, category D, red.

1. Refit the main bearing caps as described previously and check that the crankshaft end float is within specified limits using a magnetic base with dial gauge.

	Subject	Value
1	CRANKSHAFT	mm
-	End float	0,032 - 0,007

- If the end float is not within specified limits, grind the crankshaft and fit new oversize thrust washers to restore the initial clearance.

	Subject	Value
.	MAIN BEARINGS	mm
-	Thickness of thrust half-rings, 1st oversize	1,95
-	Thickness of thrust half-rings, 2nd oversize	2,00
-	Thickness of thrust half-rings, 3rd oversize	2,05

- Remove the rings (1a) from the pistons using tool (1b).

	Description	Code	Function
1b	Extractor/Fitting tool	1.860.183.000	Extracting/fitting piston circlips

1. Remove the pin on a press using tools (1a) and (1b) and an appropriate pusher.</

	Description	Code	Function