1004E20 ENGINE - DISMANTLE AND REASSEMBLE FOLLOWING OPERATION 1004E10 - WASH AND CHECK DISMANTLED PARTS - REFIT CYLINDER HEAD AND OIL SUMP - DOES NOT INCLUDE REPAIRS TO CYLINDER HEAD AND AUXILIARY UNIT - Fiat - NUOVA 500 - eLearn

312002366 - 1004E20 ENGINE - DISMANTLE AND REASSEMBLE FOLLOWING OPERATION 1004E10 - WASH AND CHECK DISMANTLED PARTS - REFIT CYLINDER HEAD AND OIL SUMP - DOES NOT INCLUDE REPAIRS TO CYLINDER HEAD AND AUXILIARY UNIT

) 1. Undo bolt (1a) and remove rpm sensor (1b).2. Undo bolts (2a) and remove the rigid coolant inlet pipe to water pump (2b) complete with O-Ring (2c).

- Undo the bolts and remove the engine oil heat exchanger protection.1. Undo bolts (1a) and remove engine oil filter mounting (1b) complete with engine oil filter (1c), engine oil heat exchanger (1d) and engine oil filler fitting (1e).- Remove the gasket.2. Undo bolts (2a) and remove air conditioner compressor (2b).

1. Undo bolts (1a) and remove air conditioner compressor mounting (1b).

1. Undo connectors (1a) and remove engine oil pipe (1b).

1. Undo bolts (1a) and remove alternator (1b).

1. Undo bolts (1a) and remove alternator mounting (1b).

1. Undo bolts (1a) and remove vacuum reservoir (1b).

1. Undo bolts (1a) and remove engine oil recovery manifold (1b).2. Undo bolts (2a) and remove starter motor (2b).

- Rotate the engine through 180° on the overhaul stand.1. Undo the lower crankcase retaining bolts.2. Cut the lower crankcase sealant using the tool.

Tool	Description	Function	Validity
1.870.718.000	Blade	Cut sealant	all versions

3. Remove the lower crankcase.- Remove the lower main half-bearings.

1. Undo bolts (1a) and remove connecting rod caps (1b).2. Remove the lower connecting rod half-bearings.3. Remove the connecting rod - piston assemblies.4. Remove the upper connecting rod half-bearings.

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

Measurement	Value	Validity
Crankshaft endfloat (mm)	0.055 ÷ 0.265	1.2 8V1.3 Mjet

- If the value for the crankshaft endfloat is not within the recommended limits, when refitting regrind the crankcase seat and use suitable oversize thrust half-washers.

1. Remove crankshaft (1a) complete with rear oil seal (1b).2. Remove the upper main half-bearings.

The central main bearing half is joined to the thrust half-washers. Press the ends of the half-bearing to separate.

1. Undo bolts (1a) and remove engine oil jets (1b).2. Remove the lower engine block locating bushes.

- Use an appropriate tool to support the upper engine block.- Unscrew the retaining bolts and separate the upper crankcase from the overhaul stand plate.- Position the upper crankcase on a suitable workbench. Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH - Drill and remove the water/oil sealing plugs from the crankcase to allow for washing the ducts.

Refitting ( Removing

) - Clean sealant residues off the mating surfaces between: cylinder head extension/lower cylinder head, upper crankcase/lower crankcase and lower crankcase/crankcase sump.- Clean the parts removed thoroughly and check their condition visually.- Fit the water/oil sealing plugs in the crankcase using suitable fitting tools.- Lubricate all the mechanical coupling components with engine oil.1. Measure the cylinder liner diameter according to the diagram shown in the figure.

Measurement	Value	Validity
Cylinder liner diameter - Grade A (mm)	69.600 ÷ 69.610	1.3 Mjet

Measurement	Value	Validity
Cylinder liner diameter - Grade B (mm)	69.610 ÷ 69.620	1.3 Mjet

Measurement	Value	Validity
Cylinder liner diameter - Grade C (mm)	69.6200 ÷ 69.630	1.3 Mjet

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

Measurement	Value	Validity
Cylinder liner taper (mm)	± 0.010	1.3 Mjet

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

Measurement	Value	Validity
Cylinder liner ovality (mm)	± 0.005	1.3 Mjet

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

If reaming, ensure all the liners have the same oversize.

Measurement	Value	Validity
Cylinder liner diameter oversize (mm)	0.1	all versions

- Use an appropriate support tool to replace the upper crankcase on the overhaul stand.- Refit the lower crankcase locating bushes in their seats.- Provisionally fit the lower engine block on the upper engine block to measure the main journal seats and then remove it.1. Loosen central bolts (1a) securing the lower crankcase to the specified torque, following the order shown in the figure. Use angular tightening tool (1b).

Component	Fastening	dia	Value (daNm)	Validity
Lower crankcase (on engine block)	Bolt	M10x1.25x96	2.0 + 80°	1.3 Multijet1.4 16V

Tool	Description	Function	Validity
1.860.942.000	Torque wrench	Tighten bolts to torque plus angle	1.3 Mjet

2. Tighten the lower crankcase side bolts to the specified torque, following the order shown in the figure.

Component	Fastening	dia	Value (daNm)	Validity
Lower crankcase (on engine block)	Bolt	M8x1.25x40	3.0	1.3 Multijet1.4 16V

3. Check that the diameter of the main journal seats is within specified limits (without fitting the half-bearings).

Measurement	Value	Validity
Main journal seat diameter - Category A (mm)	54.710 ÷ 54.714	1.3 Mjet

Measurement	Value	Validity
Main journal seat diameter - Category B (mm)	54.714 ÷ 54.718	1.3 Mjet

Measurement	Value	Validity
Main journal seat diameter - Category C (mm)	54.718 ÷ 54.722	1.3 Mjet

- Check that there are no deposits or blockages in the crankshaft lubrication ducts.- Check that the diameter of the main journals is within the recommended limits.

Measurement	Value	Validity
Main journal diameter - Category A (mm)	50.994 ÷ 51.000	1.3 Mjet

Measurement	Value	Validity
Main journal diameter - Category B (mm)	50.988 ÷ 50.994	1.3 Mjet

Measurement	Value	Validity
Main journal diameter - Category C (mm)	50.982 ÷ 50.988	1.3 Mjet

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

Measurement	Value	Validity
Main journal diameter undersize (mm)	0.127	1.2 8V1.4 16V

Crankpin undersizes higher than the value mentioned will adversely affect the structural resistance of the crankshaft (following contact between the tool and rolled connectors). As far as the above is concerned, if the regrinding requires undersizes greater than 0.127 mm, then the crankshaft must be replaced and a new one ordered from the Parts Dept. The half-bearings used for undersizes of more than 0.127 mm should not be ordered from the Parts Dept. (even if the number is still quoted).

- Check that the diameter of the crankpins is within the recommended limits.

Measurement	Value	Validity
Crankpin diameter - Category A (mm)	42.591 ÷ 42.600	1.3 Mjet

Measurement	Value	Validity
Crankpin diameter - Category B (mm)	42.582 ÷ 42.591	1.3 Mjet

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

Measurement	Value	Validity
Crankpin diameter undersize (mm)	0.127	1.2 8V1.4 16V

- Check the crankshaft and connecting rod bearings, keeping in mind that no adjustment operations should be carried out on the half-bearings. Replace them if scoring or signs of binding are noted.- The size of the main half-bearings is given.

Measurement	Value	Validity
Main half-bearings - Category 1 (red) (mm)	1.836 ÷ 1.841	1.3 Mjet

Measurement	Value	Validity
Main half-bearings thickness - Category 2 (blue) (mm)	1.841 ÷ 1.846	1.3 Mjet

Measurement	Value	Validity
Main half-bearings thickness - Category 3 (yellow) (mm)	1.846 ÷ 1.851	1.3 Mjet

Measurement	Value	Validity
Main journal half-bearing thickness oversize (mm)	0.127	1.3 Mjet

- The size of the connecting rod half-bearings is given.

Measurement	Value	Validity
Crankpin half-bearings - Category A (red) (mm)	1.546 ÷ 1.552	1.3 Mjet

Measurement	Value	Validity
Crankpin half-bearings - Category B (blue) (mm)	1.550 ÷ 1.556	1.3 Mjet

Measurement	Value	Validity
Main journal half-bearing thickness oversize (mm)	0.127	1.3 Mjet

- Place the upper main bearing halves in their seats taking great care over cleanliness.

Half-bearings of different categories may be fitted to the same journal to reduce the clearance. In the above case, observe the following installation requirements. Fit the thickest half-bearing to the main bearing cap and the thinnest to the crankcase.

If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions. The thrust half-washers are built into the central main bearing half.

- The thrust half-washer thickness is given.

Measurement	Value	Validity
Thrust half-washer thickness (mm)	2.310 ÷ 2.360	1.3 Mjet

The thrust half-washer undersize is 0.127 mm.

- Fit the crankshaft into its seat on the upper crankcase.1. Fit the calibrated wire (plastigage) for measuring the main journal clearance.

1. Refit the lower crankcase with lower main bearing halves in its seat.2. Tighten central bolts (2a) securing the lower crankcase to the specified torque, following the order shown in the figure. Use angular tightening tool (2b).

Component	Fastening	dia	Value (daNm)	Validity
Lower crankcase (on engine block)	Bolt	M10x1.25x96	2.0 + 80°	1.3 Multijet1.4 16V

Tool	Description	Function	Validity
1.860.942.000	Torque wrench	Tighten bolts to torque plus angle	1.3 Mjet

3. Tighten the lower crankcase side bolts to the specified torque, following the order shown in the figure.

Component	Fastening	dia	Value (daNm)	Validity
Lower crankcase (on engine block)	Bolt	M8x1.25x40	3.0	1.3 Multijet1.4 16V

1. Remove the lower crankcase with main bearing halves and, using a suitable graduated measuring instrument (1a), measure the clearance shown by calibrated wire (1b).

Check one journal at a time, without rotating the crankshaft.

Measurement	Value	Validity
Clearance between main bearings - crankshaft main journals (mm)	0.028 ÷ 0.048	1.3 Mjet

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

1. After checking all the main journals, apply a strip of specified silicone sealant to the contact surfaces between the lower crankcase and the upper crankcase as shown in the diagram in the figure.

The sealant strip must be unbroken. The sealant strip diameter must be 2.5 - 3.5 mm.

- After applying the sealant clean the crankshaft lower oil seal seat.

- Fit the lower crankcase to the upper crankcase permanently by tightening the bolts as shown previously.- Check that the small end bush bore diameter is within the recommended limits; if not, replace the connecting rod assemblies.

Measurement	Value	Validity
Small end bush inner diameter (mm)	23.006 ÷ 23.012	1.3 Mjet

- Check that the diameter of the piston pin housing in the piston is within the recommended values.

Measurement	Value	Validity
Piston pin housing diameter (mm)	22.990 ÷ 22.996	1.3 Mjet

- If the piston pin bore diameter is not within specified values, replace the piston complete with its piston pin and retaining rings.- Check that the outer diameter of the piston pins is within the recommended limits; if not, replace the worn piston pins.

Measurement	Value	Validity
Piston pin outer diameter (mm)	22.892 ÷ 22.987	1.3 Mjet

- Fit the sealing rings in the cylinder liner and check that the opening between the ends is within the recommended values; if this is not the case, replace the retaining rings.

Measurement	Value	Validity
Cylinder compression 1st sealing ring gap (mm)	0.20 ÷ 0.30	1.3 Mjet

Measurement	Value	Validity
Cylinder compression 2nd sealing ring gap (mm)	1.0 ÷ 1.5	1.3 Mjet

Measurement	Value	Validity
Cylinder compression 3rd sealing ring gap (mm)	0.25 ÷ 0.50	1.3 Mjet

- Check that the thickness of the sealing rings is within the recommended limits.

Measurement	Value	Validity
Cylinder compression 1st sealing ring thickness (mm)	1.970 ÷ 1.995	1.3 Mjet

Measurement	Value	Validity
Cylinder compression 2nd sealing ring thickness (mm)	1.470 ÷ 1.490	1.3 Mjet

Measurement	Value	Validity
Cylinder compression 3rd sealing ring thickness (mm)	1.970 ÷ 1.990	1.3 Mjet

- Check that the piston ring seats are within the recommended values.

Measurement	Value	Validity
Sealing ring seat in piston - 1st groove (mm)	2.08 ÷ 2.10	1.3 Mjet

Measurement	Value	Validity
Sealing ring seat in piston - 2nd groove (mm)	1.53 ÷ 1.55	1.3 Mjet

Measurement	Value	Validity
Sealing ring seat in piston - 3rd groove (mm)	2.02 ÷ 2.04	1.3 Mjet

- Check that the outer diameter of the pistons corresponds to the recommended figures; if not, replace the piston complete with sealing rings and piston pin.

Measurement	Value	Validity
Piston outer diameter -Grade A (mm)	69.520 ÷ 69.530	1.3 Mjet

Measurement	Value	Validity
Piston outer diameter - Grade B (mm)	69.530 ÷ 69.540	1.3 Mjet

Measurement	Value	Validity
Piston outer diameter - Grade C (mm)	69.540 ÷ 69.550	1.3 Mjet

Measure perpendicular to the piston pin axis, 12 mm from the lower edge of the skirt.

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

Measurement	Value	Validity
Cylinder compression 1st sealing ring endfloat (mm)	0.09 ÷ 0.13	1.3 Mjet

1. Check that endfloat (1a) between second ring (1b) and the housing in piston (1c) corresponds to the recommended figure.

Measurement	Value	Validity
Cylinder compression 2nd sealing ring endfloat (mm)	0.04 ÷ 0.08	1.3 Mjet

- Check that the endfloat between the oil scraper ring and the housing in the piston corresponds to the recommended figures.

Measurement	Value	Validity
Oil scraper ring endfloat (mm)	0.030 ÷ 0.070	1.3 Mjet

1. Fit caps (1b) on connecting rods (1a) and secure them by tightening bolts (1c) to the recommended torque.

The connecting rods are pre-set fracture rods and are supplied already fractured by Parts together with the cap bolts. The connecting rod caps are not interchangeable because the fracture profile differs from part to part.

Component	Fastening	dia	Value (daNm)	Validity
Connecting rod	Bolt