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 the bolts (1a) and the nuts (1b) and remove the mounting (1c) complete with the alternator (1d) and air conditioning compressor (1e).

1. Undo the bolt (1a) and remove the rigid engine coolant pump inlet pipe (1b) with seal.

1. Undo bolts (1a) and nut (1b) securing the water pump to the crankcase.2. Remove the sealant using the tool (2a) and remove the water pump (2b).

Tool	Description	Function	Validity
1.870.718.000	Blade	Cut sealant	all versions

- Clean thoroughly between the crankcase and water pump mating surfaces.3. Using a suitable tool remove the engine oil filter cartridge.4. Remove the minimum engine oil pressure switch.

1. Undo the bolts (1a) and remove the crankcase front cover (1b) with the oil pump incorporated, complete with gasket (1c) and intake duct (1d).

1. Fit the tool (1a) and undo the bolt (1b) securing the crankshaft gear.

Tool	Description	Function	Validity
2.000.004.500	Template	Locking drive pulley	1.2 8V1.4 16V

- Remove the template fitted previously.2. Remove the crankshaft gear.3. Undo the bolt (3a) and remove the rpm sensor (3b).

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

- Rotate the engine block through 180°.1. Fit the tool for rotating the crankshaft.

Tool	Description	Function	Validity
1.860.815.000	Flange	Crankshaft rotation	1.3 Mjet1.4 16V

1. Undo the bolts (1a) and remove the 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.

The arrow on the piston crown facing the timing side indicates the fitting direction.The matching of the connecting rod-cap is the "BREAKING" type therefore the position is compulsory and the number corresponding to the position of the cylinder must be present.

- Remove the flange for rotating the crankshaft fitted previously.1. Using a dial gauge, check that the crankshaft endfloat is within specified limits.

Measurement	Value	Validity
Crankshaft endfloat (mm)	0.155 ÷ 0.355	1.4 16V

- Remove the dial gauge.

If the value for the crankshaft endfloat does not correspond with the recommended figures, when refitting, regrind the crankcase seat and use the central main bearing half incorporating appropriately oversized crankshaft thrust half-washers.

1. Undo the bolts (1a) and remove the lower crankcase (1b), complete with lower half-bearings, from the engine block.

1. Remove the lower main half bearings from the engine block.2. Remove the crankshaft.3. Remove the upper main half-bearings.

1. Undo the bolt and remove the knock sensor.

- Remove the engine block base locating bushes with the engine block.- Raise the engine block using a hydraulic lift and place it 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 1. Remove the coolant chamber plugs from the crankcase using an appropriate steel striker.2. Remove the lubrication duct plug from the crankcase using a steel striker.

1. Remove the oil jets (1a) using the tool (1b).

Tool	Description	Function	Validity
1.860.395.000	Striker	Engine oil jet removal	1.2 8V1.4 16V

Insert the drift guide hole on the nozzle surface to prevent the drift from slipping and damaging the cylinder liner during the removal operation.

Use new oil jets when refitting.

Refitting ( Removing

) - Wash and check the appearance of all components removed.- Place the crankcase on the overhaul stand.- Fit the water/oil sealing plugs in the crankcase using suitable fitting tools and sealant.- Fit the locating bushes for the crankcase.1. Use the tool (1a) and a plastic mallet to fit the new oil jets (1b).

Tool	Description	Function	Validity
1.860.313.000	Fitting tool	Engine oil jet fitting	1.2 8V1.4 16V

1. Using a calibrated metal rule (1a) and a feeler gauge (1b), check the flatness of the cylinder head - engine block support surface.2. If the measurement does not correspond to the recommended values, regrind the cylinder head support surface.

Measurement	Value	Validity
Cylinder head support surface flatness (mm)	< 0.1	1.2 8V1.4 16V

- Measure the diameter of the cylinder liners and check that they correspond to the recommended figures.

Measurement	Value	Validity
Cylinder liner diameter - Grade A (mm)	72.000 ÷ 72.010	1.4 16V

Measurement	Value	Validity
Cylinder liner diameter - Grade B (mm)	72.010 ÷ 72.020	1.4 16V

Measurement	Value	Validity
Cylinder liner diameter - Grade C (mm)	72.020 ÷ 72.030	1.4 16V

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

Measurement	Value	Validity
Cylinder liner ovality (mm)	± 0.05	1.2 8V1.4 16V

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

Measurement	Value	Validity
Cylinder liner taper (mm)	± 0.005	1.2 8V1.4 16V

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

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

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

- Check that the diameter of the main journals is within the recommended limits.

Measurement	Value	Validity
Main journal diameter - Category A (mm)	47.997 ÷ 48.003	1.4 16V

Measurement	Value	Validity
Main journal diameter - Category B (mm)	47.988 ÷ 47.994	1.4 16V

Measurement	Value	Validity
Main journal diameter - Category C (mm)	47.982 ÷ 47.988	1.4 16V

- If the diameter of the main journals does not fall within the recommended values, they should be reground to the recommended undersize.

Because the crankshaft has undergone nitriding, this treatment should be repeated and the size re-checked if it is ground.

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

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

Measurement	Value	Validity
Crankpin diameter (mm)	41.990 ÷ 42.008	1.2 8V1.4 16V

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

Because the crankshaft has undergone nitriding, this treatment should be repeated and the size re-checked if it is ground.

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

- Check the main bearings, noting that the half-bearings should not be adapted. Replace them if scoring or signs of binding are noted.- Fit the main bearing halves in their seats on the upper crankcase, aligning the lubrication ports and ensuring scrupulous cleanliness. The central main bearing half incorporates thrust half-washers because it performs a load-bearing function and also acts as a thrust bearing.- If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions.1. Fit the crankshaft in the special housing in the engine block with the upper half-bearings.2. Fit the calibrated wire (plastigage) for measuring the main journal clearance.

1. Fit the main half-bearings in the lower crankcase.2. Fit the lower crankcase on the engine block, checking that the codes stamped on both parts of the crankcase correspond, because the crankcase components are not interchangeable.

- The size of the main half-bearings is given.

Measurement	Value	Validity
Main half-bearings - Category 1 (red) (mm)	1.836 ÷ 1.840	1.2 8V1.4 16V

Measurement	Value	Validity
Main half-bearings thickness - Category 2 (blue) (mm)	1.843 ÷ 1.847	1.2 8V1.4 16V

Measurement	Value	Validity
Main half-bearings thickness - Category 3 (yellow) (mm)	1.848 ÷ 1.852	1.2 8V1.4 16V

Measurement	Value	Validity
Main bearing half undersize (mm)	0.127	1.4 16V

- Tighten the bolts securing the lower crankcase to the engine block to the specified torque.

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

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 and check the main journal clearance. Use an appropriate measuring device to measure the width of the plastigage.

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

Measurement	Value	Validity
Clearance between main bearings - crankshaft main journals (mm)	0.025 ÷ 0.040	1.2 8V1.4 16V

- After checking all the main journals, apply sealant to the contact surfaces between the lower crankcase and upper crankcase. Then fit the lower crankcase permanently by tightening the bolts to torque in the order described previously.

Apply a 2-mm thick continuous sealant strip to the lower crankcase surface.

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

Measurement	Value	Validity
Piston outer diameter -Grade A (mm)	71.960 ÷ 71.970	1.4 16V

Measurement	Value	Validity
Piston outer diameter - Grade B (mm)	71.970 ÷ 71.980	1.4 16V

Measurement	Value	Validity
Piston outer diameter - Grade C (mm)	71.980 ÷ 71.990	1.4 16V

Measure perpendicular to the gudgeon pin axis, 9 mm from the lower edge of the skirt.

- Position the pistons in the cylinder liners and use a feeler gauge to measure the specified clearance.

Measurement	Value	Validity
Clearance between piston - cylinder liner (mm)	0.030 ÷ 0.050	1.4 16V

- Check that the inner bore of the piston pin housings is within the recommended limits; if not, replace the pistons.

Measurement	Value	Validity
Piston pin housing diameter (mm)	17.982 ÷ 17.986	1.4 16V

- Check that the outer diameter of the piston pins is within the recommended limits; if not, replace the worn parts.

Measurement	Value	Validity
Gudgeon pin outer diameter (mm)	17.970 ÷ 17.974	1.2 8V1.4 16V

- Use a micrometer gauge to measure the thickness of the piston sealing rings.

Measurement	Value	Validity
Cylinder compression 1st sealing ring thickness (mm)	0.970 ÷ 0.990	1.4 16V

Measurement	Value	Validity
Cylinder compression 2nd sealing ring thickness (mm)	1.170 ÷ 1.190	1.4 16V

Measurement	Value	Validity
Cylinder compression 3rd sealing ring thickness (mm)	1.975 ÷ 1.990	1.4 16V

Measurement	Value	Validity
Sealing ring oversize (mm)	0.1	1.2 8V1.4 16V

1. Fit the sealing rings (1a) in the cylinder liners/bores and use a feeler gauge (1b) to check the gap between the seal ends is within specified limits. Otherwise replace the sealing rings.

Measurement	Value	Validity
Cylinder compression 1st sealing ring gap (mm)	0.20 ÷ 0.40	1.4 16V

Measurement	Value	Validity
Cylinder compression 2nd sealing ring gap (mm)	0.25 ÷ 0.45	1.4 16V

Measurement	Value	Validity
Cylinder compression 3rd sealing ring gap (mm)	0.20 ÷ 0.40	1.4 16V

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

Measurement	Value	Validity
Sealing ring seat in piston - 1st groove (mm)	1.020 ÷ 1.040	1.4 16V

Measurement	Value	Validity
Sealing ring seat in piston - 2nd groove (mm)	1.210 ÷ 1.230	1.4 16V

Measurement	Value	Validity
Sealing ring seat in piston - 3rd groove (mm)	2.010 ÷ 2.030	1.4 16V

1. Use a feeler gauge (1a) to check mating clearance between retaining rings (1b) and grooves on pistons (1c).

Measurement	Value	Validity
Cylinder compression 1st sealing ring endfloat (mm)	0.030 ÷ 0.070	1.4 16V

Measurement	Value	Validity
Cylinder compression 2nd sealing ring endfloat (mm)	0.020 ÷ 0.060	1.4 16V

Measurement	Value	Validity
Cylinder compression 3rd sealing ring endfloat (mm)	0.020 ÷ 0.055	1.4 16V

- Check that the diameters of the big ends and the small ends are within the recommended values.

Measurement	Value	Validity
Big end diameter (mm)	45.128 ÷ 45.138	1.4 16V

Measurement	Value	Validity
Small end diameter (mm)	17.939 ÷17.956	1.4 16V

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 - Fit the tool for rotating the crankshaft.

Tool	Description	Function	Validity
1.860.815.000	Flange	Crankshaft rotation	1.3 Mjet1.4 16V

- Fit the connecting rod-piston assemblies and align in accordance with the following references.1. Piston class and arrow indicating timing side.2. Area where the number of the cylinder liner matching the connecting rod is stamped.3. Gudgeon pin offset

The matching of the connecting rod-cap is the "BREAKING" type therefore the position is compulsory and the number corresponding to the position of the cylinder must be present.

Letters identifying the cylinder liner classes are shown on the crankcase.

1. Fit connecting rod/piston assemblies (1a) with half-bearings, using tool (1b) to compress retaining rings and then fit the piston into the liner.

- Rotate the engine on the overhaul stand.1. Apply the calibrated wire (plastigage) for measuring the crankpin clearance.

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

Measurement	Value	Validity
Connecting rod half-bearing thickness (mm)	1.544 ÷ 1.548	1.2 8V1.4 16V

- Refit the connecting rod caps complete with half-bearings and secure them by tightening the bolts to the recommended torque.

The connecting rod caps are fracture type. If replaced, they are supplied pre-fractured by the manufacturer. Check that the parts are free of burrs, blisters, scratches or any other surface defect. Before installation, parts must be thoroughly washed, cleaned and dried. Fit the connecting rod caps so that the number stamped on each cap faces towards the same side as the number stamped on the big end.

Each connecting rod must be paired with its cap, respecting the numerical references stamped on the parts. Connecting rods and connecting rod caps are not interchangeable.

Component	Fastening	dia	Value (daNm)	Validity
Connecting rod	Bolt	M8x1x38.5	2.0 + 40°	1.3 Multijet1.4 16V

1. Remove the connecting rod caps and check the crankpin clearance. Use an appropriate gauge to measure the width of the plastigage.

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

Measurement	Value	Validity
Clearance between connecting rod bearings - crankpin bearings (mm)	0.023 ÷ 0.060	1.4 16V

- If the value measured is not within the recommended figures, replace the connecting rod bearings.

- Refit the connecting rod caps complete with half-bearings and secure them by tightening the bolts to the torque given previously.- Rotate the engine on the overhaul stand.- Position a new oil pump gasket.- Fit the front crankcase cover with built-in oil pump complete with intake chamber and secure by tightening the bolts.- Place the engine oil filter in its housing.- Place the minimum engine oil pressure switch in position and tighten it to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil pressure switch	-	M14x1.5	3.2	all versions

- Fit the oil seal on the crankshaft front cover using the tool.

Tool	Description	Function	Validity
1.860.990.000	Fitting tool	Fitting oil seal on exhaust camshaft	1.4 16V

- Remove the flange for rotating the crankshaft fitted previously.- Place the crankcase rear cover in position and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Crankshaft front and rear cover	Bolt	M6x1x16	1.0	1.4 16V

Component	Fastening	dia	Value (daNm)	Validity
Crankshaft front and rear cover	Bolt	M6x1x32	1.0	1.4 16V

Component	Fastening	dia	Value (daNm)	Validity
Crankshaft front and rear cover	Bolt	M6x1x22	1.0	1.4 16V

- Place the crankshaft gear in its housing.1. Because the timing is adjusted with the four pistons in line, i.e. half-way along their effective strokes, it is essential to position the crankshaft in phase with the camshafts. They can be approximately positioned by turning the crankshaft gear (1a) until the locating dowel (1b) is positioned opposite to the rpm sensor seat (1c) with the first cylinder piston in descending phase, i.e. intake.

1. Position the counter-torque tool.

Tool	Description	Function	Validity
2.000.004.500	Template	Locking drive pulley	1.2 8V1.4 16V

2. Secure the crankshaft gear (2a) by tightening the bolt (2b) to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Toothed drive pulley (on crankshaft)	Bolt	M12x1x46 (left)	2.0 + 110°	1.4 16V

3. Position the rpm sensor (3a) in its housing and secure it by tightening the bolt (3b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine rpm sensor (on oil pump)	Bolt	M6X1X16	0.9	1.4 16V

- Apply silicon sealant to the outer edge of the water pump.- Position the water pump in its housing and secure it, tightening the bolts and the nut to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Water pump (on engine block)	Nut	M6x1	1.0	1.4 16V

Component	Fastening	dia	Value (daNm)	Validity
Water pump (on engine block)	Nut	M6x1	0.9	1.3 Multijet

- Place the water pump rigid inlet pipe, complete with new gasket, in position and secure it using the bolt.- Rotate the engine through 180° on the overhaul stand.- Clean the lower crankcase and oil sump contact surfaces, removing the silicone sealant residues.- Apply the sealant without a break to the entire perimeter of the oil sump.- Position the oil sump in its housing and secure it, tightening the bolts and the nuts to the recommended torque.

When positioning the oil sump, avoid significant sideways movements that could remove the sealant.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump (on lower crankcase)	Bolt	M6x1x25	0.9	1.4 16V

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump (with engine oil pump)	Nut	M6x1	0.9	all versions

- Rotate the engine through 180° on the overhaul stand.- Fit the locating dowels in the crankcase.- Fit a new cylinder head gasket on the cylinder block.- Position the cylinder head on the crankcase by aligning the locating dowels.1. Tighten the bolts securing the cylinder head to the recommended torque.

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

Component	Fastening	dia	Value (daNm)	Validity
Cylinder head (on engine block)	Bolt	M9x1.25x96	3.0 + 90° + 90°	1.2 8V1.4 16V

- Fit the locating dowels and position the cylinder head extension gasket on the cylinder head support plane.- Position the tappet retaining tools beneath the camshaft housing, then place the camshaft housing on the cylinder head and withdraw the tools.- Use the tool to tighten the camshaft housing bolts to the specified torque.

Tool	Description	Function	Validity
1.860.834.000	Spanner	Loosen/tighten the cylinder head extension bolts	1.4 16V

Component	Fastening	dia	Value (daNm)	Validity
Camshaft housing (on cylinder head)	Bolt	M8x1x50	1.5	1.4 16V

- Refit the plugs complete with new O-rings and tighten them to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Camshaft housing bolts sealing plug	-	M16x1	1.5	1.4 16V

- Place the thermostat in its housing with the new O-ring and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Thermostat unit (on cylinder head)	Bolt	M6x1x22	1.0	1.4 16V

- Place the timing belt moving tensioner in its housing without tightening the nut.- Place the driven pulley/phase transformer in its housing.- Fit the driven pulley/phase transformer locking tool.

Tool	Description	Function	Validity
2.000.015.800	Counter-torque	Locking driven pulley	1.4 16V

- Tighten the driven pulley/phase transformer fixing bolt to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Variable valve timing	Bolt	M12x1.25x40	2.0 + 50°	1.4 16V

- Tighten the retaining bolts for the camshaft idler gears to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Camshsaft idler gear (inlet side)	Bolt	M12x1.25x40	12.0	1.4 16V

Component	Fastening	dia	Value (daNm)	Validity
Camshsaft idler gear (exhaust side)	Bolt	M12x1.25x40	12.0	1.4 16V

- Loosen the bolt securing the driven pulley/phase transformer and remove the locking tool.- Remove the tool used previously for counter-torque for tightening the bolt securing the crankshaft gear.

Tool	Description	Function	Validity
2.000.004.500	Template	Locking drive pulley	1.2 8V1.4 16V

1. Position the tools (1a) in the seats for the spark plug for 1st and 2nd cylinder, tightening the pins (1b) to a torque of 0.5 daNm.

Tool	Description	Function	Validity
1.860.992.000	Bearings	Crankshaft timing	1.4 16V

2. Rotate the crankshaft in its normal direction of rotation until the tool moving pins fitted previously are aligned with one another.

Rotate the crankshaft proceeding gradually to prevent the tool pins being expelled by the compression of the pistons.

3. The camshaft timing was adjusted previously by fitting the tools illustrated.

Tool	Description	Function	Validity
1.860.985.000	Locating pins	Camshaft timing	1.4 16V

- Proceed with fitting the timing drive belt, firstly fitting it on the crankshaft gear, the water pump pulley, the driven pulley/phase transformer and lastly on the moving tensioner.

Ensure that this operation is performed with the driven pulley/phase transformer slack.

1. Tension the timing belt by turning it anticlockwise with the tool (1a) and the moving tensioner (1b) and then secure it when the reference fork (1c) is in contact (1d).

Tool	Description	Function	Validity
1.860.987.000	Spanner	Tensioning toothed timing drive belt	1.2 8V1.4 16V

- Fit the driven pulley/phase transformer locking tool.

Tool	Description	Function	Validity
2.000.015.800	Counter-torque	Locking driven pulley	1.4 16V

- Tighten the driven pulley/phase transformer fixing bolt to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Variable valve timing	Bolt	M12x1.25x40	2.0 + 50°	1.4 16V

- Place the driven pulley/phase transformer sealing plug in position and tighten it to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Phase transformer sealing plug	-	M27x1.5	3.0	1.4 16V

- Remove the tools positioned previously for the timing and locking of the camshafts and rotate the crankshaft through two revolutions.1. Loosen the moving tensioner nut and adjust the front fork using the tool (1a) until it is aligned with the rear fork (1b).2. Tighten the nut securing the moving tensioner to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing system moving tensioner	Nut	M8	2.5	1.4 16v

- Turn the crankshaft through two revolutions in its normal rotation direction, then reposition the tools used to adjust engine timing and check the engine is in phase.- Remove the tools used for timing the engine.- Place the side plugs in their seats in the cylinder head extension and tighten them to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Camshaft housing bolts sealing plug	-	M16x1	1.5	1.4 16V

- Place the flywheel side camshaft seal rear cover in its housing and secure it using the nuts.- Position the timing sensor in its housing and secure it using the bolt.- Refit the connector carrier bracket in its housing.- Place the timing belt inner guard in its housing and secure it using the bolt.- Place the oil vapour separator in its housing and secure it using the bolts and the nut.- Fit the spark plugs and tighten them to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Spark plugs	-	M12x1.2	1.8	1.4 16V

- Fit the ignition coils and tighten them to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Coils	Bolt	M6x1x22	0.9	1.4 16V

- Place the intake manifold on the cylinder head and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Intake manifold (on cylinder head)	Bolt	M7x1x42	1.5	1.4 16V

Component	Fastening	dia	Value (daNm)	Validity
Intake manifold (on cylinder head)	Bolt	M7x1x47	1.5	1.4 16V

- Connect the pipe to the oil vapour separator and secure it using the band.- Place the engine oil dipstick pipe back in its housing and secure it with the bolt.- Fit the upper and lower timing belt covers and secure them using the bolts.- Place the timing side rigid engine support in position and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing side engine support	Bolt	M10x1.25x55	6.0	1.2 8V1.4 16V

- Position the knock sensor in its housing and secure it by tightening the bolt to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Knock sensor	Bolt	M8x1.25x28	2.5	1.4 16V

- Place the mounting complete with alternator and air conditioning compressor in position and secure by tightening the nuts and bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Alternator/compressor mounting (side on crankcase)	Bolt	M10x1.25x35	5.0	1.2 8V1.4 16V

Component	Fastening	dia	Value (daNm)	Validity
Alternator/compressor mounting (side on crankcase)	Bolt	M10x1.25x60	5.0	1.2 8V1.4 16V

Component	Fastening	dia	Value (daNm)	Validity
Alternator/compressor mounting (side on crankcase)	Bolt	M10x1.25x85	5.0	1.2 8V1.4 16V

- Position the crankshaft pulley in its housing and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Service pulley (on crankshaft)	Bolt	M8x1.25x18	2.5	1.2 8V

- Fit the auxiliary drivebelt.- Place the phase transformer solenoid guard back in its housing and secure it using the bolts.- Connect the engine block earth lead and tighten the bolt.- Connect the alternator earth lead and tighten the nut.- Connect the electrical connection for the slider solenoid valve.- Connect the electrical connection for the air conditioning compressor engagement solenoid valve.- Connect the electrical connection for the knock sensor.- Connect the injector wiring junction.- Secure the electrical connection for the fuel vapour recovery solenoid.- Connect the electrical connection for the slider position sensor.- Connect the electrical connection for the throttle body.- Secure the electrical connection for the timing sensor.- Connect the electrical connection for the engine coolant temperature sensor.- Connect the electrical connections for the ignition coils.- Connect the electrical connection for the absolute pressure sensor.- Connect the earth lead and tighten the bolt.- Connect the electrical connection for the air pressure/temperature sensor.- Connect the electrical connection for the phase transformer actuator.- Connect the electrical connection for the rpm sensor.- Connect the electrical connection for the engine oil pressure switch.- Fasten the cable loom retaining duct to the camshaft housing and attach the intermediate retaining clips.