323002054 - 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

Removing ( Refitting ) 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 the bolts (1a) and remove the alternator (1b). 1. Undo bolts (1a) and remove alternator mounting (1b). 1. Undo bolts (1a) and remove vacuum reservoir (1b). 1. Undo the bolts (1a) and remove the engine oil recovery manifold (1b).2. Undo the bolts (2a) and remove the 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
1870718000	Blade	Cut sealant

3. Remove the lower crankcase.- Remove the lower main half-bearings. 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. 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	1.4 8v1.3 Multijet

- If the value for the crankshaft endfloat is not within the recommended limits, when refitting regrind the crankcase seat and use suitable oversize thrust washers. 1. Remove the 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 Multijet

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

Measurement	Value	Validity
Cylinder liner diameter - Grade C (mm)	69.620 ÷ 69.630	1.3 Multijet

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

Measurement	Value	Validity
Cylinder liner taper (mm)	< 0.010	1.3 Multijet

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

Measurement	Value	Validity
Cylinder liner ovality (mm)	+/- 0.005	1.3 Multijet

- 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	1.4 8v1.3 Multijet1.4 16v T-JET

- 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 the central bolts (1a) securing the lower crankcase to the specified torque, following the order shown in the figure. Use the angular tightening tool (1b).

Component	Fastening	dia	Value (daNm)	Validity
Crankcase	Central bolt	M10	1.9 ÷ 2.1 + 80° ± 3°	1.3 Multijet

Tool	Description	Function	Validity
1860942000	Torque wrench	Tighten bolts to torque plus angle

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

Component	Fastening	dia	Value (daNm)	Validity
Crankcase	Side bolt	M8	2.9 ÷ 3.2	1.3 Multijet

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 Multijet

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

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

- 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 Multijet

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

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

- 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	1.4 8v1.3 Multijet1.4 16v T-JET

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 Multijet

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

- 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	1.4 8v1.3 Multijet1.4 16v T-JET

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 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 journal half-bearings - Category A (red) (mm)	1.836 ÷ 1.841	1.3 Multijet

Measurement	Value	Validity
Main journal half-bearings - Category B (blue) (mm)	1.841 ÷ 1.846	1.3 Multijet

Measurement	Value	Validity
Main journal half-bearings - Category C (yellow) (mm)	1.846 ÷ 1.851	1.3 Multijet

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

- 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 Multijet

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

Measurement	Value	Validity
Connecting rod half-bearing thickness oversize (mm)	0.127	1.3 Multijet

- 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 Multijet

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 the centre bolts (2a) securing the lower crankcase to the specified torque, following the order shown in the figure. Use the angular tightening tool (2b).

Component	Fastening	dia	Value (daNm)	Validity
Crankcase	Central bolt	M10	1.9 ÷ 2.1 + 80° ± 3°	1.3 Multijet

Tool	Description	Function	Validity
1860942000	Torque wrench	Tighten bolts to torque plus angle

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

Component	Fastening	dia	Value (daNm)	Validity
Crankcase	Side bolt	M8	2.9 ÷ 3.2	1.3 Multijet

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

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 Multijet

- 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)	22.991 ÷ 22.996	1.3 Multijet

- 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)	22.982 ÷ 22.987	1.3 Multijet

- 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 Multijet

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

Measurement	Value	Validity
Piston oil scraper ring gap (mm)	0.25 ÷ 0.50	1.3 Multijet

- 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 Multijet

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

Measurement	Value	Validity
Piston oil scraper ring size (mm)	1.970 ÷ 1.990	1.3 Multijet

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

Measurement	Value	Validity
Sealing ring seat in piston - 1st groove (mm)	2.10 ÷ 2.12	1.3 Multijet

Measurement	Value	Validity
Sealing ring seat in piston - 2nd groove (mm)	1.54 ÷ 1.54	1.3 Multijet

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

- 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.

Measurement	Value	Validity
Piston outer diameter -Grade A (mm)	69.546 ÷ 69.556	1.3 Multijet

Measurement	Value	Validity
Piston outer diameter - Grade B (mm)	69.556 ÷ 69.566	1.3 Multijet

Measurement	Value	Validity
Piston outer diameter - Grade C (mm)	69.566 ÷ 69.576	1.3 Multijet

Measure perpendicular to the gudgeon 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)	0.11 ÷ 0.15	1.3 Multijet

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)	0.05 ÷ 0.09	1.3 Multijet

- Check that the backlash 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 Multijet

1. Fit the caps (1b) on the 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 caps	Bolt	M8	1.9 ÷ 2.1 + 40° ± 2°

- Use the tool for the angular tightening of the connecting rod cap bolts.

Tool	Description	Function	Validity
1860942000	Torque wrench	Tighten bolts to torque plus angle

2. Check that the big end diameter (without fitting the half-bearings) is within the recommended limits; if not, replace the connecting rods.

Measurement	Value	Validity
Big end diameter (mm)	45.734 ÷ 45.744	1.3 Multijet

    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 - Check that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it.- Refit the engine oil jets in their seats and secure by tightening the bolts to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil jet	Bolt	M6	0.8 ÷ 1.0	1.3 Multijet

The crankshaft supplied by the Parts Dept. comes without half-bearings and the main journals and crankpins are the normal size; the half-bearings to be fitted must therefore be selected by identifying the class of each main journal and crankpin for the new crankshaft.

The letter code stamped on the timing side counter-weight is required for selecting the grade.Below is an example of identification of the main journal and crankpin grade referring to an engine with nominal diameter main journals (51.000 mm). 1. Crankpin alphabetical identification code - B B B B (the same for all bearings): the first letter from the left refers to the first timing side bearing.2. Main journal alphabetical identification code - A A A A A (the same for all bearings): the first letter from the left refers to the first timing side bearing.3. Alphabetical identification code for thrust washers - R.

Only use the alphabetical codes for references 1, 2 and 3 in the diagram, all the other codes on the counter-weight should not be used.

For the identification of the main journal grade, refer to the alphabetical code 2 shown in the diagram.In the case of the diagram, for example, the letter code A A A A A (Grade A - Normal) indicates that all five bearings are prepared for the fitting of half-bearings with a Red coloured paint mark on the edge; as a result, specific half-bearings should be identified for different alphabetical codes (bearing grade).Normal grades are usually used on new engines with undersizes only used in exceptional cases.ALLOCATION OF HALF-BEARINGS TO MAIN JOURNALSHaving defined the grade for each crankshaft bearing (to which a specific diameter corresponds according to the grade), it is necessary to select the pair of bearings which are the same colour; by consulting the Parts CD-ROM it is possible to find the order no. for the pair of half-bearings required.The above is designed to guarantee the optimum operational clearances for all the bearings.- Main journal grade A (normal), diameter 51.000 - 50.994 mm, RED paint mark- Main journal grade B (normal), diameter 50.994 - 50.988 mm, BLUE paint mark- Main journal grade C (normal), diameter 50.988 - 50.982 mm, YELLOW paint mark- Main journal grade AM (0.127 undersize), diameter 50.873 - 50.867mm, BROWN paint mark- Main journal grade BM (0.127 undersize), diameter 50.867 - 50.861mm, GREEN paint mark- Main journal grade CM (0.127 undersize), diameter 50.861 - 50.855mm, BLACK paint markLastly, we wish to point out that, generally, the clearance between the main journal and the half-bearing, obtained through the selection method indicated above, should be within the following values:Minimum: 0.025 mm - Maximum: 0.052 mm; this value can be measured, as a final check, using the calibrated wire (plastigage).CLASSIFICATION OF CRANKPINS AND ALLOCATION OF HALF-BEARINGSThe procedure described for the main half-bearings should also be carried out for selecting the crankpin half-bearings.- Crankpin grade A (normal), diameter 42.600 - 42.5914 mm, RED paint mark- Crankpin grade B (normal), diameter 42.591 - 42.582 mm, BLUE paint mark- Crankpin grade AM (0.127 undersize), diameter 42.473 - 42.464 mm, BROWN paint mark- Crankpin grade BM (0.127 undersize), diameter 42.464 - 42.455 mm, GREEN paint markBy way of example, if the alphabetical code identified is the one indicated by reference 1 in the diagram, i.e. - B B B B, this means that the four crankpins are all Grade B (to which a specific diameter belongs) and are therefore ready for the fitting of half-bearings with a blue coloured paint mark on the edge.The first letter on the left - B of the alphabetical code is always related to the first timing side crankpin.Refer to the instructions above for the pair of half-bearings to be allocated to each bearing.The order number for the half-bearings to be fitted which are identified by the colour can be obtained by consulting the Parts CD ROM.CLASSIFICATION AND ALLOCATION OF THRUST WASHERSThe selection of thrust washers for the centre main journal should be made using reference 3 in the diagram (i.e. R for the normal size, RM for a 0.127 mm oversize), therefore the selection should be made using the crankshaft endfloat measured previously.- Half-ring grade R (normal ), thickness 2.310 - 2.360 mm- Half-ring grade RM (0.127 mm oversize), thickness 2.437 - 2.487 mm

It is advisable to keep stocks of the main journal and crankpin half-bearings currently in use in all workshop parts departments to ensure they are immediately available is required.

1. Fit the tool.

Tool	Description	Function	Validity
1860815000	Flange	Crankshaft rotation	1.3 Multijet1.4 16v TJET

- Turn the crankshaft using the tool fitted previously.- Fit the connecting rod-piston assemblies and align in accordance with the following references.1. Piston grade code that may be: A - B - C or AM - BM - CM for oversize pistons2. The arrow shows the timing side.3. Area where the number of the cylinder liner matching the connecting rod is stamped.4. Exhaust (4a) on the piston skirt which should be aligned with oil jet (4b). 1. Refit the piston-connecting rod assemblies (1a) in their seats with upper connecting rod bearing halves using tool (1b).

The connecting rod bearing halves may be identified as follows:- upper connecting rod bearing half, connecting rod side, trimetallic and dark in colour;- lower connecting rod bearing half, cap side bimetallic, light coloured with a hole.Never reverse the positioning of the connecting rod bearing halves under any circumstances.

- Rotate the engine through 180° on the overhaul stand.1. Fit the calibrated wire (plastigage) for measuring the bearing clearance. 1. Refit connecting rod cap assemblies (1a) in their seats with upper connecting rod bearing halves using tool (1b).

The connecting rod bearing halves may be identified as follows:- upper connecting rod bearing half, connecting rod side, trimetallic and dark in colour;- lower connecting rod bearing half, cap side bimetallic, light coloured with a hole.Never reverse the positioning of the connecting rod bearing halves under any circumstances.

2. Tighten the connecting rod cap bolts (2a) to the recommended torque using the angular tightening tool (2b).

Component	Fastening	dia	Value (daNm)	Validity
Connecting rod caps	Bolt	M8	1.9 ÷ 2.1 + 40° ± 2°

Tool	Description	Function	Validity
1860942000	Torque wrench	Tighten bolts to torque plus angle

- Undo the bolts and remove the connecting rod caps with the half-bearings fitted previously.1. Use an appropriate graduated measuring tool (1a) to measure the clearance indicated by plastigage (1b).

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

Measurement	Value	Validity
Clearance between connecting rod bearings - crankpin bearings (mm)	0.030 ÷ 0.062	1.3 Multijet

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

- Fit the connecting rod caps permanently by tightening the bolts as shown previously.- Remove the tool.

Tool	Description	Function	Validity
1860815000	Flange	Crankshaft rotation	1.3 Multijet1.4 16v TJET

1. Fit the crankshaft rear oil seal (1a) using the tool (1b).

Tool	Description	Function	Validity
1870900200	Fitting tool	Fitting crankshaft rear oil seal	1.3 Multijet

- Rotate the engine through 180° on the overhaul stand.- Place the starter motor in its housing and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Starter motor	Bolt	M8	2.25 ÷ 2.75

- Place the separator condensed oil manifold in its housing and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil recovery manifold	Bolt	M6	0.8 ÷ 1.0	1.3 Multijet

- Place the vacuum reservoir back in its housing and secure it using the bolt.- Place the alternator mounting in its housing and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Alternator mounting	Bolt	M8x1.25x45	2.0 ÷ 2.2	1.3 Multijet

- Place the alternator in position and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Alternator	Bolt	M8x1.25x85	2.0 ÷ 2.2	1.3 Multijet

- Refit the engine oil pipe in its seat on the crankcase and secure with the connectors.- Place the air conditioner compressor mounting in its housing and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Compressor support	Bolt	M8x1.25x35	2.0 ÷ 2.4

- Place the air conditioning compressor in its housing and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Compressor	Bolt	M8x1.25x80	2.0 ÷ 2.4	1.3 Multijet

- Replace the engine oil filter mounting complete with the engine oil filter and engine oil filler fitting and secure by tightening the bolts to the specified torque.

Ensure the gasket is present, undamaged and correctly positioned.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil filter mounting	Bolt	M6	0.8 ÷ 1.0	1.3 Multijet

- Place the water pump rigid inlet pipe, complete with O-ring in position and secure it using the bolts.

Fit the rigid pipe in the crankcase very carefuly to ensure the O-ring is correctly positioned.

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

Component	Fastening	dia	Value (daNm)	Validity
Rpm sensor	Bolt	M6	0.8 ÷ 1.0	1.3 Multijet

- Fit the engine oil heat exchanger protection.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.

Tool	Description	Function	Validity
1870404001	Dial gauge mount	Piston projection from cylinder head support plane check	1.3 Multijet

- Select the correct size cylinder head gasket, according to the maximum value of the averages for the protrusion for each individual piston.

Measurement	Value	Validity
Cylinder head gasket size with average maximum piston projection (mm)	projection0.028 ÷ 0.127thickness (no opening)0.67 ÷ 0.77	1.3 Multijet

Measurement	Value	Validity
Cylinder head gasket size with average maximum piston projection (mm)	projection0.128 ÷ 0.227thickness(one opening)0.77 ÷ 0.87	1.3 Multijet

Measurement	Value	Validity
Cylinder head gasket size with average maximum piston projection (mm)	projection0.228 ÷ 0.327thickness (two openings)0.87 ÷ 0.97	1.3 Multijet

1. Fit the crankshaft timing tool.

Tool	Description	Function	Validity
1870900300	Template	Crankshaft tuning	1.3 Multijet

1. Fit the lower cylinder head centring bushes on the engine block.

Before fitting the locating bushes, check that the height is 10 mm.

2. Fit the new cylinder head gasket selected.3. Position the cylinder head on the crankcase.4. Tighten the cylinder head bolts to the recommended torque using the angular tightening tool.

Follow the order shown in the diagram for each tightening sequence. The nominal tightening of 4.0 daNm is performed in two stages: a pretightening to 2.0 daNm followed by an additional tightening of 2.0 daNm.There is a tolerance of approximately 3° for the two angular tightenings.

Component	Fastening	dia	Value (daNm)	Validity
Cylinder head	Bolt	M10	3.8 ÷ 4.2 + 90° + 90°	1.3 Multijet

Tool	Description	Function	Validity
1860942000	Torque wrench	Tighten bolts to torque plus angle

- Check the cylinder head - crankcase misalignment.

It is only possible for the crankcase to project.

Measurement	Value	Validity
Cylinder head - crankcase misalignment (mm)	0.1	1.3 Multijet

- Connect the condensed engine oil recovery pipe, oil vapour separator side, and tighten the band.- Tighten the bolt securing the water/exhaust gas heat exchanger for the EGR to the engine block.- Connect the coolant supply pipe to the engine oil heat exchanger and secure it using the band and the bolts.

Fold over the gasket safety tabs.

- Connect the E.G.R. pipe to the thermostat and secure it using the band.1. If not already done during cylinder head overhaul, remove plugs (1a) and fit camshaft timing adjustment tools (1b) to the cylinder head extension.

Fit the tools and position with their millings horizontal. Ensure they fit into the seats on the camshafts.

Tool	Description	Function	Validity
1870896900	Templates	Engine tuning	1.3 Multijet

- Remove the intake camshaft timing tool and tighten the plug. - Place the camshaft housing bushes on the cylinder head.

Before fitting the locating bushes, check that the height is 13 mm.

- Place the cylinder head extension complete with gasket in position.1. Tighten the single cylinder head extension M8 bolts (1a) to a pre-torque of 1.5 daNm and M7 (1b) to a pre-torque of 1.2 daNm2. Tighten the bolts (2a) and (2b) securing the single camshaft housing to the specified torque.

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

Component	Fastening	dia	Value (daNm)	Validity
Engine cylinder head extension	Bolt	M8	2.5	1.3 Multijet

Component	Fastening	dia	Value (daNm)	Validity
Engine cylinder head extension	Bolt	M7	1.8	1.3 Multijet

- Check the misalignment between the cylinder head extension - cylinder head.

It is only possible for the camshaft housing to protrude.

Measurement	Value	Validity
Misalignment between cylinder head extension - cylinder head (mm)	0.1	1.3 Multijet

- Refit the new injector dust seals into their seats in the cylinder head extension.1. Refit the injectors (1a) complete with brackets (1b) in their seats.

Before refitting, replace the copper seal on the injectors.

2. Refit the tapered washer (2a) and the washer (2b) in their seats.3. Tighten the nut securing the injector bracket to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Injector brackets	Nut	M8	1.8 ÷ 2.2	1.3 Multijet

- Use a suitable tool (e.g. vice) to set the chain tensioner and hold it fully back with a retaining pin.1. Place chain tensioner (1a) in its housing and secure it by tightening bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing system moving tensioner	Bolt	M6	0.8 ÷ 1.0	1.3 Multijet

- Refit the exhaust side camshaft toothed drive pulley together with chain and toothed drive pulley.

Fit the exhaust side camshaft toothed drive pulley and the toothed drive pulley according to the position marked on disassembly. If the pulleys are replaced, fit with the wording facing outwards.

- Place the timing chain moving pad back in its housing and secure it using the pin.- Place the timing chain fixed pad back in its housing and secure it using the bolts.- Tighten the bolt securing the exhaust side camshaft toothed pulley to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Toothed driven pulley	Bolt	M12	13.5 ÷ 16.5	1.3 Multijet

- Remove the chain tensioner retaining pin and check that the piston is in contact with the mobile pad.- Refit the support bracket complete with single fuel manifold pipe, fuel pressure regulator, fuel pressure sensor and secure using the bolts.- Connect the fuel return pipe to the single fuel manifold and tighten the band.- Fit new pipes from the fuel manifold to the injectors and secure with connectors without tightening.- Tighten the connectors for the pipes from the fuel manifold to the injector side injectors to the recommended torque using an appropriate commercial wrench.

Component	Fastening	dia	Value (daNm)	Validity
Pipes from fuel manifold to injectors - injectors side	Connector	M12	2.3 ÷ 2.5	1.3 Multijet

- Tighten the connectors for the pipes from the fuel manifold to the fuel manifold side injectors to the recommended torque using an appropriate commercial wrench.

Component	Fastening	dia	Value (daNm)	Validity
Pipes from fuel manifold to injectors - fuel manifold side	Connector	M14	2.6 ÷ 2.9	1.3 Multijet

Clean the threaded pipe seats on the manifold and injectors with heptane.

- Place a new pipe from the pressure pump to the single fuel manifold in its housing and secure it using the connectors without tightening them.- Tighten the connector for the pipe from the pressure pump to the single fuel manifold, pump side, to the recommended torque using an appropriate commercial wrench.

Component	Fastening	dia	Value (daNm)	Validity
Pipe from pressure pump to fuel manifold - pressure pump side	Connector	M12	2.3 ÷ 2.5	1.3 Multijet

- Tighten the connector for the pipe from the pressure pump to the single fuel manifold, fuel manifold side, to the recommended torque using an appropriate commercial wrench.

Component	Fastening	dia	Value (daNm)	Validity
Pipe from pressure pump to fuel manifold - fuel manifold side	Connector	M14	2.6 ÷ 2.9	1.3 Multijet

- Connect the fuel outlet pipe from the injectors, injector side and push in until the clips click into place.- Place the timing cover gasket back in its housing.1. Fit the tool on the timing cover.

Tool	Description	Function	Validity
1870900600	Hose	Timing cover centering	1.3 Multijet

2. Refit the timing cover (2a) complete with engine oil suction head (2b) and engine oil pump. 1. Tighten the bolts (1a) and the nuts (1b) securing the timing cover to the specified torque.

Follow the order shown in the diagram for each tightening sequence. The tightening to 0.8 - 1.0 daNm is performed in two stages: a pre-tightening stage to 0.4 daNm followed by an additional tightening of 0.8 - 1.0 daNm.

Component	Fastening	dia	Value (daNm)	Validity
Crankshaft oil seal front cover	Bolt	M6	0.8 ÷ 1.0

Component	Fastening	dia	Value (daNm)	Validity
Crankshaft oil seal front cover	Nut	M6	0.8 ÷ 1.0	1.3 Multijet

- Connect the engine oil vapour recirculation pipe connector to the timing cover and tighten the bolts.

Ensure the O-ring is present and correctly positioned.

- Rotate the engine through 180° on the overhaul stand.- Place the crankcase oil sump partition back in its housing and secure it using the bolts.- Apply a strip of silicone sealant to the contact surfaces between the crankcase sump and lower engine block as shown in the diagram in the figure.

The sealant strip must be unbroken. The sealant strip diameter must be 3.0 - 4.0 mm.

1. Position crankcase sump (1a) in its housing and secure it by tightening bolts (1b) and nuts (1c) to the recommended torque.

Follow the order shown in the figure for each tightening sequence. The tightening to 0.8 - 1.0 daNm is performed in two stages: a pretightening to 0.4 daNm followed by an additional tightening of 0.8 - 1.0 daNm.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump - lower engine crankcase side	Bolt	M6	0.8 ÷ 1.0	1.3 Multijet

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump - timing cover side	Nut	M6	0.8 ÷ 1.0	1.3 Multijet

2. Place bracket (2a) in its housing and secure it by tightening bolts (2b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Bracket joining manual gearbox/differential to engine	Bolt	M8	2.7 ÷ 3.3	1.3 Multijet

- Rotate the engine through 180° on the overhaul stand.- Place the engine oil dipstick pipe back in its housing and fasten it with the bolt.- Place the intermediate driveshaft mount in position and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Intermediate driveshaft bearing support	Bolt	M8	2.0 ÷ 2.4	1.3 Multijet

- Remove the tool.

Tool	Description	Function	Validity
1870900600	Hose	Timing cover centering	1.3 Multijet

- Position the crankcase pulley support flange in its housing and secure it with the anti-clockwise threaded bolt without tightening it to the recommended torque.- Place the water pump, complete with gasket in position, then tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Water pump	Nut	M6	0.8 ÷ 1.0	1.3 Multijet

- Position the crankshaft pulley in its housing and secure it without tightening the bolts.- Position the auxiliary drivebelt moving tensioner in its housing and secure it by tightening the bolt to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Auxiliary drive belt moving tensioner	Bolt	M10	4.5 ÷ 5.5	1.3 Multijet

- Adjust the mobile tensioner with a wrench and fit the auxiliary drive belt.- Place the timing side rigid engine support in its housing with the engine lift bracket and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support to engine block	Bolt	M10	5.7 ÷ 6.3	1.3 Multijet

- Place the turbocharger unit complete with catalytic converter back in its housing and secure it by tightening the nuts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Turbocharger to exhaust manifold	Nut	M8	2.2 ÷ 2.7	1.3 Multijet

- Refit the exhaust manifold heat shield with the engine lift bracket and secure with the nut and bolts.- Position the pipe carrying engine oil to the turbocharger in its housing and secure it by tightening connectors to the recommended torque.

Replace the copper washers on the connectors.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil supply pipe to turbocharger	Connector	M10	1.3 ÷ 1.6	1.3 Multijet

- Position a new gasket between the crankcase and the engine oil return pipe to the turbocharger.- Tighten the bolts securing the engine oil return pipe from the turbocharger, crankcase side, to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil return pipe from turbocharger	Bolt	M6	0.8 ÷ 1.0	1.3 Multijet

- Fit the protective strips to the oil filter and the engine oil heat exchanger.- Place the electrical wiring in position and fasten it to the bands on the air capacity chamber.- Connect the electrical connection to the E.G.R. solenoid valve.- Connect the electrical connection to the fuel pressure regulator.- Secure the electrical connection to the excess pressure sensor.- Connect the electrical connection to the fuel pressure sensor.- Refit the electrical wiring in its seat and secure.- Tighten the bolts securing the wiring duct to the cylinder head.- Connect the electrical connection for the air conditioning compressor engagement solenoid valve.- Connect the electrical connection to the timing sensor.- Secure the electrical connections to the injectors.- Secure the electrical connections to the glow heater plugs.- Connect the electrical connection to the engine oil pressure warning light switch.- Connect the electrical connection for the engine rpm sensor.- Secure the electrical connection to the engine coolant temperature sensor.- Connect the electrical connection for the (pneumatic) throttle control solenoid valve.- Remove the engine from the overhaul stand.