1004E20 ENGINE - DISMANTLING AND REASSEMBLY FOLLOWING OP. [OP_1044E10] - WASHING AND CHECKING DISMANTLED COMPONENTS - REFITTING CYLINDER HEAD AND OIL SUMP - DOES NOT INCLUDE OPERATIONS ON THE CYLINDER HEAD AND AUXILIARY UNIT - Lancia - THESIS - eLearn

727081 - 1004E20 Engine - Dismantling and Reassembly following Op. [OP_1044E10] - Washing and checking dismantled components - Refitting cylinder head and oil sump - Does not include operations on the cylinder head and auxiliary unit

) - Rotate the crankcase through 180° on the overhaul stand.1. Completely undo the side bolts (1a) loosended previously and remove the pressure pump (1b) complete with support (1c).2. Undo the upper alternator bolt.3. Undo the bolts (3a) and remove the alternator rear mounting bracket (3b).4. Undo the lower bolt (4a) and remove the alternator (4b).

	Description	Connector
4b	Alternator	A010A

5. Undo the bolts (5a) and remove the intermediate shaft support (5b).

1. Undo the bolts (1a) and remove the crankshaft pulley (1b).2. Undo the bolt (2a) and remove the fixed timing tensioner (2b).3. Remove the timing belt.4. Undo the bolts (4a) and remove the power steering pump (4b) complete with support (4c).

1. Undo the bolts (1a) and remove the air conditioning compressor (1b) complete with support (1c).2. Undo the bolts (2a) and timing side power unit support (2b).3. Undo the bolts for the heat exchanger water inlet pipe mounting bracket.4. Undo and remove the engine oil filter using a suitable tool.5. Unscrew the connector.6. Remove the engine oil heat exchanger complete with pipes.- Undo the connector and remove the turbocharger supply pipe.

1. Fit the tool.

	Description	Code	Function
1	Counter-torque	1.860.846.000	Flywheel lock

2. Undo the bolt (left hand thread) (2a) and remove the toothed timing drive pulley (2b).3. Undo the bolts (3a) and remove the flywheel (3b).- Remove the tool (1).

	Description	Code	Function
1	Counter-torque	1.860.846.000	Flywheel lock

- Rotate the engine through 180° on the overhaul stand.1. Fit the tool.

	Description	Code	Function
1	Flange	1.860.815.000	Crankshaft rotation

2. Undo the bolts (2a) and remove the engine oil intake duct (2b).3. Remove the O-ring.4. Undo the bolts (4a) and remove the crankcase front cover (4b) with the oil pump incorporated.5. Remove the seal.- Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C.6. Undo the bolts (6a) and remove the connecting rod cap (6b).7. Remove the lower connecting rod half-bearing.8. Remove the connecting rod-piston assembly.9. Remove the upper connecting rod half-bearing.- Carry out the same operations to remove the pistons and connecting rods for the remaining cylinders.

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

	Subject	Value
1	Crankshaft	mm
-	End float	0.049 - 0.211

- If the value for the crankshaft endfloat does not correspond with the recommended figures, when refitting, regrind the crankcase seat and use suitable oversize thrust washers.

1. Undo the bolts (1a) and remove the crankcase rear cover (1b) with the oil seal incorporated.2. Undo the bolts (2a) and remove the bearing caps (2b).3. Remove the lower main journal half-bearings.4. Remove the crankshaft.5. Remove the upper main journal half-bearings.6. Remove the thrust washers.7. Undo the bolts (7a) and remove the jets (7b) from the crankcase.8. Undo the bolt (8a) and remove the rpm and timing sensor (8b).9. Remove the engine oil minimum pressure warning light sensor.

1. Undo the bolts (1a) and remove the crankcase (1b) from the mounting brackets, then place it on a special workbench.2. Undo the bolts (2a) and remove the flywheel guard (2b).

See in Op. 1028H60 - Undo the bolts and remove the intake duct from the oil pump. See in Op. 1084B18 - Drill and remove the water/oil sealing plugs from the crankcase to allow for washing.

Refitting ( Removing

) - 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
.	Cylinder block/crankcase	mm
-	Cylinder head support surface flatness	< 0.1

1. Measure the cylinder bore diameter using the diagram illustrated.

	Subject	Value
1	Cylinder block/crankcase	mm
-	Cylinder liner bore	82.000 - 82.010
-	-		82.010 - 82.020
-	-		82.020 - 82.030

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

	Subject	Value
.	Cylinder block/crankcase	mm
-	Cylinder liner taper	< 0.005

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

	Subject	Value
.	Cylinder block/crankcase	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
.	Cylinder block/crankcase	mm
-	Cylinder liner oversize	0.1

1. Fit the bearing caps.

The bearing caps have progressively numbered references (from zero to four starting from the front of the engine) which define the fitting position.

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

	Value - daNm	Fastening	Component	Ø
1a	(engine crankcase side) 2.5 + 100°	Bolt	MAIN BEARING CAPS	M12

	Description	Code	Function
1b	Torque wrench	1.860.942.000	Angular tightening of bearing cap bolts

2. Check that the diameter of the main journal seats is within specified limits.

	Subject	Value
2	Bearing caps	mm
-	Main journal seat diameter	63.691 ÷ 63.732

- Check that there are no deposits or blockages in the crankshaft lubrication ducts.- Check that the diameter of the main journals corresponds to the recommended figures.

	Subject	Value
.	Crankshaft	mm
-	Main journal diameter	59.994 ÷ 60.000
-	-		59.987 ÷ 59.993
-	-		59.982 ÷ 59.986

- 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	0.127

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 corresponds to the recommended figures.

	Subject	Value
.	Crankshaft	mm
-	Crankpin diameter	50.799 ÷ 50.805
-	-		50.793 ÷ 50.799
-	-		50.787 ÷ 50.793

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

	Subject	Value
.	Crankshaft	mm
-	Crankpin undersize	0.127

See in Op. 1028H58 - Check that the small end bush internal diameter is within the recommended limits; if not, replace the worn small end bush.

	Subject	Value
.	Small end bush	mm
-	Inner diameter	26.006 - 26.012

- Check that the inner diameter of the piston bushes corresponds to the recommended figures; if not, replace the piston complete with piston rings, gudgeon pin and bushes.

	Subject	Value
.	Pistons	mm
-	Piston bush internal diameter	25.999 ÷ 26.004

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

	Subject	Value
.	Gudgeon pins	mm
-	Outer diameter	25.982 ÷ 25.987

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

	Subject	Value
.	Piston rings	mm
-	1st piston ring gap	0.25 ÷ 0.40
-	2nd piston ring gap	0.25 ÷ 0.50

	Subject	Value
.	Oil scaper ring	mm
-	Oil scraper ring gap	0.25 ÷ 0.50

- 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
.	Pistons	mm
-	Outer diameter	81.920 ÷ 81.930
-	-		81.930 ÷ 81.940
-	-		81.940 ÷ 81.950

Measure perpendicular to the gudgeon pin axis, 8 mm from the lower edge of the skirt.

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

	Subject	Value
1a	Piston rings	mm
-	End float	0.020 ÷ 0.060

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

	Subject	Value
.	Oil scaper ring	mm
-	End float	0.030 - 0.065

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

	Value - daNm	Fastening	Component	Ø
1c	2.5 + 60°	-	CONNECTING ROD CAPS	M9

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

	Description	Code	Function
.	Torque wrench	1.860.942.000	Angular tightening of bearing cap bolts

2. - Check that the diameter of the big end corresponds to the recommended figures; if not, replace the connecting rods.

	Subject	Value
2	Connecting rods	mm
-	Big end diameter	53.883 ÷ 53.923

See in Op. 1028H60 See in Op. 1084B18 - Fit the intake duct and secure it using the bolts.- Check that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it.- Fit the flywheel guard and tighten the bolts.- Fit the crankcase on the overhaul stand and secure it using the bolts.- Fit the minimum engine oil pressure warning light sensor and tighten it to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.7 ÷ 4.0	-	MINIMUMM ENGINE OIL PRESSURE WARNING LIGHT SENSOR

- Fit the rpm and timing sensor and secure it using the bolt.- Fit the jets on the crankcase and secure them using the bolt.- Fit the thrust washers on the fourth bearing support.

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 identifying the class of each main journal and crankpin for the new crankshaft.

- The following must be determined for the selection of main journal half-bearings:- the numerical code stamped on the flywheel;- the paint mark, if present, next to the main journals.- Below is an example of the identification of main journal grades:- 1. Crankpin identification numerical code: the number on the left refers to the first timing side bearing; for 4 cylinder engines, there is an "N" in place of the number for the 5th bearing- 2. Main journal identification numerical code: the first number on the left refers to the first timing side bearing; for 4 cylinder engines, there is an "N" in place of the number for the 6th bearing- 3. Series of numbers (if present), in groups of two digits, which indicate the dimensions (thousandth part) of the main journals: the first two numbers on the left refer to the first timing side bearing

Only use the codes that relate to the key, all other codes on the flywheel should not be used.

- For the identification of the main journal grade, refer to the numerical code for reference 2.- In the case of the example, the numbers 111111 indicate that all six bearings are Grade A (red) as indicated in the Table.- A further method for identifying the grade of the bearings is to read reference 3 (if present) in the diagram.- In the case of the example, the number 94 (first on the left) corresponds to the dimensions 59.994 for the first timing side bearing which, as indicated in the Table, identifies Grade A (red); the same method should be applied for other groups of two digits for the same reference 3 (97 - 95 - 95 - 94 - 95).- Bearing grade A - Normal, diameter (mm) 59.994 - 60.000, RED paint mark, numerical code 1 (94 00)°- Bearing grade B - Normal, diameter (mm) 59.987 - 59.993, BLUE paint mark, numerical code 2 (87 93)°- Bearing grade C - Normal, diameter (mm) 59.982 - 59.986, YELLOW paint mark, numerical code 3 (82 86)°- Bearing grade D - Undersize, diameter (mm) 59.867 - 59.873, BROWN paint mark, numerical code 6 (67 73)°- Bearing grade E - Undersize, diameter (mm) 59.860 - 59.866, GREEN paint mark, numerical code 7 (60 66)°- Bearing grade F - Undersize, diameter (mm) 55.885 - 59.859, BLACK paint mark, numerical code 8 (55 59)°- (*) 0.127 mm undersize- (°) Last two numbers (thousandth part) of the main journal dimensions- In the case of the usage of a crankshaft where the maximum undersize for the bearings is 0.127 mm through grindings, the grade should be selected through the measurement of the diameter of the bearing using the Table as a reference.- Having defined the grade and the colour of each new or reground crankshaft bearings, it is necessary to select the thickness of the bearings that should be the same colour as the corresponding bearing; the pair of half-bearings required can be ordered from the Parts Dept. by quoting the order no.- The above is designed to guarantee the optimum operational clearances for all the bearings.- Lastly, 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 (plastic gauge).1. Fit the bolts (1a) and fasten the jets (2b) to the crankcase at the recommended torque.2. Fit the bolt (3a) and fasten the rpm and timing sensor (3b).

	Value - daNm	Fastening	Component	Ø
1a	0.9 - 1.2	Bolt	PISTON COOLING NOZZLES

	Value - daNm	Fastening	Component	Ø
3b	1.8 - 2.7	-	ENGINE RPM AND TIMING SENSOR

- Fit the main journal half-bearings in the cylinder block/crankcase.- Fit the crankshaft in the crankcase.1. Fit the main bearing caps complete with half-bearings.

The bearing caps have progressively numbered references (from zero to five starting from the engine pulley side) which define the fitting position.

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

	Value - daNm	Fastening	Component	Ø
1a	2.5 + 100°	Bolt	MAIN BEARING CAPS	M12

	Description	Code	Function
1b	Torque wrench	1.860.942.000	Angular tightening of bearing cap bolts

1. Fit the tool.

	Description	Code	Function
1	Flange	1.860.815.000	Crankshaft rotation

- Rotate the crankcase through 90° on the overhaul stand.- Rotate the crankshaft using the tool fitted previously 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).

The piston-connecting rod assemblies are fitted in the cylinder block/crankcase so that the combustion chamber in the piston is facing the intake side.

For the selection of the connecting rod half-bearings, follow the procedure described previously for the main journal half-bearings.

2. Fit the connecting rod cap (2a) complete with half-bearing and secure it without tightening the bolts (2b).

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 (inlet side).

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

- Rotate the crankcase through 90° on the overhaul stand.1. Tighten the connecting rod cap bolts (1a) to the recommended torque using the angular tightening tool (1b).

	Value - daNm	Fastening	Component	Ø
1a	2.5 + 60°	Bolt	CONNECTING ROD CAPS	M9

	Description	Code	Function
1b	Torque wrench	1.860.942.000	Angular tightening of bearing cap bolts

1. Fit the crankcase rear cover (1a) with built in oil seal using a suitable tool (1b).2. Tighten the crankcase rear cover bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2	0.9 - 1.2	Bolt	CRANKCASE REAR COVER	M6

- Remove the tool.

- Rotate the crankshaft so that cylinder no. 1 is at T.D.C.1. Fit the crankcase front cover complete with oil pump (1a) and gasket (1b) with the timing references aligned as indicated previously.2. Tighten the crankcase front cover bolts, complete with oil pump, to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2	0.9 - 1.3	Bolt	FRONT COVER CRANKCASE COMPLETE WITH OIL PUMP	M6

3. Fit the engine oil intake duct (3a) complete with O-Ring (3b) and secure it using the bolts (3c).

	Value - daNm	Fastening	Component	Ø
3c	0.9 - 1.3	-	OIL SECTION PUMP	-

- Apply the recommended sealant to the entire perimeter of the crankcase sump.

	Description	Qty.	Component	Type	Classification
.	Dow Corning 7091	-	-	Silicone sealant	-

1. Fit the crankcase sump.2. Tighten the side bolts (2a) fixing the crankcase sump to the recommended torque using the tool (2b).

	Value - daNm	Fastening	Component	Ø
2a	(engine crankcase side) 0.9 - 1.2	Side bolts	CRANKCASE SUMP	M6

	Description	Code	Function
2b	Spanner	1.860.833.000	Loosen/tighten crankcase sump side bolts

3. Tighten the front and rear bolts (3a) fixing the crankcase sump to the recommended torque using the tool (3b).

	Value - daNm	Fastening	Component	Ø
3a	(engine crankcase side) 2.1 - 2.6	Front and rear bolts	CRANKCASE SUMP	M8

	Value - daNm	Fastening	Component	Ø
3a	(engine crankcase side) 2.3 - 3.3	Front and rear bolts	CRANKCASE SUMP	M8

	Description	Code	Function
3b	Spanner	1.860.833.000	Loosen/Tighten front and rear crankcase sump bolts

- Rotate the engine through 180° on the overhaul stand.1. Fit the tool.

	Description	Code	Function
1	Counter-torque	1.860.846.000	Flywheel lock

2. Fit the flywheel (2a) and tighten the fixing bolts (2b) to the recommended torque using thread-locking agent.

	Value - daNm	Fastening	Component	Ø
2b	(crankshaft side) 14.7 - 21.2	Bolt with thread-locking agent	ENGINE FLYWHEEL	M12

3. Fit the toothed drive pulley (3a) for the timing belt and tighten the (left hand thread) bolt (3b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
3b	(crankshaft side) 32.9 - 44.1	Bolt (left hand thread)	TOOTHED DRIVE PULLEY	M16

- Remove the tool.

	Description	Code	Function
.	Counter-torque	1.860.846.000	Flywheel lock

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

- Select the correct size cylinder head gasket depending on the maximum value between of the averages of the projection for each individual piston.

	Subject	Value
.	Cylinder head gasket	mm
-	Shim (no reference)	0.770 ÷ 0.870
-	Shim (one reference)	0.870 ÷ 0.970
-	Shim (two references)	0.970 ÷ 1.070

	Subject	Value
.	Cylinder head gasket	mm
-	Average maximum piston projection	0.014 ÷ 0.104
-	Average maximum piston projection	0.105 ÷ 0.205
-	Average maximum piston projection	0.206 ÷ 0.294

- Place the cylinder head centering bushes on the cylinder block.- Fit the cylinder head gasket selected.

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

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

	Value - daNm	Fastening	Component	Ø
1a	(engine crankcase side) 2.0 + 2.0 + 90* + 90° + 90°	Bolt	CYLINDER HEAD	M10

	Description	Code	Function
1b	Torque wrench	1.860.942.000	Cylinder head bolts angular tightening

- Fit the tappet cover, complete with a new gasket, and secure it tightening the bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	(cylinder head side) 0.9 -1.2	Bolt	CAM COVER	M6

- Place the turbocharger oil supply pipe in its housing and secure it to the cylinder block/crankcase using a new connector.

Use a new connector because it is fitted with an oil filter.

- Fit the heat exchanger complete with pipes.- Tighten the engine oil heat exchanger connector to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	3.3 ÷ 4.8	Connector	ENGINE OIL HEAT EXCHANGER	-

- Place the engine oil filter in its housing and tighten it fully by hand after having lubricated the gasket using engine oil.- Fasten the heat exchanger water inlet pipe mounting bracket using the bolts.- Fit the mounting complete with power assisted steering pump and secure it using the bolts.- Fit the fixed timing tensioner and secure it by tightening the bolt to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.3 ÷ 3.3	Bolt	TIMING BELT FIXED TENSIONER	M8

- Fit the intermediate shaft support and secure it using the bolts.- Fit the plates connecting the crankcase sump to the intermediate shaft support and secure them using the bolts.- Fit the mounting complete with pressure pump and secure it using the bolts.1. Undo the oil pump bolt shown in the diagram.- Temporarily fit the toothed timing drive belt on the toothed drive pulley.2. Fit the tool (2a) and fasten it using the calibrated screw (2b).

The crankshaft must be rotated, using small movements, to allow the locating dowel on the timing drive pulley to be inserted in the opening in the tool.

	Description	Code	Function
2a	Template	1.860.905.000	Engine tuning

	Description	Code	Function
2b	Calibrated screw	1.860.905.010	Engine tuning

1. Rotate the driven toothed pulley until the timing references are aligned.2. Fully fit the toothed timing drive belt.3. Use a screwdriver for leverage in the opening (3a) until the reference for the tensioner (3b) is aligned with the opening reference (3c) and, in this position, tighten the nut (3d) for the belt tensioner to the recommended torque.

	Value - daNm	Fastening	Component	Ø
3d	4.2 - 5.2	Nut	TIMING BELT TENSIONER	M10

- Remove the tools.

	Description	Code	Function
.	Template	1.860.905.000	Engine tuning

	Description	Code	Function
.	Calibrated screw	1.860.905.010	Engine tuning

- Tighten the oil pump bolt removed previously.

1. Fit the tool in the special opening to keep the automatic belt tensioner for the engine components drive belt in the "fixed" position.

	Description	Code	Function
1	Lock	1.870.645.000	Retaining tensioner for various components drive belt

- Fit the crankshaft pulley and tighten the bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.3 - 3.3	Bolt	CRANKSHAFT PULLEY	M8

- Fit the timin side power unit support and secure it using the bolts.- Fit the air conditioning compressor complete with mounting and secure it using the bolts.- Fit the timing belt covers and secure them using the bolts.- Fit the power unit reaction rod mounting bracket and secure it using the bolts.- Fit the auxiliary units drive belt fixed tensioner and secure it tightening the bolt to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.3 ÷ 3.3	Bolt	SINGLE BELT FIXED TENSIONER ENGINE	M8

- Fit the alternator and secure it using the lower bolt.- Fit the alternator rear mounting and secure it using the bolts.- Tighten the upper alternator bolt.- Fit the engine components single belt.1. Rotate the fixed tensioner (1a) for the engine components drive belt using the tool (1b) until the tool (1c) is released, then tighten the bolt (1d) for the cam tensioner to the recommended torque.

	Description	Code	Function
1b	Spanner	1.860.968.000	Tensioning engine components drive belt

	Description	Code	Function
1c	Lock	1.870.645.000	Retaining tensioner for various components drive belt

	Value - daNm	Fastening	Component	Ø
1d	4.6 ÷ 6.6	Bolt	COMPONENTS SINGLE BELT CAM BELT TENSIONER ENGINE	M10

- Fit the plastic caps on the fixed tensioner and the cam belt tensioner for the engine components drive belt.- Fit the fuel filter assembly and secure it using the nuts.- Connect the return manifold fuel return pipe to the fuel filter.- Fit the oil vapour separator complete with pipes and bracket and secure it using the nuts.- Connect the condensation oil recovery pipe to the crankcase sump.- Connect the oil vapour recovery pipe to the crankcase.- Connect the water-oil heat exchanger coolant supply pipe to the thermostat.- Connect the heat exchanger coolant outlet pipe to the manifold.- Fit the exhaust manifold gasket.- Fit the exhaust manifold, complete with turbocharager and E.G.R. valve and secure it tightening the nuts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	(cylinder head side) 2.3 -3.3	Nut	EXHAUST MANIFOLD	M8

- Tighten the exhaust manifold bracket bolt to the cylinder block/crankcase.- Tighten the exhaust gas recirculation pipe fastener bracket bolt.- Fit the exhaust gas recirculation pipe gasket.- Connect the exhaust gas recirculation pipe and secure it to the intake manifold using the nuts.- Connect the turbocharger oil outlet pipe to the crankcase sump.- Fit the turbocharger oil outlet pipe guard and secure it using the bolts.- Connect the oil inlet pipe to the turbocharger.- Fit the engine oil dipstick assembly and secure it using the bolts.- 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 a spanner.

	Value - daNm	Fastening	Component	Ø
.	(Pressure pump side) 2.1 - 2.8	Connector	PRESSURE PUMP PIPE TO FUEL MANIFOLD	M12

- Tighten the connector for the pipe from the pressure pump to the single fuel manifold, fuel manifold side, to the recommended torque using a spanner.

	Value - daNm	Fastening	Component	Ø
.	(Fuel manifold side) 2.1 - 2.8	Connector	PRESSURE PUMP PIPE TO FUEL MANIFOLD	M14

- Connect the rubber pipe to the pressure pump.