1004E20 ENGINE - DISMANTLING AND REASSEMBLY FOLLOWING OP. [OP-1004E10] - WASHING/CHECKING DISMANTLED COMPONENTS - REFITTING CYLINDER HEAD AND OIL SUMP - DOES NOT INCLUDE OPERATIONS ON THE CYLINDER HEAD - Lancia - THESIS - eLearn

495636 - 1004E20 ENGINE - Dismantling and Reassembly following op. [OP-1004E10] - Washing/checking dismantled components - Refitting cylinder head and oil sump - Does not include operations on the cylinder head

) - Rotate the engine through 180° on the overhaul stand.1. Remove the pump coolant return manifold.2. Undo the bolts (2a) and rmeove the detonation sensors (2b) E.

	Description	Connector
2b	Detonation sensor - 2	K050

	Description	Connector
2b	Detonation sensor - 2	K051

3. Undo the bolts (3a) and remove the water pump cover (3b) and the bracket (3c).4. Undo the bolts (4a) and remove the water pump drive pulley (4b).

1. Undo the bolts (1a) and remove the water pump (1b).2. Remove the water pump gasket.3. Fit the tool A.

	Description	Code	Function
3	Counter-torque	1.860.779.000	-

4. Undo the nut (4a) and remove the single engine components drive pulley (4b).5. Remove the timing belt.6. Remove the timing belt drive pulley.

- Rotate the engine through 180° on the overhaul stand.1. Undo the bolt fixing the oil pump drive chain to the oil pump.2. Move the drive chain away from the oil pump using the tool A.

	Description	Code	Function
2	Extractor	1.860.954.002	-

1. Undo the bolts (1a) and remove the oil pump assembly (1b).

1. Undo the bolts (1a) and remove the crankcase front cover (1b) complete with gasket (1c) and crankshaft front oil seal (1d).2. Remove the crankshaft key using a flat drift.

1. Remove the oil pump drive chain.2. Undo the bolt (2a) and remove the engine oil supply connector (2b) in the crankcase.

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

	Description	Code	Function
2	Counter-torque	1.860.779.000	-

1. Fit the tool A.

	Description	Code	Function
1	Flange	1.860.815.000	-

- Rotate the crankshaft so that the right bearing cap bolts are accessible.2. Undo the nuts (2a) and remove the connecting rod caps (2b) complete with the right half-bearings (2c).

- Rotate the engine through 180° on the overhaul stand.1. Remove the tools A from the right side.

	Description	Code	Function
1	Cylinder bore lock	1.860.829.000	-

2. Remove the cylinder bores (2a), the connecting rod-piston assemblies (2b) and the half-bearings (2c) for the right side.- Separate the connecting rod-piston assemblies from the cylinder bores.- Carry out the same operations for the removal for the bores and the connecting rod-piston assemblies for the left side.- Remove the tool A.

	Description	Code	Function
.	Flange	1.860.815.000	-

- Rotate the engine through 180° on the overhaul stand.- Check that the crankshaft endfloat M corresponds to the recommended figures using a magnetic base and dial gauge.

	Subject	Value
.	Crankshaft	mm
-	End float	0.080 - 0.265

1. Undo the nuts (1a) and remove the front and centre bearing caps (1b) using a suitable tool (1c).2. Remove the main journal half-bearings.

1. Undo the nuts (1a) and remove the rear bearing cap (1b) using tools (1c), (1d) and (1e).

	Description	Code	Function
1c	Mallet	1.846.011.000	-

	Description	Code	Function
1d	Extractor	1.860.782.000	-

	Description	Code	Function
1e	Adapator	1.860.953.000	-

2. Remove the rubber seals.3. Remove the main journal half-bearing.

1. Remove the crankshaft.2. Remove the crankshaft rear oil seal3. Remove the main journal half-bearings.4. Remove the thrust washers.5. Remove the piston cooling engine oil jets in the crankcase.

See in Op. 1028H60 Piston, pin set - Replace with pistons and connecting rods at the bench - Includes alignment and balancing See in Op. 1084B18 Engine oil pump, removed - Check at the bench- 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.- Measure the cylinder bore inner diameter M and check that the value corresponds to the recommended figures; if this is not the case, replace the cylinder bores.

	Subject	Value
.	Cylinder bores
-	Inner diamter CL. A	92.985 - 92.994
-	CL. B	92.995 - 93.004
-	CL. C	93.005 - 93.014

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

	Subject	Value
.	Cylinder bores
-	Ovality	< 0.01

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

	Subject	Value
.	Cylinder bores	mm
-	Taper	0.01

1. Fit the bearing caps (1a) and tighten the nuts (1b) to torque C.

	Value - daNm	Fastening	Component	Ø
1b	2.4 - 2.6 + 77° - 81° (Engine crankcase side)	Nut	MAIN BEARING CAPS	M12

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

	Description	Code	Function
.	Torque wrench	1.860.942.000	-

2. Check that the inner diameter of the main journals M is within specified limits.

	Subject	Value
2	Bearing caps
-	Bearing support inner diameter CL. A	59.979 - 59.997
-	CL. B	59.973 - 59.991
-	CL. C	59.967 - 59.985

- Check that there are no deposits or blockages in the crankshaft lubrication ducts.- Check that the main journal diameter is within the recommended limits; if not, replace the crankshaft.

	Subject	Value
.	Crankshaft	-
-	Main journal diameter CL. A	59.973 - 59.979
-	CL. B	59.967 - 59.973
-	CL. C	59.961 - 59.967

- Check that the bearing diameter M is within the recommended limits; if not, replace the crankshaft.

	Subject	Value
.	Crankshaft
-	Main journal diameter CL. A	51.990 - 52.000
-	CL. B	51.980 - 51.990

- Check that the small end inner diameter M is within the recommended limits; if not, replace the connecting rod.

	Subject	Value
.	Small end bush	mm
-	Small end inner diameter	25.120 - 25.145

- Check that the small end bush diameter is within the recommended limits; if not, replace the bush.

	Subject	Value
.	Small end bush	mm
-	2nd bush inner diameter	22.004 - 22.014

The bush diameter is measured with the bush fitted in the small end.

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

	Subject	Value
.	Gudgeon pin	mm
-	Gudgeon pin outer diameter	21.996 - 22.000

- Fit the piston rings in the cylinder bore and, using a feeler gauge, check that the gap M between the ends is within the recommended values; if this is not the case, replace the piston rings.

	Subject	Value
.	Piston rings
-	1st piston ring gap	0.30 - 0.50
-	2nd piston ring gap	0.40 - 0.65

	Subject	Value
.	Oil scaper ring
-	Oil scraper ring gap	0.30 - 0.60

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

	Subject	Value
.	Pistons	-
-	Outer diamter (*) CL. A	92.925 - 92.935
-	CL. B	92.915 - 92.925
-	CL. C	92.905 - 92.915

(*) Measure perpendicular to the gudgeon pin axis, 17 mm from the lower edge of the skirt.

- Check that the gudgeon pin seat inner diameter is within the recommended limits; if not, replace the piston and the gudgeon pin.

	Subject	Value
.	Pistons	mm
-	Gudgeon pin housing diameter	22.005 - 22.010

- Check that the axial clearance M between the rings and the housings corresponds to the recommended figures.

	Subject	Value
.	Piston rings
-	1st pin ring endfloat	0.025 - 0.070
-	2nd pin ring endfloat	0.035 - 0.070

	Subject	Value
.	Oil scaper ring
-	Oil scraper ring end float	0.025 - 0.060

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

	Value - daNm	Fastening	Component	Ø
1c	2.0 + 50°	Bolt in oil	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	-

2. Check that the big end diameter M is within the recommended limits; if not, replace the connecting rods.

	Subject	Value
2	Connecting rods
-	Big end diameter	55.511 - 55.524

See in Op. 1084B18 Engine oil pump, removed - Check at the bench See in Op. 1028H60 Piston, pin set - Replace with pistons and connecting rods at the bench - Includes alignment and balancing- Check that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it.1. Fit the piston cooling engine oil jets in the crankcase.2. Fit the thrust washers.

The thrust washer lubrication ducts should be facing the crankshaft thrust washers.

3. Fit the main journal half-bearings in the cylinder block/crankcase.4. Fit the crankshaft in the crankcase.5. Fit the main bearing caps (5a) complete with half-bearings (5b).

The bearing caps are numbered from 1 to 4 starting from the engine pulley side.

6. Tighten the nuts fixing the bearing caps to torque C.

	Value - daNm	Fastening	Component	Ø
6	(Engine crankcase side) 2.5 + 79°	Nuts in oil	MAIN BEARING CAPS	M12

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

	Description	Code	Function
.	Torque wrench	1.860.942.000	-

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

The oil seal should be fitted in the housing so that it covers the small openings (1c).

	Description	Code	Function
1b	Fitting tool	1.860.843.000	Tool for fitting crankshaft rear oil seal

1. Apply the recommended sealant (1a) through the openings (1b) and check that it comes out about 5 mm through the openings (1c).

	Description	Qty.	Component	Type	Classification
1a	Loctite 5900	-	REAR ENGINE SUPPORT SEALING PLANES	Sealant	-

- Rotate the engine through 180° on the overhaul stand.1. Fit the cylinder bores (1a) complete with seals (1c) in the cylinder block/crankcase and secure them using the tool (1c) A tightening the nuts (1d) to torque C.

	Description	Code	Function
1c	Cylinder bore lock	1.860.829.000	-

	Value - daNm	Fastening	Component	Ø
1d	1.0 - 1.5	Nut	CYLINDER BORE LOCKS	M12

the oil sump should be fitted within 15 minutes of applying the sealant in the openings for sealing the crankshaft rear support.

If this is not the case, remove the excess sealant.

1. Measure the cylinder bore projection in relation to the cylinder block/crankcase plane M using the tool (1a) A fitted with a dial gauge (1b) and check that the figure corresponds to the recommended values.

	Description	Code	Function
1a	Dial gauge support	1.870.404.000	-

	Subject	Value
1	Cylinder bores	-
-	Cylinder block/crankcase projection	0.01 - 0.06

1. Fit the connecting rod-piston assemblies (1a) complete with half-bearings (1b) in the cylinder bores using a suitable tool (1c).

The pistons should be fitted with the arrow stamped on the crown facing the engine pulley side.

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

	Description	Code	Function
1	Flange	1.860.815.000	-

2. Rotate the crankshaft and fit the connecting rod caps (2a) complete with half-bearings (2b) and tighten the bolts (2c) to the recommended torque.

The connecting rod caps have the number of the cylinder to which they belong on the side: when fitting, this number should be on the same side as the number on the big end.

	Value - daNm	Fastening	Component	Ø
2c	2.0 + 50°	Bolt in oil	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	-

- Remove the tool A.

	Description	Code	Function
.	Flange	1.860.815.000	-

- Rotate the engine through 180° on the overhaul stand.1. Fit the wheel and secure it without tightening the bolts.2. Fit the tool A.

	Description	Code	Function
2	Counter-torque	1.860.779.000	-

3. Tighten the flywheel bolts to torque C.

	Value - daNm	Fastening	Component	Ø
3	3.0 + 50°	-	ENGINE FLYWHEEL	M10

- Remove the tool A.

	Description	Code	Function
.	Counter-torque	1.860.779.000	-

- Rotate the engine through 180° on the overhaul stand.- Fit the engine oil supply connector in the crankcase and secure it using the bolt.- Fit the oil pump drive chain.- Fit the crankshaft key.- Fit the front crankcase cover complete with gasket and secure it using the bolts.

	Value - daNm	Fastening	Component	Ø
.	0.8 - 1.2	Bolt	FRONT COVER CRANKSHAFT	M6

- Fit the oil pump assembly and secure it using the bolts.

	Value - daNm	Fastening	Component	Ø
.	4.6 - 6.6	Bolt	ENGINE OIL PUMP	M10

- Tighten the bolt fixing the oil pump drive chain to torque C.

	Value - daNm	Fastening	Component	Ø
.	7.9 - 9.7	Bolt	ENGINE OIL PUMP DRIVE CHAIN	M14

1. Fit the crankshaft timing side oil seal (1a) using the tool (1b) A.

	Description	Code	Function
1b	Fitting tool	1.860.949.000	Tool for fitting crankshaft front oil seal

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

	Description	Qty.	Component	Type	Classification
.	Loctite 5900	-	OIL SUMP	Sealant	-

- Fit the crankcase sump.- Tighten the bolts securing the crankcase sump to torque C.

	Value - daNm	Fastening	Component	Ø
.	1.4 - 2.0	Bolt	CRANKCASE SUMP	M7

- Fit the water pump complete with gasket and secure it to the crankcase tightening the bolts to torque C.

	Value - daNm	Fastening	Component	Ø
.	0.8 - 1.2	-	WATER PUMP	M6

- Fit the water pump cover and bracket and secure it using the bolts.- Fit the detonation sensors and secure them tightening the bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.3 - 3.3	Bolt	TIMING SIDE DETONATION SENSOR	m8

- Fit the pump coolant return manifold.- Rotate the crankshaft until cylinder no.1 is at T.D.C.1. Before fitting the cylinder heads, rotate the camshafts using the tools (1a) so that the reference marks (1b) on the actual shafts are aligned with the cylinder head upper planes.

	Description	Code	Function
1a	Support for counter-torque	1.860.831.000	-

- Remove the tool A.

	Description	Code	Function
.	Cylinder bore lock	1.860.829.000	-

- Fit the cylinder head centering bushes on the cylinder block/crankcase.- Fit new cylinder head gaskets.

Astadur type cylinder head gaskets are fitted.

The material from which these gaskets are 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 heads on the cylinder block/crankcase.1. Tighten the cylinder head nuts (1a) to torque C using the angular tightening tool A (1b).

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

The right cylinder head is illustrated; the tightening order for the left cylinder head is symmetrical.

	Value - daNm	Fastening	Component	Ø
1a	2.4 - 2.6 + 240°	Nuts in oil	CYLINDER HEAD	M12

	Description	Code	Function
1b	Tool	1.860.832.000	-

	Description	Code	Function
1b	Torque wrench	1.860.942.000	-

- ENGINE TUNING1. Remove caps 4 to 7 from the left cylinder head.2. Remove caps B and G from the right cylinder head.

1. Fit tool A in place of the camshaft caps removed.

	Description	Code	Function
.	Template Kit	1.860.820.000	-

	Description	Code	Function
.	Right cylinder 1 A template	1.860.820.001	-

	Description	Code	Function
.	Left cylinder 1 S template	1.825.040.002	-

	Description	Code	Function
.	Left cylinder 4 S template	1.825.040.003	-

	Description	Code	Function
.	Right cylinder 6 A template	1.860.820.002	-

- Loosen the bolts for the camshaft drive pullies using the special tool for counter-torque.

	Description	Code	Function
.	Support for counter-torque	1.860.831.000	Support

- Fit the timing belt drive pulley.- Fit the single components belt fixed tensioner and secure it tightening the bolt to torque.- Fit the alternator mounting and secure it using the bolts.- Fit the alternator rear bracket and secure it using the bolts.1. Fit the tool A (1a) complete with dial gauge (1b) in the seat for the spark plug for cylinder no. 1.

	Description	Code	Function
1a	Extension	1.860.895.000	T.D.C. check

- Rotate the crankshaft through small rotations (in both directions) until the piston for the right head timing side cylinder no. 1 is at T.D.C. in the explosion stroke.

Take care that the last rotation of the crankshaft is in the direction of operation.

1. Fit the timing drive belt starting from the drive pulley and continuing in an anti-clockwise direction making sure that the drive branches are properly taut.

1. Fit the tool (1a) and secure it using bolt (1b) for the alternator and the bolt (1c) for the water pump.

	Description	Code	Function
1a	Belt tensioner	1.860.950.000	-

2. Act on the belt tensioner tool nut (2a) until the moving reference for the belt tensioner (2b) is under the fixed reference.

a suitable spacer is used for the bolt (1b) to ensure the alternator measurement is correct.

the tooth (1d) for the tool should engage with the moving part of the timing belt tensioner.

1. Tighten the bolts (1a) for the camshaft drive pullies to torque C using tools (1b) A for counter-torque.

	Value - daNm	Fastening	Component	Ø
1a	7.3 - 10.6	-	CAMSHAFT DRIVE PULLIES	M12

	Description	Code	Function
1b	Support for counter-torque	1.860.831.000	Support

- Remove the tool A.

	Description	Code	Function
.	Templates (4)	1.860.820.000	-

- Fit the camshaft caps in place of the tool removed and secure them by tightening the bolts to torque C.

	Value - daNm	Fastening	Component	Ø
.	1.8 - 2.5	Bolt	CAMSHAFT CAPS	M8

- Rotate the crankshaft through two revolutions in its direction of rotation to allow the timing belt to bed in.1. Check that the moving reference for the timing belt tensioner coincides with the fixed reference.2. If the references are not aligned, gently release the tensioner tension acting on the nut for the tensioning tool until the reference coincide.3. Tighten the bolts for the timing belt tensioner to torque C.

	Value - daNm	Fastening	Component	Ø
3	1.7 - 2.1	Bolt	TIMING BELT TENSIONER	M8

- Remove the tool A.

	Description	Code	Function
.	Belt tensioner	1.860.950.000	-

1. Fit the tool A.

	Description	Code	Function
1	Counter-torque	1.860.779.000	-

2. Fit the engine components single belt pulley (2a) and secure it tightening the nuts (2b) to torque C.

	Value - daNm	Fastening	Component	Ø
2b	23.2 ÷ 31.2	Nut	SINGLE ENGINE COMPONENTS DRIVE BELT PULLEY	M28

- Remove the tool A.

	Description	Code	Function
.	Counter-torque	1.860.779.000	-

- Fit the water pump drive pulley and secure it using the bolts.- Fit the intermediate shaft and oil filter mounting complete with gasket and secure it using the bolts.- Fit the engine oil filter.- Fit the engine components single drive belt automatic belt tensioner.- Fit the timing side power unit rigid support and secure it using the bolts.- Fit the air conditioning compressor and secure it using the bolts.- Fit the tappet covers and secure them using the bolts.- Fit the exhaust manifold and secure them using the nuts.- Fit the left cylinder head exhaust manifold guard and secure it using the nuts.- Fit the oil dipstick and secure it using the bottom nut and the top bolt.- Fit the thermostat and secure it using the bolts.- Connect the engine oil heat exchanger coolant supply pipe to the thermostat unit.- Fit the ignition coils and secure them using the bolts.- Fit the protective timing cover mounting bracket and secure it using the bolts.- Connect the flexible pipe to the rigid pipe for the fuel distribution manifold.- Tighten the bolt securing the rear timing belt guards.- Fit the timing belt guards and secure them using the bolts.- Fit the engine components single drive belt.- Use a spanner on the engine components single drive belt tensioner to remove the belt tensioner retaining lug.- Place the electrical wiring in position and fasten it to the bands.- Connect the electrical connections to the ignition coils.- Connect the electrical connections to the injectors.- Fit the electrical wiring mounting brackets to the tappet covers and secure them using the bolts.- Connect the electrical connection for the detonation sensor.- Connect the electrical connection for the air conditioning compressor.- Fit the ignition coil cover for the left cylinder head and secure it using the bolts.- Connect the earth lead to the left cylinder head tappet cover.- Connect the electrical connection to the engine coolant temperature sensor.- Connect the electrical connection for the rear detonation sensor (black).- Connect the electrical connection for the engine rpm and timing sensor (black).- Connect the electrical connection for the cam angle sensor (light blue).- Fit the intake chamber assembly and secure it using the bolts.- Tighten the bands securing the air intake manifolds to the intake chamber.- Connect the condensation oil return pipe to the separator- Connect the engine oil vapour recovery pipe.- Connect the electrical connection for the throttle casing.- Connect the earth lead to the left cylinder head tappet cover. See in Op. 1004D40 ENGINE - Position on stand and Remove