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

Removing ( Refitting

) 1. Release the water pump rigid inlet pipe and remove it.

1. Undo the bolts (1a) and remove the water pump cover (1b) and the gasket (1c).2. Remove the bracket.

1. Undo the fixing bolts (1a) and remove the water pump assembly (1b).2. Remove the seal.

1. Undo the bolts (1a) and remove the detonation sensors (1b).

1. Undo the nuts (1a) and remove the air conditioning compressor mounting (1b).2. Undo the bolt (2a) and remove the engine components single belt moving tensioner (2b).

1. Fit the flywheel lock.

	Description	Code	Function
1	Counter-torque	1.860.779.000	-

1. Undo the nut (1a) and remove the crankshaft pulley (1b).2. Remove the toothed timing belt.3. Remove the toothed 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 engine oil pump drive chain (2a) away from the pump using the tool (2b).

	Description	Code	Function
2b	Extractor	1.860.954.001	Tool for extracting chain from engine oil pump

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

1. Remove the crankshaft key using a suitable drift.2. Undo the bolts (2a) and remove the engine block front cover (2b).- Remove the crankshaft front oil seal from the crankcase front cover.3. Remove the seal.

1. Remove the engine 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).

The engine flywheel fixing bolts have been treated with a special agent; therefore they should be replaced each time they are removed.

2. Remove the flywheel lock

	Description	Code	Function
2	Counter-torque	1.860.779.000	-

1. Fit the tool for rotating the crankshaft.

	Description	Code	Function
1	Flange	1.820.618.000	Crankshaft rotation

- Rotate the crankshaft so that the right bearing cap bolts are accessible.2. Undo the bolts (2a) and remove the bearing caps (2b) on the right side.3. Remove the crankpin half-bearings.

- Rotate the engine through 180° on the overhaul stand. 1. Remove the cylinder liner/bore locks from the right side.

	Description	Code	Function
1	Cylinder bore lock	1.820.279.000	Keep the cylinder liners/bores in their seats

2. Remove the cylinder liner/bore (2a), piston and connecting rod assemblies (2b) for the right side.- Separate the connecting rod-piston assemblies from the cylinder liners/bores.3. Remove the crankpin half-bearings.- Work in the same way to remove the cylinder liner/bore, piston and connecting rod assemblies for the left side.

- Remove the tool for rotating the crankshaft.

	Description	Code	Function
.	Flange	1.820.618.000	Crankshaft rotation

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

	Subject	Value
.	Crankshaft	mm
-	Crankshaft endfloat	0.080 ÷ 0.265

1. Undo the nuts (1a) and remove the front and centre crankshaft bearings.2. Remove the main journal half-bearings.

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

	Description	Code	Function
1c	Lever	1.821.006.001	Removing rear bearing cap

	Description	Code	Function
1d	Extractor	1.821.006.002	Removing rear bearing cap

2. Remove the main journal half-bearing.

1. Remove the crankshaft rear oil seal

1. Remove the crankshaft.2. Remove the main journal half-bearings.3. Remove the thrust washers.

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 the ducts.

Refitting ( Removing

) - Wash all the dismantled components thoroughly.- Clean any residues of sealant from the matching surfaces for the engine oil sump and the rear bearing cap with the engine block.- Place the crankcase water/oil sealing plugs back in their housings using suitable fitting tools.- Lubricate all the mechanical components with engine oil.- 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

- Remove the seals from the cylinder liners/bores.- Check that the internal diameter of the cylinder liners/bores is within the recommended limits; if not, replace them.

	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 liners/bores is within the recommended limits; if not, replace them.

	Subject	Value
.	Engine block cylinder liners/bores	mm
-	-	Maximum permitted cylinder liner/bore ovality
-	X - Y	0.01

- Remove the crankshaft lubrication duct plugs using a suitable drift, then remove any residues.- Clean the lubrication ducts thoroughly using hot petroleum, then dry with a compressed air jet.- Apply (LOCTITE 270 GREEN) sealant to the new plugs, then fit them in the housings in the crankshaft using a suitable fitting tool and bevel them.- 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

The nitriding treatment which the crankshaft has undergone means that it cannot be reground.

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

	Subject	Value
.	Crankshaft
-	Crank pin diameter - Grade A	51.990 ÷ 52.000
-	Category B	51.980 ÷ 51.990

The nitriding treatment which the crankshaft has undergone means that it cannot be reground.

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

	Subject	Value
.	Engine connecting rod small end bush	mm
-	Small end bush inner diameter (reaming)	20.005 ÷ 20.015

- Check the matching between the gudgeon pin and the piston housing: it should be possible to insert the gudgeon pin by applying gentle pressure and it should not slip out.- Check that the outer diameter of the gudgeon pins is within the recommended limits; if not, replace the worn gudgeon pins.

	Subject	Value
.	Gudgeon pin	mm
-	Gudgeon pin outer diameter	19.996 ÷ 22.000

- 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 seals	mm
-	-	Piston seal gap
-	1st Ring	0.30 ÷ 0.50
-	2nd ring	0.40 ÷ 0.60

	Subject	Value
.	Piston oil scraper rings	mm
-	-	Piston oil scraper ring gap
-	Oil scaper ring	0.20 ÷ 0.40

1. If necessary, reface the ends of the piston rings using a suitable tool.

- 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
.	Engine pistons	mm
-	Piston outer diamter, Grade A	92.905 ÷ 92.915
-	Category B	92.915 ÷ 92.925
-	Category C	92.925 ÷ 92.935

Measure perpendicular to the gudgeon pin axis, 13.1 mm from the lower edge of the skirt.

- Check that the endfloat between the seals and the housings in the piston is within the recommended values; if this is not the case, replace the seals.

	Subject	Value
.	Piston seals
-	-	Seal endfloat
-	1st Ring	0.035 ÷ 0.070
-	2nd ring	0.030 ÷ 0.075

	Subject	Value
.	Piston oil scraper rings	mm
-	-	Oil scraper ring endfloat
-	Oil scaper ring	0.020 ÷ 0.065

- Check that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it. 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 the half-bearings show no signs of grooves or traces of seizing; if this is not the case, replace them.

No adjustment operations whatsoever should be carried out on the half-bearings.

- Place the half-bearings in their seats in the engine block.

The half-bearings and the main journals should be matched using parts belonging to the same class (same distinctive colour)

Great care should be taken over cleanliness when refitting.

1. Place the crankshaft in its housing.2. Fit the calibrated wire (plastigage) for measuring the bearing clearance.

1. Place the bearing cap (1a), complete with half-bearing, back in its housing and secure it tightening the nuts (1b) to the recommended torque.

The bearing caps are marked with a progressive number (from one to four starting from the timing side) which defines the fitting position.

The safety references on the cylinder block/crankcase and on the bearing caps should be on the same side.

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

2. Use the tool for the angular tightening of the bearing cap bolts.

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

1. Remove the bearing cap fitted previously and, using a suitable graduated measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).

Measure the clearance for all the bearings taking care to take the measurements one at a time without moving the crankshaft at any time.

	Subject	Value
1b	Crankshaft	mm
-	Main journal/bearing clearance, Grade A	0.000 ÷ 0.024
-	Category B	0.000 ÷ 0.024
-	Category C	0.000 ÷ 0.025

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

- Place the hafl-bearings in their seats.- Place the thrust washers (with the size depending on the crankshaft endfloat measured during the dismantling) in their housings in the rear bearing support.

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

- Place the crankshaft in its housing.1. Place the bearing caps (1a), complete with half-bearing, back in their housings and secure them tightening the nuts (1b) to the recommended torque.

The bearing caps are marked with a progressive number (from one to four starting from the timing side) which defines the fitting position.

The safety references on the cylinder block/crankcase and on the bearing caps should be on the same side.

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

2. Use the tool for the angular tightening of the bearing cap bolts.

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

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	1.821.250.000	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	-

The oil sump should be fitted within 15 minutes of applying the sealant in the openings for sealing the rear bearing support. If this is not the case, remove the excess sealant.

- Rotate the engine through 180° on the overhaul stand.- Fit the new seals in their housings in the cylinder liners/bores.1. Fit the cylinder liners/bores (1a), complete with seals (1b).2. Fit the cylinder liner/bore locks (2a) and tighten the nuts (2b) to the recommended torque.

	Description	Code	Function
2a	Cylinder bore lock	1.820.279.000	Keep the cylinder liners/bores in their seats

	Value - daNm	Fastening	Component	Ø
2b	2.4 ÷ 2.6 + 228° ÷ 232°	Nut	CYLINDER LINER/BORE LOCK TOOLS	M12

1. Measure the projection of the cylinder liners/bores in relation to the cylinder block/crankcase (1a) plane using the tool (1b) fitted with a dial gauge (1c) and check that it corresponds to the recommended values.

	Subject	Value
1a	Engine block cylinder liners/bores	mm
-	Cylinder liner/bore projection in relation to the cylinder block/crankcase	0.01 ÷ 0.06

	Description	Code	Function
1b	Dial gauge support	1.825.003.000	Measure cylinder liner/bore projection

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

The piston-connecting rod assemblies are fitted with the arrows stamped on the piston crowns facing the timing side and the reference on the connecting rods facing the timing side for the right side and the flywheel side for the left side.

- Rotate the engine through 180° on the overhaul stand.- Fit the tool for rotating the crankshaft.

	Description	Code	Function
.	Flange	1.820.618.000	Crankshaft rotation

- Rotate the crankshaft so that the connecting rod bearings are accessible.1. Fit the calibrated wire (plastigage) for measuring the bearing clearance.

1. Place the bearing cap (1a) in its seat complete with half-bearings (1b) and secure it by tightening the bolts (1c) to the recommended torque.

The safety references on the connecting rod cap and the big end should be on the same side.

	Value - daNm	Fastening	Component	Ø
1c	1.9 ÷ 2.1 + 48° ÷ 52°	Bolt	CONNECTING ROD CAPS	M9

- Use the 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

1. Remove the bearing cap fitted previously and, using a suitable graduated measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).

Measure the clearance for all the bearings taking care to take the measurements one at a time.

	Subject	Value
1b	Crankshaft	mm
-	-	Main journal/bearing clearance
-	Category A	0.020 ÷ 0.060
-	Category B	0.023 ÷ 0.063

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

- Rotate the crankshaft so that the connecting rod bearings are accessible.1. Place the bearing caps (1a) in their seats complete with half-bearings (1b) and secure them by tightening the bolts (1c) to the recommended torque.

The safety references on the connecting rod cap and the big end should be on the same side.

	Value - daNm	Fastening	Component	Ø
.	1.9 ÷ 2.1 + 48° ÷ 52°	Bolt	CONNECTING ROD CAPS	M9

- Use the 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

- Remove the tool for rotating the crankshaft.

	Description	Code	Function
.	Flange	1.820.618.000	Crankshaft rotation

- Fit the engine oil supply connector in the crankcase and secure it using the bolt.1. Position the engine oil pump (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Main bearing caps side) 4.5 - 5.5	Bolt	ENGINE OIL PUMP	M10

1. Position the engine oil pump drive chain (1a) in its housing and secure it without tightening the bolt (1b) to the recommended torque.

1. Place the crankcase front cover (1a), complete with gasket, back in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Engine crankcase side) 0.8 - 1.0	Bolt	FRONT COVER CRANKSHAFT	M6

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

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

- Place the key in the housing in the crankshaft.- Place the toothed drive pulley in its housing.1. Position the engine components single belt moving tensioner (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Engine crankcase side) 2.7 - 3.3	Bolt	SINGLE BELT MOVING TENSIONER VARIOUS	-

2. Place the air conditining compressor mounting (2a) in its housing and secure it by tightening the nuts (2b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2b	(Engine crankcase side) 2.3 - 2.8	Nut	COMPRESSOR MOUNTING (AC)	M8

1. Place the detonation sensors (1a) in their housings and secure them tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Engine crankcase side) 2.3 - 2.8	Bolt	Flywheel side detonation sensor	M8

1. Position the water pump (1a), complete with gasket (1b), in its housing and secure it tightening the bolts (1c) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1c	(Engine crankcase side) 0.8 - 1.0	Bolt	COOLANT PUMP	M6

1. Position the water pump cover (1a), complete with gasket (1b) and bracket (1c), in its housing and secure it tightening the bolts (1d) to the recommended torque.

- Place the water pump rigid coolant inlet pipe complete with seals in its housing.1. Carry out the initial timing of the camshafts. fit a spanner in the housing (1a) in the centre of the camshafts and rotate them until the references (1b) on the shafts are aligned with the references on the cylinder head upper plane.

The references should be facing the centre of each cylinder head

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

1. Position the timing templates in place of the camshaft caps removed.

	Description	Code	Function
1	Cylinder bore lock	1.820.279.000	Keep the cylinder liners/bores in their seats

- Place the cylinder head centering bushes on the cylinder block.1. Fit new cylinder head gaskets (1a) taking care to fit the seals (1b) for the lubrication ducts (two for each cylinder head).

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 cylinder no. 1 at T.D.C. before fitting the cylinder heads on the cylinder block.- Position the cylinder heads on the cylinder block/crankcase.1. Tighten the nuts (1a) fixing the cylinder heads to the recommended torque using tools (1b) and (1c) for the angular tightening.

Lubricate the threads, nuts and washers with engine oil.

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	(Engine crankcase) 2.4 ÷ 2.6 + 228° ÷ 232°	Nut	CYLINDER HEAD	M12

	Description	Code	Function
1b	Torque wrench	1.860.942.000	Tightening cylinder head nuts

	Description	Code	Function
1c	Spanner	1.822.121.000	Tightening cylinder head nuts

- Place the alternator bracket in its housing and secure it using the bolts.- Fit the timing belt rear protective covers and secure them using the bolts.1. Place the fixed timing tensioners (1a) in their housings and secure them tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Cylinder head side) 4.5 - 5.5	Bolt	FIXED TENSIONER	M10

2. Place the toothed driven pullies (2a) in their housings and secure them without tightening the bolts (2b).

- Tighten the bolt fixing the left rear protective timing cover to the right cylinder head.1. Fit the tool (1a) complete with dial gauge (1b) in the seat for the spark plug for cylinder no. 1.

	Description	Code	Function
1a	Extension	1.821.225.000	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 toothed timing drive belt starting from the toothed 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 to the alternator bracket using bolt (1b) and to the water pump using bolt (1c).

The tooth for the tool should engage with the moving part of the timing belt tensioner.

	Description	Code	Function
1a	Belt tensioner	1.860.950.000	Toothed timing drive belt tensioner

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

1. Tighten the bolts (1a) fixing the toothed driven pullies to the recommended torque using the tool (1b) for counter-torque.

	Value - daNm	Fastening	Component	Ø
1a	(camshaft side) 7.2 - 8.8	bolt	TIMING DRIVEN PULLIES	M12

	Description	Code	Function
1b	Counter-torque	1.822.146.000	Loosen/tighten driven toothed pulley bolts

- Remove the tools for timing the camshafts.

	Description	Code	Function
.	Templates	1.870.849.000	Engine tuning

- Place the camshaft caps in their housings in place of the tools removed and tighten the bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	(Cylinder head side) 1.8 -2.0	Bolt	CAMSHAFT CAPS	M8

- Rotate the crankshaft through two revolutions in its direction of rotation to allow the toothed timing drive belt to bed in.1. Check that the moving reference for the moving 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 fixing the moving timing tensioner to the recommended torque.

	Value - daNm	Fastening	Component	Ø
3	(Cylinder head side) 1.9 - 2.3	Bolt	MOBILE TIMING TENSIONER	M8

- Remove the belt tensioner tool.

	Description	Code	Function
.	Belt tensioner	1.860.950.000	Toothed timing drive belt tensioner

- Rotate the engine through 180° on the overhaul stand.1. Fit the engine flywheel and secure it without tightening the bolts.

There is only one position for the engine flywheel as the openings for the fixing bolts are not equidistant.

2. Fit the flywheel lock.

	Description	Code	Function
2	Counter-torque	1.860.779.000	Flywheel lock

3. Tighten the bolts securing the engine flywheel to the recommended torque.

The engine flywheel fixing bolts have been treated with a special agent; therefore they should be replaced each time they are removed.

	Value - daNm	Fastening	Component	Ø
3	(Crankshaft side) 2.9 -3.2 + 48° - 51°	Bolt	FLYWHEEL (MECH.)	M12

- Use the tool for the angular tightening of the flywheel bolts.

	Description	Code	Function
.	Torque wrench	1.860.942.000	Engine flywheel bolts angular tightening

1. Tighten the bolt fixing the engine oil pump drive chain to the oil pump to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1	(Engine oil pump side) 4.5 - 5.5	Bolt	ENGINE OIL PUMP DRIVE CHAIN	M10

2. Position the crankshaft pulley (2a) in its housing and secure it tightening the nut (2b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2b	(Crankshaft side) 22.8 - 25.2	Left nut	CRANKSHAFT PULLEY	M28

- Remove the flywheel lock

	Description	Code	Function
.	Counter-torque	1.860.779.000	Flywheel lock

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

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

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

	Value - daNm	Fastening	Component	Ø
1b	(Engine crankcase side) 1.4 - 1.7	Bolt	OIL SUMP	M7

- Place the rpm sensor complete with support in its housing- Place the rpm sensor guard in its housing and secure it using the bolts.1. Position the engine components single belt fixed tensioner (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Crankcase sump side) 2.3 - 2.8	Bolt	SINGLE BELT FIXED TENSIONER VARIOUS	M8

1. Place the cylinder head tappet covers (1a) in their housings complete with seals and secure them tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Cylinder head side) 1.4 - 1.7	Bolt	TAPPET COVERS	M7

1. Tighten the power assisted steering pump retaining bolt to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1	(Mount side) 2.3 - 2.8	Bolt	POWER STEERING PUMP	M8

2. Place the bracket (2a) in its housing and secure it using the bolt (2b) and the bolts (2c).

- Fit the timing belt lower protective covers and secure them using the bolts.- Fit the timing belt upper protective cover in its housing and secure it using the bolts.- Connect the fuel manifold pipe rapid connector.1. Place the ignition coils (1a) in their housings in the left cylinder head and secure them tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Cam cover side) 0.8 ÷ 1.0	Bolt	IGNITION COIL/REEL	M6

- Place the engine wiring in position.- Place the electrical wiring duct in its housing and secure it using the bolts.- Connect the electrical connections to the ignition coils on the right cylinder head.- Connect the electrical connections to the injectors for the right cylinder head.- Place the ignition coil cover on the left cylinder head back in its housing and secure it using the bolts.- Connect the earth lead to the left cylinder head and secure it using the nut.- Connect the electrical connection for the flywheel side knock sensor.- Connect the electrical connection for the rpm sensor.1. Place the connector back in its housing.2. Place the thermostat (2a) in its housing and secure it by tightening the bolts (2b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2b	(Cylinder head side) 0.8 - 1.0	Bolt	THERMOSTAT	M6

- Place the wiring and the connections in the connections box, then close the cover.- Connect the electrical connection to the water temperature sensor.1. Place the ignition coils (1a) in their housings in the right cylinder head and secure them tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Cam cover side) 0.8 ÷ 1.0	Bolt	IGNITION COIL/REEL	M6

1. Place the cam angle sensor (1a) back in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Cylinder head side) 0.7 - 0.8	Bolt	CAM ANGLE SENSOR (MPI)	M6

- Place the electrical wiring duct in its housing and secure it using the bolts.- Connect the electrical connections to the ignition coils on the right cylinder head.- Connect the electrical connections to the injectors for the right cylinder head.1. Position the inlet manifolds (1a), complete with hoses (1b) and gaskets (1c), in their housings and tighten the bolts (1d) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1d	(Intake manifold side) 0.6 ÷ 0.9	Bolt	INTAKE AIR DUCT SHROUD	M6

- Place the air intake chamber in its housing and secure it using the bolts.- Tighten the bolt fixing the strengthening strut to the support on the engine for the reaction rod.- Connect the earth lead to the air intake chamber and secure it using the fixing bolt.- Connect the electrical connection to the throttle casing with D.V.L.- Tighten the band securing the engine oil vapour recovery pipe to the air intake chamber.- Tighten the bands securing the intake manifolds to the air chamber.- Connect the electrical connection for the timing side knock sensor.- Close the electrical connections box. See in Op. 1004D40 ENGINE - Position on stand and Remove