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. Undo the bolts (1a) and remove the engine oil intake duct (1b) complete with gasket.

1. Remove the engine oil filter (1a) using a suitable tool (1b).

1. Undo the nut (1a) and remove the engine oil heat exchanger (1b) complete with pipes (1c).

- Undo the bolt loosened previously and remove the toothed timing drive pulley.1. Undo the bolts (1a) and remove the crankshaft oil seal front cover (1b) with engine oil pump incorporated.- Remove the gasket.

1. Undo the bolts (1a) and remove the detonation sensors (1b).2. Undo the bolt (2a) and remove the rpm sensor (2b).3. Undo and remove the minimum engine oil pressure sensor.

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

- Fit the tool for rotating the crankshaft and rotate the crankshaft to gain access to the cap bolts.

	Description	Code	Function
.	Flange	1.860.815.000	Crankshaft rotation

1. Undo the bolts (1a) and remove the connecting rod caps (1b) and half-bearings (1c).2. Remove the piston-connecting rod assemblies (2a) complete with half-bearings (2b).

- Remove the tool for rotating the crankshaft.

	Description	Code	Function
.	Flange	1.860.815.000	Crankshaft rotation

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

	Subject	Value
.	Crankshaft bearings	mm
-	Thrust washer	2.469 - 2.485

	Subject	Value
.	Crankshaft	mm
-	End float	0.059 - 0.161

- If the value for the crankshaft endfloat does not correspond to the recommended figures, when refitting regrind the crankcase seat according to the oversize of the thrust washers available as spares.- The oversize is distributed on both sides.

	Subject	Value
.	Crankshaft thrust washers	mm
-	Oversize	< = 0.254

1. Undo the bolts (1a) and remove the main journal caps (1b) complete with half-bearings (1c).2. Remove the crankshaft.3. Remove the main journal half-bearings.4. Remove the thrust washers.

1. Remove the circlips (1a) and (1b) fastening the counter-balance shaft front bearing.2. Remove the counter-balance shaft (2a) complete with rear bearing (2b) using a suitable drift.3. Keep the rear plug.

1. Remove the counter-balance shaft front bearing (1a) from the crankcase using tools (1b) and (1c).

	Description	Code	Function
1b	Extractor	1.840.207.814	Extracting counter-balance shaft front bearing

	Description	Code	Function
1c	Mallet	1.840.206.000	Extracting counter-balance shaft front bearing

- Position the counter-balance shaft in a vice fitted with protective jaws.1. Remove the counter-balance shaft rear bearing circlip.2. Remove the counter-balance shaft rear bearing (2a) using a suitable drift (2b).

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

See in Op. 1024A28 Crankshaft FLYWHEEL for rpm and timing sensor - Replace with crankshaft removed- < R1 > [Flywheel from crankshaft]. See in Op. 1084B18 Engine oil pump, removed - Check at the bench- < R1 > [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- < R1 > [Piston, gudgeon pin and seal set - replace with pistons and connecting rods at the bench - Includes alignment and balancing].- Drill and remove the water/oil sealing plugs from the crankcase to allow for washing the ducts.

Refitting ( Removing

) - Wash all the dismantled components.- Apply LOCTITE 270 sealant to the water/oil sealing plugs, then fit them 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 cylinder head support surface flatness is within specified limits; if this is not the case, regrind it.

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

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

	Subject	Value
.	Cylinder block/crankcase	mm
-	Cylinder liner bore	83.000 - 83.010

	Subject	Value
.	Cylinder block/crankcase	mm
-	Cylinder liner bore	83.010 - 83.020

	Subject	Value
.	Cylinder block/crankcase	mm
-	Cylinder liner bore	83.020 - 83.030

- 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	< 0.10

- 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 cylinder bores must have the same oversize.

	Subject	Value
.	Cylinder block/crankcase	mm
-	Cylinder liner oversize	0.4

- Clean the lubrication ports in the crankshaft using an air jet.- Check the static balance of the crankshaft resting the main journals on suitable parallels.- Measure the diameter of the main journals and check that they correspond to the recommended figures.

	Subject	Value
.	Crankshaft	mm
-	main journal diameter	59.994 - 60.000

	Subject	Value
.	Crankshaft	mm
-	Main journal diameter	59.988 - 59.994

	Subject	Value
.	Crankshaft	mm
-	Main journal diameter	59.982 - 59.989

- If the diameter of the main journals is not correct, they should be reground to the recommended undersizes.

	Subject	Value
.	Crankshaft	mm
-	Main journal undersize	< = 127

- Measure the diameter of the crankpins check that they correspond to the recommended figures.

	Subject	Value
.	Crankshaft	mm
-	Crankpin diameter	50.805 - 50.799

	Subject	Value
.	Crankshaft	mm
-	Crankpin diameter	50.799 - 50.793

	Subject	Value
.	Crankshaft	mm
-	Crankpin diameter	50.793 - 50.787

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

	Subject	Value
.	Crankshaft	mm
-	Main journal undersize	< = 127

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

- Visually inspect the crankshaft bearings and crankpins bearing in mind that no adjustments should be made to the half-bearings; if there are signs of grooves or traces of seizing they should be replaced.- Place the half-bearings in their seats taking great care over cleanliness.

If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions.

1. Fit the crankshaft in the crankcase.2. Fit the calibrated wire (plastigage) for measuring the bearing clearance.3. Place the bearing cap (3a) in its seat and secure it by tightening the bolts (3b) to the recommended torque.

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

	Value - daNm	Fastening	Component	Ø
3b	2,0 + 100°	Bolt	MAIN BEARING CAPS	M12

- Use the tool for the angular tightening of the bearing 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 without moving the crankshaft at any time.

	Subject	Value
1b	Crankshaft	mm
-	Main journal/bearing clearance	0.030 - 0.056

- Clean any carbon residues carefully from the pistons.- 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.

The outer diameter of the pistons should be measured perpendicular to the gudgeon pin axis and 12.5 mm from the lower edge of the skirt.

	Subject	Value
.	Engine piston	mm
-	Outer diameter	82.952 - 82.962

	Subject	Value
.	Engine pistons	mm
-	Outer diameter	82.959 - 82.971

	Subject	Value
.	Engine pistons	mm
-	Outer diameter	82.968 - 82.978

- Position the piston in the cylinder bore and, using a feeler gauge, check that the clearance is within the recommended values.

	Subject	Value
.	Engine pistons	mm
-	Piston/cylinder bore clearance	< = 0.048

	Subject	Value
.	Engine pistons	mm
-	Piston/cylinder bore clearance	< = 0.051

	Subject	Value
.	Engine pistons	mm
-	Piston/cylinder bore clearance	< = 0.062

- Check that the inner diameter of the gudgeon pin housing in the piston is within the recommended values.

	Subject	Value
.	Engine pistons	mm
-	Gudgeon pin housing diameter	22.002 - 22.007

- If the diameter of the gudgeon pin housing is not within the recommended values, ream it in accordance with the recommended oversize.

	Subject	Value
.	Engine pistons	mm
-	Gudgeon pin housing diameter oversize	0.02

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

	Subject	Value
.	Gudgeon pin	mm
-	Outer diameter	19.996 -20.000

- Check that the thickness of the piston rings is within the recommended values; if this is not the case, replace the piston rings.

	Subject	Value
.	Piston ring set	mm
-	Size	1.190 - 1.170

	Subject	Value
.	Piston ring set	mm
-	Size	1.490 - 1.475

	Subject	Value
.	Engine piston ring set.	mm
-	Size	2.990 - 2.975

The piston rings are available as spares in 0.4 mm oversizes.

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

	Subject	Value
.	Piston ring set	mm
-	Gap	0.250 - 0.500

	Subject	Value
.	Piston ring set	mm
-	Gap	0.300 - 0.500

	Subject	Value
.	Piston ring set	mm
-	Gap	0.250 - 0.450

See in Op. 1028H58 Small end bush (one) - Replace- Check that the small end bush diameter is within the recommended limits; if not, replace the small end bush.

	Subject	Value
.	Small end bush	mm
-	Inner diameter	20,006 - 20,014

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	2.0 + 60°	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

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

	Subject	Value
2	Engine connecting rod assemblies	mm
-	Big end diameter	53.909 - 53.897

See in Op. 1028H60 Piston, pin set - Replace with pistons and connecting rods at the bench - Includes alignment and balancing- < R1 > [Piston, gudgeon pin and seal 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- < R1 > [Engine oil pump removed check at the bench]. See in Op. 1024A28 Crankshaft FLYWHEEL for rpm and timing sensor - Replace with crankshaft removed- < R1 > [Flywheel for crankshaft].- Position the counter-balance shaft in a vice fitted with protective jaws.1. Fit the rear bearing (1a) on the counter-balance shaft (1b) using a suitable drift (1c).- Fasten the rear bearing to the counter-balance shaft using the circlip.

1. Fit the counter-balance shaft front bearing (1a) on the cylinder block/crankcase using the tool (1b).

	Description	Code	Function
1b	Fitting tool	1.860.816.000	Fitting counter-balance shaft front bearing on crankcase

- Fasten the counter-balance shaft front bearing using the circlip.

1. Fit the counter-balance shaft complete with rear bearing (1a) in the cylinder block/crankcase using the tool (1b).

	Description	Code	Function
1b	Fitting tool	1.860.816.000	Fitting counter-balance shaft front bearing on crankcase

- Place the counter-balance shaft rear plugs in their seats.- Place the jets (1b) in their housings and tighten the bolts (1a) to the recommended torque.

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

1. Fit the main journal half-bearings.2. Fit the crankshaft in the crankcase.3. Fit the thrust washers on the centre bearing support.4. Fit the main bearing caps (4a) complete with half-bearings (4b).

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

5. Tighten the bolts fixing the bearing caps to the recommended torque.

	Value - daNm	Fastening	Component	Ø
5	2,0 + 100°	Bolt	MAIN BEARING CAPS	M12

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

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

- Fit the tool for rotating the crankshaft.

	Description	Code	Function
.	Flange	1.860.815.000	Crankshaft rotation

- Place the piston-connecting rod assemblies complete with half-bearings in their housings.

Use a suitable tool for compressing the piston rings and fitting them in the cylinder bore.

The pistons and connecting rods are fitted in the cylinder block/crankcase with the large references (for the inlet valves) on the piston crown facing the inlet side.

- Measure the bearing clearance as described below.1. Fit the calibrated wire (plastigage) for measuring the bearing clearance.2. Fit the cap (2a) complete with half-bearing and tighten the bolts (2b) to the recommended torque.

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.

	Value - daNm	Fastening	Component	Ø
2b	2.0 + 60°	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 without moving the crankshaft at any time.

	Subject	Value
1b	Crankshaft	mm
-	Main journal/bearing clearance	0.030 - 0.056

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

- Place the caps complete with half-bearings in their housings and secure them tightening the bolts to the recommended torque.

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.

	Value - daNm	Fastening	Component	Ø
.	2.0 + 60°	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	1.860.815.000	Crankshaft rotation

1. Fit the crankcase rear cover (1a) with the oil seal incorporated and tighten the bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	0.9 - 1.2 (engine crankcase side)	Bolt pre-treated with eslok	CRANKCASE REAR COVER	M6

- Place the minimum engine oil pressure sensor in its housing and tighten it to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.7 ÷ 4.0		ENGINE OIL PRESSURE WARNING LIGHT SWITCH	M14

- Position the rpm sensor in its housing and secure it using the bolt.- Fit the detonation sensors and secure them tightening the bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.3 -3.3 (engine crankcase side)	Bolt	DETONATION SENSOR(S)	M8

- Rotate the crankshaft so that cylinder no. 1 is at T.D.C.1. Fit the crankshaft front cover complete with gasket with the engine oil pump timing references aligned.2. Tighten the bolts securing the front crankshaft oil seal cover to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2	0.9 - 1.2 (crankcase side)	Bolt	CRANKSHAFT FRONT COVER	M6

- Place the engine oil heat exchanger complete with pipes in its housing and secure it using the nut.

	Value - daNm	Fastening	Component	Ø
.	3.3 - 4.8	Nut	ENGINE OIL HEAT EXCHANGER	M20

- Fit the engine oil filter and tighten it fully by hand.- Position the engine oil intake duct complete with gasket in its housing and secure it using the olts.

	Value - daNm	Fastening	Component	Ø
.	0.9 - 1.2	Bolts	OIL SECTION PUMP	M6

- Clean the matching surfaces between the crankcase sump and the cylinder block/crankcase.- Apply silicon sealant to the entire perimeter of the crankcase sump.1. Place the crankcase sump in its housing.2. Tighten the side bolts (2a) fixing the crankcase sump to the recommended torque using the spanner (2b).

	Value - daNm	Fastening	Component	Ø
2a	0.9 - 1.2	Side bolts	OIL SUMP	M6

	Description	Code	Function
2b	Spanner	1.860.833.000	Loosen/Tighten engine oil sump side bolts

	Value - daNm	Fastening	Component	Ø
.	1.8 - 2.7	-	ENGINE OIL DRAIN PLUG	M18

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

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

	Description	Code	Function
3b	Spanner	1.860.834.000	Loosen/tighten front and rear crankcase sump bolts

- Place the pipe from the thermostat to the crankcase in its housing and secure it using the bolts.1. Place the support on the engine for the reaction rod (1a) complete with moving timing tensioner (1b) in its housing and fasten it by tightening the bolts (1c) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1c	2.3 - 3.3 (crankcase side)	Bolt	ENGINE LINK AND VARIOUS COMPT.MOUNTS	M8

	Value - daNm	Fastening	Component	Ø
1c	(Cylinder block/crankcase side) 4.6 - 6.6	Bolt	ENGINE LINK AND VARIOUS COMPT.MOUNTS	M10

2. Position the fixed timing tensioner (2a) in its housing and secure it tightening the bolt (2b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2b	4.6 ÷ 6.6	Bolt	FIXED TENSIONER	M10

- Place the rear flywheel guard in its housing and secure it using the bolts.1. Fit the flywheel lock.

	Description	Code	Function
1	Counter-torque	1.860.846.000	Flywheel lock

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

	Value - daNm	Fastening	Component	Ø
2b	14.7 -21.2 (crankshaft side)	Bolt pre-treated with eslok	ENGINE FLYWHEEL	M12

1. Position the toothed timing drive pulley (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	32.9 -44.1 (Crankshaft side)	Left hand bolt	TOOTHED TIMING DRIVE PULLEY(PULLIES)	M16

- Remove the flywheel lock.

	Description	Code	Function
.	Counter-torque	1.860.846.000	Flywheel lock

- Position cylinder no. 1 at T.D.C.- Place the cylinder head centering bushes on the cylinder block.- Place the cylinder head gasket in position.

The cylinder head gasket is the 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 taking care to ensure that the camshafts are positioned with the front cams facing outwards (valves closed).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	2 + 2 + 90° + 90° + 90°	Bolt	CYLINDER HEAD	M10

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

- Connect the engine crankcase coolant tank supply pipe to the thermostat unit.- Place the water pump rigid inlet pipe, complete with gasket, in position and secure it using the bolts.- Connect the electrical connections for the detonation sensors.- Connect the electrical connection for the rpm sensor.- Connect the coolant outlet pipe from the engine oil heat exchanger to the water pump rigid inlet pipe.- Connect the engine oil heat exchanger coolant supply pipe to the thermostat unit.- Tighten the fastenings for the engine oil heat exchanger supply/return pipes.1. Loosen the bolt (1a) for the exhaust side driven timing pulley using tools (1b) and (1c) for counter-torque.

	Description	Code	Function
1b	Support for counter-torque	1.860.831.000	Loosen/tighten bolt fixing exhaust side driven timing pulley

	Description	Code	Function
1c	Counter-torque	1.860.848.000	Loosen/tighten bolt fixing exhaust side driven timing pulley

2. Loosen the bolts (2a) for the inlet side camshaft pulley using tool (2a) for counter-torque.

	Description	Code	Function
2b	Counter-torque	1.860.856.000	Loosen/tighten inlet side camshaft drive pulley bolts

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	1.860.895.000	T.D.C. check

- Rotate the crankshaft until the piston for cylinder no. 1 is at T.D.C. in the explosion stroke.- Undo the bolts and remove the inlet side camshaft third cap and the exhaust side camshaft second cap.

Mark the position of the camshaft caps removed so that they can be correctly positioned when refitting.

2. Fit the templates (2a) in place of the camshaft caps that have been removed and secure them tightening the bolts (2b) to the recommended torque.

Check that the camshaft cam profile and the templates are correctly aligned.

	Description	Code	Function
2a	Templates	1.870.828.000	Camshaft timing adjustment

	Value - daNm	Fastening	Component	Ø
2b	1.4 - 2.0 (cylinder head side)	Bolt	TEMPLATES	M7

1. Fit the timing toothed drive belt in the following order:- toothed drive pulley (1a)- fixed tensioner (1b)- exhaust side toothed driven pulley (1c)- inlet side toothed driven pulley (1d)- moving tensioner (1e)- water pump pulley (1f)

The belt is fitted with the arrow facing the direction of rotation of the engine.There are also three reference on the belt that should coincide during the initial fitting with the references on the toothed drive pulley and the exhaust and inlet side toothed driven pullies.

- Using a screwdriver, rotate the moving timing tensioner until the timing belt is completely taut.1. Tighten the nut fixing the moving timing tensioner to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1	2.3 ÷ 3.3	Nut	MOBILE TIMING TENSIONER	M8

2. Tighten the bolts (2a) for the inlet side toothed timing driven pulley using tool (2b) for counter-torque.

	Value - daNm	Fastening	Component	Ø
2a	(inlet camshaft side) 0.9 - 0 1.2	Bolt	TIMING DUCT PULLEY	M6

	Description	Code	Function
2b	Counter-torque	1.860.856.000	Loosen/tighten inlet side camshaft drive pulley bolts

3. Tighten the bolt (3a) for the exhaust side toothed timing driven pulley using the tools (3b) and (3c) for counter-torque.

	Value - daNm	Fastening	Component	Ø
3a	11.0 - 15.9 (exhaust camshaft side)	Bolt	TIMING DUCT PULLEY	M12

	Description	Code	Function
3b	Support for counter-torque	1.860.831.000	Loosen/tighten bolt fixing exhaust side driven timing pulley

	Description	Code	Function
3c	Counter-torque	1.860.848.000	Loosen/tighten bolt fixing exhaust side driven timing pulley

- Undo the bolts and remove the tool.

	Description	Code	Function
.	Templates	1.870.828.000	Camshaft timing adjustment

- Fit the camshaft cams removed previously and tighten the bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	1.4 - 2.0 (cylinder head side)	Bolt	CAMSHAFT CAPS	M7

- Rotate the crankshaft throught two revolutions in the direction of rotation.- Loosen the moving timing tensioner nut.4. Using a screwdriver, rotate the moving timing tensioner until the moving tensioner reference (4a) coincoides with the fixed reference (4b).- Tighten the nut fixing the moving timing tensioner to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.3 ÷ 3.3	Nut	MOBILE TIMING TENSIONER	M8

- Remove the tool complete with dial gauge.

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

- Fit the spark plug for cylinder no. 1 and tighten it to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	(Cylinder head side) 2.5 - 3.6	-	SPARK PLUGS	M14

- Fit the tappet cover complete with gasket and secure it using the bolts.- Position the ignition coils and secure them using the fixing bolts.- Connect the electrical connections to the ignition coils and secure the electrical wiring.- Fit the timing belt protective cover and secure it using the bolts.- Fit the flywheel lock.

	Description	Code	Function
.	Counter-torque	1.860.846.000	Flywheel lock

- Fit the engine components single belt pulley and secure it tightening the bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.3 - 3.3 (counter-balance shaft pulley side)	Bolt	CRANKSHAFT PULLEY	M8

- Remove the flywheel lock.

	Description	Code	Function
.	Counter-torque	1.860.846.000	Flywheel lock

See in Op. 1004D40 ENGINE - Position on stand and Remove- < R1 > [Removal from overhaul stand].