939010401 - 1004E20 ENGINE - DISMANTLE AND REASSEMBLE FOLLOWING OPERATION 1004E10 - WASH AND CHECK DISMANTLED PARTS - REFIT CYLINDER HEAD AND OIL SUMP - DOES NOT INCLUDE REPAIRS TO CYLINDER HEAD AND AUXILIARY UNIT

Removing ( Refitting ) 1. Undo the bolts (1a) and remove the air conditioning compressor (1b) from the mounting.2. Undo the bolts (2a) and remove the air conditioner compressor mounting (2b).
1. Undo the bolts (1a) and remove the engine oil filter and heat exchanger mounting (1b).2. Undo the bolts (2a) and remove the alternator (2b).
1. Undo the bolts (1a) and (1b), then remove the pressure pump support assembly (1c).- Remove the locating pins.
1. Undo the bolt (1a) and remove the rpm sensor (1b).
- Undo the bolts and remove the flywheel side oil seal cover.1. Fit the tool for rotating the crankshaft.
ToolDescriptionFunctionValidity
1820618000FlangeCrankshaft rotation1.9 JTD 8V1.9 JTD 16V
1. Undo the bolts (1a) and remove the engine oil intake (1b).2. Undo the bolt (2a) and remove the timing toothed drive pulley (2b).3. Undo the bolts (3a) and remove the crankshaft oil seal front cover (3b).
1. Undo the bolts (1a) and remove the fixed timing tensioners support (1b).
Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C.1. Undo the bolts (1a) and remove the connecting rod cap (1b).2. Remove the lower connecting rod half-bearing.3. Remove the connecting rod-piston assembly.4. Remove the upper connecting rod half-bearing.Carry out the same operations to remove the pistons and connecting rods for the remaining cylinders.
Remove the tool.
ToolDescriptionFunctionValidity
1820618000FlangeCrankshaft rotation1.9 JTD 8V1.9 JTD 16V
- Check that the crankshaft endfloat corresponds to the recommended figures using a magnetic base and dial gauge.
MeasurementValueValidity
Crankshaft endfloat (mm)0.049 ÷ 0.2111.9 JTD 16V
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 connecting rod caps (1b).2. Remove the lower main journal half-bearings.3. Remove the crankshaft.4. Remove the upper main journal half-bearings.5. Remove the thrust washers.6. Undo the bolts (6a) and remove the jets (6b) from the crankcase.
- Remove the cylinder block/crankcase from the support tools, then place on a workbench.    1028H60 SERIE PISTONI, PERNI e ANELLI - Sost. a pistoni con bielle al banco - Comprende quadratura ed equilibratura    1084B18 POMPA OLIO MOTORE, staccata - Verifica al bancoDrill and remove the water/oil sealing plugs from the crankcase to allow for washing the ducts. 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.
MeasurementValueValidity
Cylinder head support surface flatness (mm)< 0.11.9 JTD 16V
1. Measure the cylinder bore diameter using the diagram illustrated.
MeasurementValueValidity
Cylinder liner inner diameter - Grade A (mm)82.000 ÷ 82.0101.9 JTD 16V
MeasurementValueValidity
Cylinder liner inner diameter - Grade B (mm)82.010 ÷ 82.0201.9 JTD 16V
MeasurementValueValidity
Cylinder liner inner diameter - Grade C (mm)82.020 ÷ 82.0301.9 JTD 16V
Check that the taper of the cylinder liners is within the recommended limits.
MeasurementValueValidity
Cylinder liner taper (mm)< 0.0051.9 JTD 16V
Check that the ovality of the cylinder liners is within the recommended limits.
MeasurementValueValidity
Cylinder liner ovality (mm)< 0.051.9 JTD 16V
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.
MeasurementValueValidity
Cylinder liner bore diameter oversize (mm)0.11.9 JTD 16V
1. Temporarily 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).
ComponentFasteningdia  Value (daNm)Validity
Bearing capsBoltM121.9 ÷ 2.1 + 100°1.9 JTD 16V
ToolDescriptionFunctionValidity
1860942000Torque wrenchTighten bolts to torque plus angle
2. Check that the diameter of the main journal seats is within specified limits.
MeasurementValueValidity
Main journal seat diameter (mm)63.705 ÷ 63.7181.9 JTD 16V
Check that there are no deposits or blockages in the crankshaft lubrication ducts.Check that the diameter of the main journals is within specified limits.
MeasurementValueValidity
Main journal diameter - Category A (mm)59.994 ÷ 60.0001.9 JTD 16V
MeasurementValueValidity
Main journal diameter - Category B (mm)59.988 ÷ 59.9941.9 JTD 16V
MeasurementValueValidity
Main journal diameter - Category C (mm)59.982 ÷ 59.9881.9 JTD 16V
If the diameter of the main journals is not correct, they should be reground to the recommended undersize.
MeasurementValueValidity
Main journal diameter undersize (mm)0.1271.9 JTD 16V
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.
MeasurementValueValidity
Crankpin diameter - Category A (mm)50.799 ÷ 50.8051.9 JTD 16V
MeasurementValueValidity
Crankpin diameter - Category B (mm)50.793 ÷ 50.7991.9 JTD 16V
MeasurementValueValidity
Crankpin diameter - Category C (mm)50.787 ÷ 50.7931.9 JTD 16V
If the diameter of the crankpins is not correct, they should be reground to the recommended undersize.
MeasurementValueValidity
Crankpin diameter undersize (mm)0.1271.9 JTD 16V
Crankpin undersizes higher than the value mentioned will adversely affect the structural resistance of the crankshaft (following contact between the tool and rolled connectors). As far as the above is concerned, if the regrinding requires undersizes greater than 0.127 mm, then the crankshaft must be replaced and a new one ordered from the Parts Dept. The half-bearings used for undersizes of more than 0.127 mm should not be ordered from the Parts Dept. (even if the number is still quoted).
Check the main bearings, noting that the half-bearings should not be adapted. Replace them if scoring or signs of binding are noted.Fit the half-bearings making sure they are scrupulously clean.
If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions.
Fit the crankshaft in the crankcase.1. Fit the calibrated wire (plastigage) for measuring the bearing clearance.
Check one journal at a time, without rotating the crankshaft.
1. Fit the main bearing caps complete with half-bearings.
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).
ComponentFasteningdia  Value (daNm)Validity
Bearing capsBoltM121.9 ÷ 2.1 + 100°1.9 JTD 16V
ToolDescriptionFunctionValidity
1860942000Torque wrenchTighten bolts to torque plus angle
1. Remove the bearing caps fitted previously and, using a suitable graduated measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).
MeasurementValueValidity
Clearance between main journals - crankshaft bearings (mm)0.011 ÷ 0.0711.9 JTD 16V
If the figure measured is outside of the tolerance, replace the half-bearings with ones of the correct size and category.
Measure the clearance for all the bearings taking care to take the measurements one at a time without moving the crankshaft at any time.Check that the small end bush internal diameter is within the recommended limits; if not, replace the worn small end bush.    1028H58 BOCCOLA PIEDE di BIELLA (una) - Sost.
MeasurementValueValidity
Small end bush inner diameter (mm)26.006 ÷ 26.0141.9 JTD 16V
Check that the inner diameter of the gudgeon pin housing in the pistons corresponds to the recommended figures; if not, replace the piston complete with piston rings, gudgeon pin and bushes.
MeasurementValueValidity
Gudgeon pin housing diameter in piston (mm)25.999 ÷ 26.0041.9 JTD 16V
Check that the outer diameter of the piston pins is within the recommended limits; if not, replace the worn piston pins.
MeasurementValueValidity
Gudgeon pin outer diameter (mm)25.982 ÷ 25.9871.9 JTD 16V
Fit the piston rings in the cylinder liner and check that the opening between the ends is within the recommended values; if this is not the case, replace the circlips.
MeasurementValueValidity
Cylinder compression 1st piston ring gap (mm)0.20 ÷ 0.351.9 JTD 16V
MeasurementValueValidity
Cylinder compression 2nd piston ring gap (mm)0.60 ÷ 0.801.9 JTD 16V
MeasurementValueValidity
Piston oil scraper ring gap (mm)0.25 ÷ 0.501.9 JTD 16V
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.
MeasurementValueValidity
Piston outer diameter -grade A (mm)81.920 ÷ 81.9301.9 JTD 16V
MeasurementValueValidity
Piston outer diameter - grade B (mm)81.930 ÷ 81.9401.9 JTD 16V
MeasurementValueValidity
Piston outer diameter - grade C (mm)81.940 ÷ 81.9501.9 JTD 16V
Measure perpendicular to the gudgeon pin axis, 9 mm from the lower edge of the skirt.
1. Check that the backlash (1a) between the first-second ring (1b) and the seats in the piston (1c) corresponds to the recommeded figures.
MeasurementValueValidity
Cylinder compression 1st piston ring endfloat (mm)0.105 ÷ 0.1501.9 JTD 16V
MeasurementValueValidity
Cylinder compression 2nd piston ring endfloat (mm)0.050 ÷ 0.0901.9 JTD 16V
Check that the backlash between the oil scraper ring and the housing in the piston corresponds to the recommeded figures.
MeasurementValueValidity
Oil scraper ring endfloat (mm)0.030 ÷ 0.0701.9 JTD 16V
1. Fit the caps (1b) on the connecting rods (1a) and secure them tightening the bolts (1c) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Connecting rod big end bearing capsBoltM92.4 ÷ 2.6 + 60°1.9 JTD 8V1.9 JTD 16V
Use the tool for the angular tightening of the connecting rod cap bolts.
ToolDescriptionFunctionValidity
1860942000Torque wrenchTighten bolts to torque plus angle
2. - Check that the diameter of the big end corresponds to the recommended figures; if not, replace the connecting rods.
MeasurementValueValidity
Big end inner diameter (mm)53.897 ÷ 53.9091.9 JTD 16V
    1028H60 SERIE PISTONI, PERNI e ANELLI - Sost. a pistoni con bielle al banco - Comprende quadratura ed equilibratura    1084B18 POMPA OLIO MOTORE, staccata - Verifica al bancoCheck that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it.Place the engine block on the overhaul stand using the mounting bracket.
ToolDescriptionFunctionValidity
1871000000Overhaul standEngine support for overhauling
ToolDescriptionFunctionValidity
1871000000BracketPositioning engine on overhaul stand
Place the jets in their housings in the crankcase and secure them using the bolts.Place the thrust washers in their seats on the third main bearing.The main journal half-bearings fitted on the crankshaft have been selected for their optimum fitting clearance.
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 left number refers to the first timing side bearing; the final "N" is an insignificant code for 4 cylinder engines.2 - Main journal identification numerical code: the first number refers to the first timing side bearing; the final "N" is an insignificant code for 4 cylinder engines.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 key.In the case of the example, the numbers 11111N indicate that all five bearings are Grade A (red) as indicated below.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 52.994 for the first timing side bearing which 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).MAIN JOURNAL IDENTIFICATIONMain journal grade A (normal), diameter 59.994.60.000 mm, RED paint mark, numerical code 1 (94 00)*Main journal grade B (normal), diameter 59.988.59.994 mm, BLUE paint mark, numerical code 2 (88 94)*Main journal grade C (normal), diameter 59.982.59.998 mm, YELLOW paint mark, numerical code 3 (82 88)*Main journal grade D (0.127 mm undersize), diameter 59.867.59.873 mm, BROWN paint mark, numerical code 6 (67 73)*Main journal grade E (0.127 mm undersize), diameter 59.861.59.867 mm, GREEN paint mark, numerical code 7 (61 67)*Main journal grade F (0.127 mm undersize), diameter 59.855.59.861 mm, BLACK paint mark, numerical code 8 (55 61)*(*): 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 above 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: 0.011 mm - Maximum: 0.071 mm; this value can be measured, as a final check, using the calibrated wire (plastic gauge).Place the upper main bearing half-bearings in their seats in the engine block.Place the crankshaft in its housing in the crankcase.- Place the bearing caps complete with lower half-bearings in position.
The bearing caps have progressively numbered references (from zero to four starting from the front of the engine) which define the fitting position.
- Tighten the connecting rod cap bolts to the recommended torque using the angular tightening tool.
ComponentFasteningdia  Value (daNm)Validity
Bearing capsBoltM121.9 ÷ 2.1 + 100°1.9 JTD 16V
ToolDescriptionFunctionValidity
1860942000Torque wrenchTighten bolts to torque plus angle
- Fit the tool.
ToolDescriptionFunctionValidity
1820618000FlangeCrankshaft rotation1.9 JTD 8V1.9 JTD 16V
Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C.1. Place the piston and connecting rod assembly (1a) in its housing complete with half-bearing using a suitable tool (1b).
For the selection of the connecting rod half-bearings, follow the procedure described previously for the main journal half-bearings.
The piston-connecting rod assemblies should be fitted in the cylinder block/crankcase so that the drain on the piston skirt is aligned with the oil jet on the engine block.
Carry out the same operations to fit the pistons and connecting rods for the remaining