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 - Alfa - 159 - eLearn

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

) 1. Undo bolts (1a) and remove oil intake duct (1b).

- Fit the tool for rotating the crankshaft.

Tool	Description	Function	Validity
1860815000	Flange	Crankshaft rotation

1. Undo bolt (anti-clockwise thread) (1a) and remove toothed drive pulley (1b).2. Undo bolts (2a) and remove crankshaft front oil seal cover with built-in oil pump (2b).- Remove the gasket.3. Undo bolt (3a) and remove timing belt fixed tensioner (3b).4. Undo bolt (4a) and remove timing belt tensioners mounting (4b).

Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH 1. Undo bolt (1a) and remove rpm sensor (1b).

1. Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C.2. Undo bolts (2a) and remove connecting rod cap (2b).3. Remove the lower connecting rod half-bearing.4. Remove the connecting rod-piston assembly.5. Remove the upper connecting rod half-bearing.

- Carry out the same operations for removing the remaining pistons. Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING - Check that the crankshaft endfloat corresponds to the recommended figures using a magnetic base and dial gauge.

Measurement	Value	Validity
Crankshaft endfloat	0.049 - 0.211 mm	2.4 JTD 20V

- 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 bolts (1a) and remove crankcase rear cover (1b) with built-in oil seal.2. Undo bolts (2a) and remove 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 bolts (7a) and remove jets (7b) from the crankcase.

- Drill and remove the water/oil sealing plugs from the crankcase to allow for washing.- Remove the engine block from the overhaul stand and place on a suitable work bench.

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 surface 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.

Measurement	Value		Validity
Cylinder head lower surface flatness	0.1 mm		1.9 JTD 8V2.4 JTD 20V

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

Measurement	Value	Validity
Cylinder liner inner diameter - Grade A	82.000 - 82.010 mm	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

Measurement	Value	Validity
Cylinder liner inner diameter - Grade B	82.010 - 82.020 mm	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

Measurement	Value	Validity
Cylinder liner inner diameter - Grade C	82.020 - 82.030 mm	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

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

Measurement	Value	Validity
Cylinder liner taper	< 0.005 mm	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

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

Measurement	Value	Validity
Cylinder liner ovality	< 0.05 mm	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

- If the cylinder bore measurements are not within the recommended limits, ream the cylinder bores following the recommended oversizes.

If reaming, ensure all the bores have the same oversize.

Measurement	Value	Validity
Cylinder liner bore diameter oversize	0.1 mm	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

- Fit the bearing caps.

The bearing caps have progressive references (from zero to five starting from the timing system side) which define the fitting position.

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

Component	Fastening	dia	Value (daNm)	Validity
Bearing caps	Bolt	M12	2.4 ÷ 2.6 + 100°	1.9 JTD 8V2.4 JTD 20V

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

Measurement	Value	Validity
Main journal seat diameter	63.705 - 63.718 mm	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

- 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.

Measurement	Value	Validity
Main journal diameter - Category A	59.994 - 60.000 mm	1.9 JTD 16V2.4 JTD 20V

Measurement	Value	Validity
Main journal diameter - Category B	59.988 - 59.994 mm	1.9 JTD 16V2.4 JTD 20V

Measurement	Value	Validity
Main journal diameter - Category C	59.982 - 59.988 mm	1.9 JTD 16V2.4 JTD 20V

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

Measurement	Value	Validity
Main journal diameter undersize	0.127 mm	1.9 JTD 16V2.4 JTD 20V

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.

- Check that the diameter of the crankpins corresponds to the recommended figures.

Measurement	Value	Validity
Crankpin diameter - Category A	50.799 - 50.805 mm	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

Measurement	Value	Validity
Crankpin diameter - Category B	50.793 - 50.799 mm	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

Measurement	Value	Validity
Crankpin diameter - Category C	50.787 - 50.793 mm	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

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

Measurement	Value	Validity
Crankpin diameter undersize	0.127 mm	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

- 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 into its seat on the crankcase.1. Fit the calibrated wire (plastigage) for measuring the bearing clearance.

Check one journal at a time, without rotating the crankshaft.

- Fit the bearing caps complete with half-bearings and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Bearing caps	Bolt	M12	2.4 ÷ 2.6 + 100°	1.9 JTD 8V2.4 JTD 20V

The bearing caps have progressive references (from zero to five starting from the timing system side) which define the fitting position.

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

Measurement	Value	Validity
Clearance between main bearings - crankshaft main journals	0.011 - 0.071 mm	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

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, being careful to take the measurements one at a time without moving the crankshaft at all.- Check that the small end bush diameter is within the recommended limits; if not, replace the worn small end bush, refer to Op. 1028H58 CONNECTING ROD SMALL END BUSH (ONE) - REPLACE

Measurement	Value	Validity
Small end bush inner diameter	26.006 - 26.014 mm	1.9 JTD 16V2.4 JTD 20V

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

Measurement	Value	Validity
Gudgeon pin outer diameter	25.982 - 25.987 mm	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

- 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.

Measurement	Value	Validity
Cylinder compression 1st piston ring gap	0.20 - 0.35 mm	1.9 JTD 16V2.4 JTD 20V

Measurement	Value	Validity
Cylinder compression 2nd piston ring gap	0.60 - 0.80 mm	1.9 JTD 16V2.4 JTD 20V

Measurement	Value	Validity
Piston oil scraper ring gap	0.25 - 0.50 mm	1.9 JTD 16V2.4 JTD 20V

- 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.

Measurement	Value	Validity
Piston outer diameter - Grade A	81.920 - 81.930 mm	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

Measurement	Value	Validity
Piston outer diameter - Grade B	81.930 - 81.940 mm	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

Measurement	Value	Validity
Piston outer diameter - Grade C	81.940 - 81.950 mm	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

Measure perpendicular to the gudgeon pin axis, 9 mm from the lower edge of the skirt.

1. Check that backlash (1a) between rings (1b) and the seats in pistons (1c) corresponds to the recommended figures.

Measurement	Value	Validity
Cylinder compression 1st piston ring endfloat	0.105 - 0.150 mm	1.9 JTD 16V2.4 JTD 20V

Measurement	Value	Validity
Cylinder compression 2nd piston ring endfloat	0.050 - 0.090 mm	1.9 JTD 16V2.4 JTD 20V

- Check that the backlash between the oil scraper ring and the housing in the piston corresponds to the recommended figures.

Measurement	Value	Validity
Engine piston oil scraper ring endfloat	0.030 - 0.070 mm	1.9 JTD 16V2.4 JTD 20V

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

Component	Fastening	dia	Value (daNm)	Validity
Connecting rod big end bearing caps	Bolt	M9	2.4 ÷ 2.6 + 60°	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

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

Measurement	Value	Validity
Big end inner diameter	53.897 - 53.909 mm	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH - Check that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it.- Fit the crankcase on the overhaul stand and secure it using the bolts.- 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 crankpin2. - 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 main journal.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 main journal.

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 category, 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).MAIN JOURNAL IDENTIFICATIONBearing grade A - Normal, diameter (mm) 59.994 - 60.000, paint mark -, numerical code 1 (94 00)°Bearing grade B - Normal, diameter (mm) 59.988 - 59.994, paint mark -, numerical code 2 (88 94)°Bearing grade C - Normal, diameter (mm) 59.982 - 59.988, paint mark -, numerical code 3 (82 88)°Bearing grade D - Undersize, diameter (mm) 59.867 - 59.873 (*), paint mark -, numerical code 6 (67 73)°Bearing grade E - Undersize, diameter (mm) 59.861 - 59.867 (*), paint mark -, code 7 (61 67)°Bearing grade F - Undersize, diameter (mm) 59.855 - 59.861 (*), paint mark -, code 8 (55 61)°(*) 0.127 mm undersize(°) Last two numbers (thousandth part) of the main journal dimensionsIn the case of using 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 bearing, it is necessary to select the pair or 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 the clearance between the main journal and the half-bearing, obtained through the selection method indicated above, should generally 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 (plastigage). - Place the lubrication jets back in their housings and secure them to the crankcase using the bolts.- Fit the crankshaft in the crankcase.1. Fit the bearing caps complete with half-bearings and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Bearing caps	Bolt	M12	2.4 ÷ 2.6 + 100°	1.9 JTD 8V2.4 JTD 20V

The bearing caps have progressive references (from zero to five starting from the timing system side) which define the fitting position.

- Fit the tool for rotating the crankshaft.

Tool	Description	Function	Validity
1860815000	Flange	Crankshaft rotation

- Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C.1. Fit piston-connecting rod assembly (1a) complete with half-bearing using 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 connecting rod cap (2a) complete with half-bearing and secure it without tightening bolts (2b).

Fit the connecting rods so that the number stamped on each rod faces toward the same side as the number stamped on the big end (inlet side).

- For the remaining cylinders, carry out the same operations to refit the pistons and connecting rods.

1. Test the crankpin clearance by applying plastigage to measure crankpin installation clearance.

- Tighten connecting rod cap bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Connecting rod big end bearing caps	Bolt	M9	2.4 ÷ 2.6 + 60°	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

- Undo the bolts and remove the connecting rod caps complete with half-bearings.1. Using an appropriate graduated measuring tool (1a), measure the clearance indicated by plastigage (1b).

Measurement	Value	Validity
Clearance between crankpins - crankshaft bearings	0.016 - 0.070 mm	2.4 JTD 20V

- If the value measured is not within the recommended figures, replace the connecting rod bearings.- Carry out this test on all the crankpins, one at a time, without ever turning the crankshaft.- Fit the connecting rod caps complete with half bearings and tighten the bolts.- Tighten connecting rod cap bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Connecting rod big end bearing caps	Bolt	M9	2.4 ÷ 2.6 + 60°	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

- Remove the flange for rotating the crankshaft.- Place the crankcase rear cover with integrated oil seal in position and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Flywheel side oil seal cover	Bolt (pretreated to be replaced)	M6	(engine block side) 0.8 - 1.0	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

- Place the crankcase front cover complete with oil pump and gasket in its seat and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Crankshaft oil seal front cover	Bolt (pretreated to be replaced)	M6	(engine block side) 0.8 - 1.0	1.9 JTD 16V2.4 JTD 20V

- Refit the engine oil intake duct complete with O-ring in its housing and secure it by tightening the bolts to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil intake	Bolt	M6	(oil pump side) 0.9	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

- Apply silicon sealant to the entire perimeter of the oil sump.- Place the oil sump back in its housing.- Tighten the bolts securing the oil sump to the crankcase to the recommended torque using the tool.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump	Front and rear bolts	M8	2.5	2.4 JTD 20V

Tool	Description	Function	Validity
1860834000	Spanner	Loosen/ tighten front and rear crankcase sump bolts	2.4 JTD 20V

- Tighten the bolts securing the oil sump to the crankcase front and rear covers to the recommended torque using the tool.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump	Side bolts	M6	0.9	2.4 JTD 20V

Tool	Description	Function	Validity
1860833000	Spanner	Loosen/ tighten the bolts securing the crankcase sump, timing side and gearbox side	1.9 JTD 8V2.4 JTD 20V

- Fit the tool for rotating the crankshaft.

Tool	Description	Function	Validity
1860815000	Flange	Crankshaft rotation

- Position the timing belt toothed drive pulley in its housing and tighten the bolt (anti-clockwise thread) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Toothed drive pulley	Left hand bolt	M16	(crankshaft side) 32.3 - 35.7	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

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.

Tool	Description	Function	Validity
1820253000	Dial gauge support	Measure the piston projection/valve recess in relation to the cylinder head plane	1.9 JTD 8V2.4 JTD 20V

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

Measurement	Value		Validity
Cylinder head gasket size with average maximum piston projection	projection -0.020 - +0.100 mmthickness (no opening) 0.82 ± 0.05 mm		1.9 JTD 16V2.4 JTD 20V

Measurement	Value		Validity
Cylinder head gasket size with average maximum piston projection	projection +0.101 - +0.200 mmthickness (one opening) 0.92 ± 0.05 mm		1.9 JTD 16V2.4 JTD 20V

Measurement	Value		Validity
Cylinder head gasket size with average maximum piston projection	projection +0.201 - +0.295 mmthickness (two openings) 1.02 ± 0.05 mm		1.9 JTD 16V2.4 JTD 20V

- Place the cylinder head centering bushes on the cylinder block.- Fit the cylinder head gasket selected.- Position the cylinder head on the cylinder block/crankcase.1. Tighten the cylinder head bolts to the specified torque.

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

Component	Fastening	dia	Value (daNm)	Validity
Camshaft housing	Bolt	M8	(cylinder head side) 2.3 - 2.8	1.9 JTD 16V2.4 JTD 20V

The value of 2 daNm in the table above is a tightening value for all the bolts following the order illustrated in the diagram.

- Position the rpm sensor in its housing and secure it using the bolt.- Place the timing belt tensioner mount in its housing and secure it using the bolt.- Place the timing belt fixed tensioner in its housing and secure it using the bolt.- Fit the pressure pump mounting complete with pump and secure it using the bolts.- Place the oil filter mounting complete with a new O-rings back in its housing and secure it to the crankcase using the bolts.- Place the oil pipes complete with a new O-rings back in their housing and secure them to the oil filter mounting using the bolts.- Tighten the bolt securing the oil pipe support bracket to the sump.- Place the engine oil dipstick pipe back in its housing and fasten it with the bolts.- Connect the pressure pump fuel return flexible pipe, return manifold side and tighten the band.- Fit the swirl valves command mechanism back into its housing and secure it using the bolts.- Connect the swirl valves control arm.- Place the vacuum reservoir back in its housing and secure it using the nuts.- Position the bracket complete with oil vapour separator and pipes, then secure it using the bolts.- Connect the condensed oil discharge pipe into the sump and tighten the band.- Connect the condensed oil discharge pipe to the oil filter mounting and tighten the band.- Connect the oil vapour intake pipe to the crankcase and tighten the band.- Place the timing belt side guard in its housing and secure it using the bolts.1. Remove plugs (1a) and fit camshaft timing tools (1b) on the camshaft housing.

Check that the tools marked "A" are correctly fitted in the seats on the camshafts.

Tool	Description	Function	Validity
1870986900	Templates	Camshaft timing adjustment	2.4 JTD 20V

- Remove the timing tool, camshaft side, and tighten the plug.- Fit a new upper cylinder head gasket in position.- Position the camshaft housing and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Camshaft housing	Bolt	M8	(cylinder head side) 2.3 - 2.8	1.9 JTD 16V2.4 JTD 20V

- Loosen the bolt fixing the exhaust side timing belt toothed drive pulley.1. Undo the bolt fixing the crankcase front cover shown in the diagram.- Temporarily fit the toothed timing drive belt on the toothed drive pulley.2. Fit tool (2a) and fasten it using 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.

Tool	Description	Function	Validity
2000003000	Template	Engine tuning	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

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

Component	Fastening	dia	Value (daNm)	Validity
Timing moving tensioner	Nut	M8	2.3 ÷ 2.8	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

- Tighten the bolt fixing the exhaust side timing belt toothed drive pulley to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Driven toothed pulley	Bolt	M12	(camshaft side) 2.9 - 3.2 + 40°	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

- Remove the camshaft timing tools, exhaust and crankshaft side.- Rotate the crankshaft through two turns and check again that the timing is correct by refitting the timing tools removed previously.- Check the collimation of the reference marks for the tensioning of the timing belt tensioner and remove the timing tools.- Tighten the bolt fixing the crankcase front cover removed previously.- Tighten the plug on the upper cylinder head for fitting the exhaust-side timing tool.- Connect the oil vapour pipe to the oil inlet duct and secure with the band.- Fit the injectors and brackets in their seats and tighten the nuts.

Start the assembly with the injector on the fifth cylinder and follow the sequence until the first cylinder.

- Place the fuel return pipe back in place and connect it to the injectors and the return manifold pipe.- Place the single fuel manifold in its housing and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Single fuel manifold pipe (rail)	Bolt	M8	(cylinder head extension side) 2.3 - 2.8	1.9 JTD 16V2.4 JTD 20V

- Connect the return pipe to the single fuel manifold and secure it with the band.- Place new rigid pipes from the fuel manifold to the injectors in their housing and tighten the connectors to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Pipes from fuel manifold to injectors	Connector	M14	(fuel manifold side) 2.2 - 2.4	1.9 JTD 16V2.4 JTD 20V

Component	Fastening	dia	Value (daNm)	Validity
Pipes from fuel manifold to injectors	Connector	M12	(injector side) 2.4 - 2.6	1.9 JTD 16V2.4 JTD 20V

- Place a new rigid pipe between the pump and the single fuel manifold back in its housing and tighten the connectors to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Pipe from pressure pump to fuel manifold	Connector	M14	(fuel manifold side) 2.2 - 2.4	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

Component	Fastening	dia	Value (daNm)	Validity
Pipe from pressure pump to fuel manifold	Connector	M12	(pressure pump side) 2.2 - 2.4	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

- Place the rigid vacuum pipes in their housings and secure them using the bolts.- Pressure fit the flexible pipes to the vacuum pump and vacuum tank.- Refit the auxiliary drivebelt pulley and secure by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Services pulley on crankshaft	Bolt	M8	(crankshaft side) 2.3 - 2.5	2.4 JTD 20V

- Place the timing side power unit rigid support in position and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support	Bolt	M10	(engine crankcase side) 4.5 - 5.5	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support	Bolt	M8	(engine crankcase side)2.3 ÷ 2.7	2.4 JTD 20V

- Refit the timing belt guard and secure it using the bolts.- Place the exhaust manifold assembly, complete with new gasket, back in its housing and secure it by tightening the nuts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Exhaust manifold	Nut	M8	(turbocharger side) 2.3 - 2.8	2.4 JTD 20V

- Connect the flexible exhaust gas coupling to the heat exchanger and secure it with the collar.- Tighten the nut securing the pre-catalyzer intermediate mounting bracket.- Connect the turbocharger lubricaton oil delivery pipe to the crankcase and tighten the connector to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil supply pipe to turbocharger - crankcase side	Connector	M12	2.2 ÷ 2.7	1.9 JTD 8V2.4 JTD 20V

- Connect the turbocharger lubrication oil outlet pipe to the sump and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil supply pipe from turbocharger	Bolt	M6	(engine block side) 0.8 - 1.0	2.4 JTD 20V

- Place the exhaust manifold heat shield in its housing and tighten the fastenings.- Place the turbocharger air inlet rigid sleeve complete with new gasket in position and secure it using the bolts.- Place the mounting complete with hydraulically assisted steering pump back in its housing and secure it using the bolts.- Place the alternator in position and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
ALTERNATOR	Bolt	M12x1.25x120	6.3 ÷ 7.7	2.4 JTD 20V

Component	Fastening	dia	Value (daNm)	Validity
ALTERNATOR	Bolt	M10x1.25x45	4.5 ÷ 5.5	2.4 JTD 20V

- Place the alternator guard in position and secure it to the mounting using the bolt.- Temporarily fit the alternator drive belt.- Place the air conditioning compressor back in its housing and secure it both to the alternator drive belt and the mounting, tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
COMPRESSOR	Bolt	M8x90	2.2 ÷ 2.6

- Place the auxiliary drivebelt automatic tensioner in position and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine components single belt moving tensioner	Bolt	M8	2.3 ÷ 2.5	2.4 JTD 20V

- Fit and tension the single auxiliary drivebelt by working on the automatic tensioner using the tool.

Tool	Description	Function	Validity
1860966000	Spanner	Loosen the single engine components drive belt tension	2.4 JTD 20V

- Secure the electrical connection for the E.G.R. command solenoid.- Secure the electrical connection for the fuel flow regulator on the pressure pump.- Secure the electrical connection for the engine oil pressure switch.- Secure the electrical connection for the engine oil level sensor.- Secure the electrical connection for the rpm sensor.- Secure the electrical connection for the swirl solenoid.- Secure the electrical connection for the throttle casing.- Attach the electrical connection for the coolant temperature sensor.- Secure the electrical connection for the fuel pressure sensor.- Secure the electrical connection for the pressure relief sensor.- Secure the electrical connections for the spark plugs.- Secure the electrical connection for the pressure regulator on the single fuel manifold.- Refit the wiring retaining channel and secure with bolts.- Secure the electrical connections for the injectors.- Secure the electrical connection for the timing sensor.- Secure the electrical connection for the alternator.- Secure the electrical connection for the compressor.- Place the alternator power supply cable back in its housing and secure it using the nut.- Secure the engine wiring using the various retaining clips.- Place the oil vapour pipe back in its housing, secure it to the water pump rigid return pipe and the intake chamber by tightening the bolts.- Connect the oil vapour pipe to the seperator and secure with the band.