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 rigid power unit support (1b).2. Undo the bolt (2a) and remove the auxiliary unit drive belt (2b).
1. Undo the bolt (1a) using the tool (1b) for counter-torque and remove the crankshaft pulley (1c).| Tool | Description | Function | Validity |
|---|
| 2000001000 | Counter-torque | Loosen/ tighten bolt securing crankshaft pulley | 1.9 JTS2.2 JTS |
2. Undo the bolts (2a) and remove the timing chain cover (2b).- Remove the gasket.
1. Undo the bolt (1a) and remove the timing chain fixed pad (1b).
1. Undo the bolt (1a) and remove the moving pad (1b) and the timing chain (1c).
1. Release the timing chain toothed wheel.2. Undo the bolt (2a) and remove the timing chain (2b) lubrication jet.
1. Undo the bolts (1a) and remove the counter-balance shaft chain hydraulic belt tensioner (1b).
1. Undo the bolts (1a) and remove the three counter-balance shaft chain pads (1b).2. Remove the counter-balance shaft chain.3. Release the counter-balance shaft chain toothed wheel.
1. Undo the bolts (1a) and remove the two counter-balance shafts (1b). | The inlet side counter-balance shaft has a green paint mark and the exhaust side one has a white paint mark. |
1. Undo the bolts (1a) and remove the water pump gear (1b).
1. Undo the fastenings (1a) and remove the thermostat complete with coolant temperature sensor and rigid supply pipe to the water pump (1b).
1. Undo the fastenings (1a) and remove the water pump cover (1b).
1. Undo the bolts (1a) and remove the pump casing (1b).
1. Undo the bolts (1a) and remove the intermediate shaft support (1b).
1. Undo the fastenings and remove the heat exchanger (1a) and mounting (1b).
1. Undo the bolts (1a) and remove the catalytic converter mounting bracket (1b).
1. Undo the bolts (1a) and remove the power steering pump (1b).2. Undo the bolts (2a) and remove the alternator (2b).
1. Undo the bolt (1a) and remove the rpm sensor (1b).2. Undo the bolt and remove the detonation sensor.3. Undo and remove the engine oil pressure warning light switch.
1. Undo and remove the engine oil filter cartridge cap.
- Check that the crankshaft endfloat corresponds to the recommended figures using a magnetic base and dial gauge.| Measurement | Value | Validity |
|---|
| Crankshaft endfloat | | 1.9 JTS2.2 JTS |
1. Undo the outer bolts (1a), undo the double row of inner bolts (1b) and remove the sealant at the two preset points (1c) and remove the panel under the crankcase (1d).
| Pay attention to the fitting position of the panel under the crankcase. |
- Remove the flywheel side crankshaft seal.
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).3. Remove the crankshaft.4. Remove the crankshaft half bearings (4a) and the thrust washers (4b).- Remove the locating bushes from the cylinder block/crankcase. | Mark the connecting rod and cap and pay attention to the cylinder sequence. The breaking surfaces of the connecting rod and the cap match individually and therefore cannot be swapped or damaged. Do not exert pressure to the breaking surfaces. |
1. Undo the engine oil duct plugs (1a) and the water duct plugs (1b).
Refitting
(
Removing
)
- Wash all the dismantled components thoroughly.- Clean the matching surfaces between the oil sump and the panel under the crankcase and between the panel under the crankcase and the crankcase.- Refit the threaded plugs for the water and engine oil ducts.- Lubricate all the mechanical components with engine oil.- Visually check that the cylinder head support surface does not have cracks or superficial grooves.- Check that the internal diameter of the cylinder liners is within the recommended limits.| Measurement | Value | Validity |
|---|
| Cylinder liner bore | 85.992 - 86.008 mm | 1.9 JTS2.2 JTS |
| Measurement | Value | Validity |
|---|
| Cylinder liner oversize | 86.117 - 86.133 mm | 1.9 JTS2.2 JTS |
- Check that the diameter of the main journals corresponds to the recommended figures.| Measurement | Value | Validity |
|---|
| Main journal diameter | 55.994 - 56.008 mm | 1.9 JTS2.2 JTS |
- Check that the diameter of the crankpins corresponds to the recommended figures.| Measurement | Value | Validity |
|---|
| Crankpin diameter | 49.000 - 49.014 mm | 1.9 JTS2.2 JTS |
- Check the matching between the gudgeon pin and the housing in the piston; it should be possible to insert the pin simply by pressing 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.| Measurement | Value | Validity |
|---|
| Gudgeon pin outer diameter | | 1.9 JTS2.2 JTS |
- 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 - 0.350 mm | 1.9 JTS2.2 JTS |
| Measurement | Value | Validity |
|---|
| Cylinder compression 2nd piston ring gap | 0.35 - 0.55 mm | 1.9 JTS2.2 JTS |
| Measurement | Value | Validity |
|---|
| Piston oil scraper ring gap | 0.38 ÷ 1.150 | 1.9 JTS2.2 JTS |
- The size of the seals is given below.| Measurement | Value | Validity |
|---|
| Cylinder compression 1st piston ring thickness | 1.17 - 1.19 mm | 1.9 JTS2.2 JTS |
| Measurement | Value | Validity |
|---|
| Cylinder compression 2nd piston ring thickness | 1.47 - 1.49 mm | 1.9 JTS2.2 JTS |
| Measurement | Value | Validity |
|---|
| Piston oil scraper ring thickness | 0.986 - 1.960 mm | 1.9 JTS2.2 JTS |
- 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 (8 mm from the bottom) | 85.957 - 85.972 mm | 1.9 JTS2.2 JTS |
- The clearance between the pistons and the liner/bore is given below.| Measurement | Value | Validity |
|---|
| Piston - cylinder bore clearance | 0.020 - 0.051 mm | 1.9 JTS2.2 JTS |
- 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 with oversize ones.| Measurement | Value | Validity |
|---|
| Cylinder compression 1st piston ring endfloat | 0.040 - 0.080 mm | 1.9 JTS2.2 JTS |
| Measurement | Value | Validity |
|---|
| Cylinder compression 2nd piston ring endfloat | 0.030 - 0.068 mm | 1.9 JTS2.2 JTS |
| Measurement | Value | Validity |
|---|
| Engine piston oil scraper ring endfloat | 0.063 - 0.172 mm | 1.9 JTS2.2 JTS |
- Check the main half bearings, noting that the half-bearings should not be adapted. Replace them if scoring or signs of binding are noted.- Fit the main bearing halves in their seats on the upper crankcase, aligning the lubrication holes and ensuring scrupulous cleanliness. The centre crankshaft bearing has thrust half-washers incorporated becuase it acts as a thrust carrier.- If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions.1. Place the crankshaft in its housing.2. Fit the calibrated wire for measuring the bearing clearance.
- Fit the main journal half-bearings in the lower cylinder block/crankcase.1. Fit the lower crankcase on the upper one.2. Tighten bolts (2a) and bolts (2b) securing the lower crankcase.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Lower engine crankcase | Bolt | M8 x 1.25 | (outer side) 2.3 | 1.9 JTS2.2 JTS |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Lower engine crankcase | Bolt | M10 x 1.5 | (inner side) 2.0 +70° +15° | 1.9 JTS2.2 JTS |
- Bolt tightening sequence (I = M10; II = M8)
1. Remove the lower crankcase and check the crankpin clearance. Use an appropriate gauge to measure the width of the plastigage. | Check one main journal at a time, without rotating the crankshaft. |
| Measurement | Value | Validity |
|---|
| Clearance between main bearings - crankshaft bearings | | 1.9 JTS2.2 JTS |
- After having checked all the main journals, apply a bead of sealant about 2 - 5 mm thick in the splining in the crankcase and then proceed with the definitive fitting of the lower crankcase tightening the bolts to torque following the order given previously.- Fit the flywheel side crankshaft seal.- Rotate the engine through 180° on the overhaul stand.- Fit the connecting rod-piston assemblies complete with half bearings in the cylinder liners/bores.- Rotate the engine through 180° on the overhaul stand.1. Apply the calibrated wire for measuring the crankpin clearance.
1. Fit the connecting rod caps (1a) complete with half-bearings (1b) and secure by tightening the new bolts (1c) to the specified torque using the torque wrench (1d).| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Connecting rod big end bearing caps | Bolt | M8 | 2.5 + 50° + 50° + 10° | 1.9 JTS2.2 JTS |
1. Remove the connecting rod caps and check the crankpin clearance. Use an appropriate gauge to measure the width of the plastigage.| Measurement | Value | Validity |
|---|
| Clearance between connecting rod bearings - crankshaft bearings | | 1.9 JTS2.2 JTS |
- If the value measured is not within the recommended figures, replace the connecting rod bearings.- Refit the connecting rod caps complete with half-bearings and secure them by tightening the bolts to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Connecting rod big end bearing caps | Bolt | M8 | 2.5 + 50° + 50° + 10° | 1.9 JTS2.2 JTS |
- Fit a new engine oil filter cartridge.- Fit the detonation sensor.- Fit the engine rpm sensor.- Fit the engine oil pressure warning light switch.- Place the starter motor in position and secure it.- Place the alternator in its housing and secure it.- Position the pump casing in its housing with the pulley and secure it.- Fit two new seals on the water pump rigid supply pipe.- Place the thermostat in its housing complete with water pump supply pipe and secure it.- Place the two counter-balance shafts in their housing and secure them.1. Fit the toothed wheel (1a), fit the chain (1b) aligning the copper mesh (a) with the arrow on the toothed wheel (1c), the silver mesh (1b) with the letters C-R on the toothed wheel (1a) and lastly the silver mesh (c) with the arrow on the toothed wheel (1d).2. Place the fixed chain tensioner pads (2a) and the moving pad (2b) in their housings.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Water pump/balancing shafts drive chain pad(s) | Bolt | M6 | (engine block side) 0.7 - 0.9 | 1.9 JTS2.2 JTS |
- Preload the hydraulic tensioner for the counter-balance shaft chain and fit it at the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Water pump/balancing shafts drive chain hydraulic tensioner | Bolt | M6 | (engine block side) 0.7 - 0.9 | 1.9 JTS2.2 JTS |
- Fit the chain lubrication jet.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Timing chain lubrication jet | Bolt | M | (engine block side) 1.0 | 1.9 JTS2.2 JTS |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Cylinder head | Bolt | M11 | (engine block side) 2.7 - 3.3 + 100° + 65° | 1.9 JTS2.2 JTS |
| Tool | Description | Function | Validity |
|---|
| 1860942000 | Torque wrench | Tighten bolts to torque plus angle | |
- Place the heat exchanger in its housing with the mounting and tighten the bolts to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Engine oil heat exchanger | Bolt | M | (support side) | 1.9 JTS2.2 JTS |
- Place the catalytic converter mounting bracket in its housing and secure it using the bolts.- Place the alternator in position and secure it tightening the bolts to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| ALTERNATOR | Bolt | M12x1.75x90 | 6.3 ÷ 7.7 | 1.9 JTD 8V1.9 JTD 16V |
- Position the power assisted steering pump in its housing and secure it tightening the bolts to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Power assisted steering pump | Bolt | M8 | (cylinder head side) 1.9 - 2.1 | 1.9 JTS2.2 JTS3.2 JTS |
- Place the rpm sensor in its housing and tighten the bolt.- Place the detonation sensor in its housing and tighten the bolt.- Place the engine oil pressure switch in its housing and tighten it.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Power assisted steering pump | Bolt | M8 | (cylinder head side) 1.9 - 2.1 | 1.9 JTS2.2 JTS3.2 JTS |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Timing fixed chain tensioner pad | Upper bolt | M6 | (cylinder head side) 0.8 | 1.9 JTS2.2 JTS |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Cap for timing fixed chain tensioner pad upper bolt | - | M22 | 6.5 | 1.9 JTS2.2 JTS |
- Place the tappet cover complete with gasket back in its housing and secure it by tightening the bolts to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Tappet cover | Bolt | M6 | (cylinder head side) 0.7 - 0.9 | 1.9 JTS2.2 JTS |
- Place the electronic power module in its housing and secure it tightening the bolts to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Ignition coil module | Bolt | M6 | (tappet cover side) 2.2 | 1.9 JTS2.2 JTS |
1. Fit a new oil seal (1a) on the timing chain cover using the tool (1b). | Before installation, spread the lip of the new seal lightly with white silicone grease. |
| Tool | Description | Function | Validity |
|---|
| 1860099000 | Fitting tool | Fitting timing chain cover oil seal | 1.9 JTS2.2 JTS |
- Place the crankshaft front oil seal cover in its housing and secure it tightening the bolts to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Crankshaft oil seal front cover | Bolt | M8 | (engine block side) 2.1 | 1.9 JTS2.2 JTS |
- Place the crankshaft pulley in its housing.- Tighten a new bolt securing the crankshaft pulley to the recommended torque using the tool for counter-torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Services pulley on crankshaft | Bolt (to be replaced) | M14 | (crankshaft side) 9.0 - 11.0 + 75° | 1.9 JTS2.2 JTS |
| Tool | Description | Function | Validity |
|---|
| 2000001000 | Counter-torque | Loosen/ tighten bolt securing crankshaft pulley | 1.9 JTS2.2 JTS |
