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 idler gears (1b) for the timing drive chains. | The words "LB FRONT" (left gear) and "RB FRONT" (right gear) are stamped on the idler gears for the correc refitting. |
2. Remove the primary timing chain drive gear.3. Undo the bolts (3a) and remove the fixed pad (3b).4. Undo the bolts (4a) and remove the engine oil pump (4b).
1. Undo the bolts (1a) and remove the connecting rod caps (1b) complete with half-bearings.2. Remove the piston and connecting rod assemblies complete with half-bearings.
1. Remove the tool fitted previously.| Tool | Description | Function | Validity |
|---|
| 1860815000 | Flange | Loosen/ tighten the bolt fixing the services pulley on the crankshaft | 3.2 JTS |
2. Undo the bolts (2a), then remove the flywheel side oil seal cover (2b). | Cut the sealant between the flywheel side oil cover and the engine crankcase. |
- Check that the crankshaft endfloat corresponds to the recommended figures using a magnetic base and dial gauge.| Measurement | Value | Validity |
|---|
| Crankshaft endfloat (mm) | 0.100 ÷ 0.330 | 3.2 JTS |
1. Undo the bolts (1a), (1b) and (1c), then remove the main journal caps (1d) complete with half-bearings.
1. Remove the crankshaft.- If necessary, remove the pin for the primary timing chain drive gear from the crankshaft.2. Remove the main journal half-bearings.3. Remove the thrust washers (together with the third main journal half-bearing).
1. Undo the nuts (1a) and remove the piston cooling jets (1b).
1. Unscrew bolt (1a) and bolts (1b) and remove the thermostat (1c) complete with pipe (1d).
1. Undo the bolts (1a) and remove the detonation sensors (1b).2. Undo the bolt (2a) and remove the rpm sensor (2b).
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 - 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 mating surfaces.- 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 internal diameter of the cylinder liners is within the recommended limits.| Measurement | Value | Validity |
|---|
| Cylinder liner inner diameter (mm) | 88.992 ÷ 89.008 | 3.2 JTS |
- Check that the ovality of the cylinder liners is within the recommended limits.| Measurement | Value | Validity |
|---|
| Cylinder liner ovality - permitted (mm) | 0.013 | 3.2 JTS |
- Check that the diameter of the main journals corresponds to the recommended figures.| Measurement | Value | Validity |
|---|
| Main journal diameter (mm) | 67.992 ÷ 68.008 | 3.2 JTS |
- 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 (mm) | 0.25 | 3.2 JTS |
- Check that the diameter of the crankpins corresponds to the recommended figures.| Measurement | Value | Validity |
|---|
| Crankpin diameter (mm) | 55.992 ÷ 56.008 | 3.2 JTS |
- If the diameter of the crankpins is not correct, they should be reground to the recommended undersize.| Measurement | Value | Validity |
|---|
| Crankpin diameter undersize (mm) | 0.25 | 3.2 JTS |
- Check that the inner diameter of the small end bushes corresponds to the recommended figures.| Measurement | Value | Validity |
|---|
| Small end bush inner diameter (mm) | 24.007 ÷ 24.021 | 3.2 JTS |
- 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 as specified.| Measurement | Value | Validity |
|---|
| Piston pin outer diameter (mm) | 23.997 ÷ 24.000 | 3.2 JTS |
- Fit the sealing rings in the cylinder liner and check the gap between the seal ends is within specified limits.| Measurement | Value | Validity |
|---|
| Cylinder compression 1st piston ring gap (mm) | 0.200 ÷ 0.350 | 3.2 JTS |
| Measurement | Value | Validity |
|---|
| Cylinder compression 2nd piston ring gap (mm) | 0.350 ÷ 0.500 | 3.2 JTS |
| Measurement | Value | Validity |
|---|
| Piston oil scraper ring gap (mm) | 0.250 ÷ 0.750 | 3.2 JTS |
- Check that the outer diameter of the pistons is as specified.| Measurement | Value | Validity |
|---|
| Piston outer diameter (mm) | 88.956 ÷ 88.974 | 3.2 JTS |
| The outer diameter of the piston is measured 30 mm below the piston crown and at a right angle to the direction of the gudgeon pin. |
- Check that the axial clearance between the pistons rings and the seats on the piston corresponds to the recommeded figures.| Measurement | Value | Validity |
|---|
| Cylinder compression 1st piston ring endfloat (mm) | 0.030 ÷ 0.065 | 3.2 JTS |
| Measurement | Value | Validity |
|---|
| Cylinder compression 2nd piston ring endfloat (mm) | 0.015 ÷ 0.060 | 3.2 JTS |
| Measurement | Value | Validity |
|---|
| Oil scraper ring endfloat (mm) | 0.030 ÷ 0.170 | 3.2 JTS |
- Check that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it. Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING 1. Place the piston cooling jets (1a) back in their housings and secure them using the nuts (1b).| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Piston cooling jet | Nut | - | 1.0 | 3.2 JTS |
- Check that the half-bearings show no signs of grooves or traces of seizing. | No adjustment operations whatsoever should be carried out to the half-bearings. |
1. Place the half-bearings in their seats in the engine block. | Great care should be taken over cleanliness when refitting. |
2. Place the crankshaft in its housing.
1. 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 bolts (1b), (1c) and (1d) 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 bearing caps are also marked with an arrow pointing towards the timing side. |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Bearing cap | Outer upper bolt | - | 1.5 + 110 ° | 3.2 JTS |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Bearing cap | Inner upper bolt | - | 2.0 + 80 ° | 3.2 JTS |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Bearing cap | Side bolt (to be replaced) | - | 3.0 + 60 ° | 3.2 JTS |
1. Remove the bearing cap fitted previously and, using a suitable graduated measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).| Measurement | Value | Validity |
|---|
| Clearance between main bearings - crankshaft main journals (mm) | 0.010 ÷ 0.060 | 3.2 JTS |
| Measure the clearance for all the bearings taking care to take the measurements one at a time without moving the crankshaft at any time. |
- Place the half-bearings in their seats.- Place the thrust washers in their seats together with the third main half-bearing. | 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-bearings, back in their housing and secure it tightening the bolts (1b), (1c) and (1d) to the recommended torque following the tightening order given. | The bearing caps are marked with a progressive number (from one to four starting from the timing side) which defines the fitting position.The bearing caps are also marked with an arrow pointing towards the timing side. |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Bearing cap | Outer upper bolt | - | 1.5 + 110 ° | 3.2 JTS |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Bearing cap | Inner upper bolt | - | 2.0 + 80 ° | 3.2 JTS |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Bearing cap | Side bolt (to be replaced) | - | 3.0 + 60 ° | 3.2 JTS |
Upper internal bolts tightening order
Upper external bolts tightening order
Side bolts tightening order
1. Apply silicone sealant to the mating surface of the flywheel side oil seal cover and engine crankcase.
1. Place the flywheel side oil seal cover (1a) back in its housing using the bolts (1b) fixing the engine crankcase sump as a guide for positioning it correctly.2. Tighten the remaining bolts securing the flywheel side oil seal cover to the engine crankcase.- Remove the bolts used as a guide and, in their place, screw in the bolts securing the oil seal cover to the engine crankcase and tighten them together with those fitted already.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Flywheel side oil seal cover | Bolt | - | 1.0 | 3.2 JTS |
- Place the piston-connecting rod assemblies in their housings complete with half-bearings using a suitable tool. | The letters "R" (right) for the right cylinder head and "L" (left) for the left cylinder head are satemped on the piston crown. The connecting rod-piston assemblies are fitted with the arrows stamped on the piston crown pointing towards the timing side and the stamp on the connecting rod pointing towards the right side of the engine. |
- Fit the tool for rotating the crankshaft.| Tool | Description | Function | Validity |
|---|
| 1860815000 | Flange | Loosen/ tighten the bolt fixing the services pulley on the crankshaft | 3.2 JTS |
- Rotate the crankshaft so that the connecting rod pins are accessible.1. Fit the calibrated wire (plastigage) for measuring the bearing clearance.
1. Place the bearing cap (1a), complete with half-bearings, back in its housing and secure it tightening the nuts (1b) to the recommended torque. | The references on the connecting rod cap and the big end should be on the same side. |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Crank pin cap | Bolt | - | 3.0; relase; 2.5 + 110 ° | 3.2 JTS |
1. Remove the bearing cap fitted previously and, using a suitable graduated measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).| Measurement | Value | Validity |
|---|
| Clearance between connectring rod bearings - crankpins (mm) | 0.010 ÷ 0.070 | 3.2 JTS |
| Carry out the operation of measuring the clearance for all the bearings, taking care to do it, one at a time. |
- Rotate the crankshaft so that the connecting rod pins 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 references on the connecting rod cap and the big end should be on the same side. |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Crank pin cap | Bolt | - | 3.0; relase; 2.5 + 110 ° | 3.2 JTS |
1. Place the rpm sensor (1a) in its housing and secure it using the bolts (1b).| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Rpm sensor | Bolt | - | 1.0 | 3.2 JTS |
2. Place the detonation sensors (2a) in their housings and secure them using the bolts (2b).| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Detonation sensor | Bolt | - | 2.3 | 3.2 JTS |
1. Place the thermostat (1a) in its housing complete with pipe (1b) and secure it using the bolts (1c).| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Thermostat | Bolt | - | 1.0 | 3.2 JTS |
2. Tighten the bolt fixing the engine cooling system rigid pipe bracket.
1. Place the engine oil pump (1a) in position and secure it using the bolts (1b).| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Engine oil pump | Bolt | - | 2.3 | 3.2 JTS |
2. Place the fixed pad (2a) in its housing on the oil pump and secure it using the bolts (2b).| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Main timing chain fixed pad | Bolt | - | 5.8 | 3.2 JTS |
3. Place the primary timing chain drive gear in its housing. | Position the shaft in such a way that the ball on the gear is aligned with the one at the bottom right of the oil pump cover. |
4. Place the idler gears (4a) for the timing drive chains in their housings and secure them using the bolts (4b).| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Timing drive chain idler gear | Bolt | - | 5.8 | 3.2 JTS |
| The words "LB FRONT" (left gear) and "RB FRONT" (right gear) are stamped on the idler gears for the correc refitting. |
- Refit the crankcase sump locating bushes in their seats.1. Apply silicon sealant to the engine crankcase.
- Position the crankcase sump in its housing and secure it tightening the bolts to the recommended torque. | Follow the tightening order illustrated in the diagram. |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Engine oil sump | Bolt | M6 | 1.0 | 3.2 JTS |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Engine oil sump | Bolt | M8 | 2.3 | 3.2 JTS |
- Place the engine oil filter mounting and heat exchanger in position complete with a new gasket and secure it using the bolts.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Engine oil filter and heat exchanger mounting | Bolt | - | 2.3 | 3.2 JTS |
- Rotate the engine through 180 ° on the overhaul stand.- Refit the right cylinder head locating bushes in their seats.- Place the right cylinder head gasket in position.- Place the right cylinder head in position.- Tighten the bolts securing the right cylinder head to the recommended torque. | Follow the order shown in the figure for each tightening sequence. |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Right cylinder head | Bolt | M11 | 4.5 + 120 ° | 3.2 JTS |
- Refit the left cylinder head locating bushes in their seats.- Place the left cylinder head gasket in position.- Place the left cylinder head in position.1. Tighten the bolts (1a) and (1b) securing the right cylinder head to the recommended torque. | Follow the order shown in the figure for each tightening sequence. |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Left cylinder head | Bolt | M11 | 4.5 + 120 ° | 3.2 JTS |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Left cylinder head | Bolt | M8 | 1.5 + 60 ° | 3.2 JTS |
1. Place the left cylinder head phase transformers (1a) in their housings and secure them tightening the bolts (1b) to the recommended torque. | Use a spanner on the hexagonal bolts on the camshafts to provide counter-torque. |
| The words IN (inlet) and EX (exhaust) are stamped on the phase transformers to identify the fitting side. |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Phase transformer | Bolt | - | 5.8 | 3.2 JTS |
- Place the engine oil dipstick pipe back in its housing and fasten it with the bolt.- Place the engine oil dipstick back in its housing.- Prepare the hydraulic tensioner for the secondary timing chain for the left cylinder head following the instructions given below.- Insert the piston in the hydraulic tensioner body.- Compress the piston in the hydraulic tensioner body rotating it and locking it in the end of travel position.- Slowly release the pressure on the hydraulic tensioner piston. | The hydraulic tensioner piston should remain in the compressed position. |
1. Fit the left cylinder head secondary timing chain. | The oil pump upper bolt must be removed in order to carry out this operation. |
| Position the chain so that the following conditions are adhered to:- the black mesh (1a) should be aligned with the opening (1b) in the idler gear through which it can be seen;- the back mesh (1c) should be aligned with the balls (1d) and the letters "L" stamped on the phase transformers. |
2. Place the fixed pad (2a) in its housing and secure it using the bolts (2b).| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Secondary chain fixed pad | Bolt | - | 2.3 | 3.2 JTS |
3. Place the moving pad (3a) in its housing and secure it using the bolt (3b).| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Secondary chain moving pad | Bolt | - | 2.3 | 3.2 JTS |
4. Place the hydraulic tensioner (4a) pre-loaded previously in its housing complete with a new gasket and secure it without tightening the bolts (4b).- Check that the gasket is correctly positioned.- Tighten the hydraulic tensioner retaining bolts.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Primary chain hydraulic tensioner | Bolt | - | 2.3 | 3.2 JTS |
- Release the hydraulic tensioner so that the piston pushes the pad.- Place the oil pump bolt removed previously in position.- Prepare the hydraulic tensioner for the primary timing chain following the instructions given below.- Insert the piston in the hydraulic tensioner body.- Compress the piston in the hydraulic tensioner body rotating it and locking it in the end of travel position.- Slowly release the pressure on the hydraulic tensioner piston. | The hydraulic tensioner piston should remain in the compressed position. |
1. The crankshaft should be positioned so that the ball (1a) stamped on the primary timing chain drive gear is aligned with the ball (1b) stamped on the oil pump.2. Fit the primary timing chain. | Position the chain so that the following conditions are adhered to:- the grey mesh (2a) should be aligned with the ball (2b) stamped on the drive gear;- the yellow mesh (2c) should be aligned with the ball (2d) stamped on the idler pulley for the left cylinder head;- the yellow mesh (2e) should be aligned with the triangle (2f) stamped on the idler pulley for the right cylinder head. |
3. Place the fixed pad (3a) in its housing and secure it using the bolts (3b).| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Main timing chain fixed pad | Bolt | - | 5.8 | 3.2 JTS |
4. Place the hydraulic tensioner (4a) pre-loaded previously in its housing complete with a new gasket and secure it without tightening the bolts (4b).- Check that the gasket is correctly positioned.- Tighten the hydraulic tensioner retaining bolts.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Primary chain hydraulic tensioner | Bolt | - | 2.3 | 3.2 JTS |
- Release the hydraulic tensioner so that the piston pushes the pad.- Prepare the hydraulic tensioner for the secondary timing chain for the right cylinder head following the instructions given below.- Insert the piston in the hydraulic tensioner body.- Compress the piston in the hydraulic tensioner body rotating it and locking it in the end of travel position.- Slowly release the pressure on the hydraulic tensioner piston. | The hydraulic tensioner piston should remain in the compressed position. |
1. Rotate the crankshaft until the ball (1a) stamped on the primary timing chain drive gear is aligned with the ball (1b) stamped on the oil pump.
1. Fit the right cylinder head secondary timing chain. | Position the chain so that the following conditions are adhered to:- the black mesh (1a) should be aligned with the ball (1b) on the idler gear;- the back mesh (1c) should be aligned with the triangles (1d) and the letters "R" stamped on the phase transformers. |
2. Place the fixed pad (2a) in its housing and secure it using the bolts (2b).| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Secondary chain fixed pad | Bolt | - | 2.3 | 3.2 JTS |
3. Place the moving pad (3a) in its housing and secure it using the bolt (3b).| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Secondary chain moving pad | Bolt | - | 2.3 | 3.2 JTS |
4. Place the hydraulic tensioner (4a) pre-loaded previously in its housing complete with a new gasket and secure it without tightening the bolts (4b).- Check that the gasket is correctly positioned.- Tighten the hydraulic tensioner retaining bolts.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Primary chain hydraulic tensioner | Bolt | - | 2.3 | 3.2 JTS |
- Release the hydraulic tensioner so that the piston pushes the pad.1. Place the oil seal (1a) in its housing on the engine front cover using the tool (1b).| Tool | Description | Function | Validity |
|---|
| 1860949000 | Fitting tool | Fitting crankshaft front oil seal | 3.2 JTS |
1. Place a new gasket in the housing on the engine front cover.
1. Apply silicon sealant to the front engine cover.
1. Place the engine front cover in its housing complete with oil seal, water pump and cam angle sensors, then secure it tightening the bolts to the recommended torque. | Follow the tightening order illustrated in the diagram. |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Engine front cover | Bolt | - | 2.3 | 3.2 JTS |
1. Place the phase transformer electromagnets (1a) in their housings on the cylinder head and secure them using the bolts (1b).| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Variable valve timing solenoid | Bolt | M6 | 1.0 | |
- Place the spacer back in its housing.- Place the water pump pulley in its housing.- Tighten the water pump pulley fixing bolts using the tool for counter-torque.| Tool | Description | Function | Validity |
|---|
| 1870815000 | Counter-torque | Loosen/ tighten the nut fixing the right front wheel hub to the driveshaftLoosen/ tighten bolts securing the water pump | |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Water pump pulley | Bolt | - | 1.0 | 3.2 JTS |
1. Position the engine components single belt moving tensioner (1a) in its housing and secure it using the bolts (1b).| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Engine components single belt moving tensioner | Bolt | - | 5.0 | 3.2 JTS |
1. Position the crankshaft service pulley (1a) in its housing and secure it using the bolt (1b). | Use a suitable spanner on tool 1860615000 fitted previously for counter-torque. |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Services pulley on crankshaft | Bolt | - | 10.0 + 150 ° | 3.2 JTS |
1. Remove the tool used for counter-torque for the bolt fixing the services pulley on the crankshaft and for rotating the crankshaft.| Tool | Description | Function | Validity |
|---|
| 1860815000 | Flange | Loosen/ tighten the bolt fixing the services pulley on the crankshaft | 3.2 JTS |
1. Place the water pump rigid inlet pipe (1a), complete with gaskets, in position and secure it using the bolts (1b).| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Water pump rigid inlet pipe | Bolt | - | 1.0 | 3.2 JTS |
2. Place the mounting bracket (2a) in its housing and secure it using the bolt (2b).3. Place the intermediate couplings for the engine electrical wiring in their housings on the mounting bracket.
- Tighten the bolt securing the pipe mounting bracket to the right cylinder head.- Place the high pressure pipe connecting the left and right fuel manifold pipes in their housings and tighten the connectors.
- Place the spark plugs back in their housings and tighten them.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Spark plugs | - | | 2.0 | 3.2 JTS |
- Place the tappet covers complete with gaskets back in their housings and secure them by tightening the bolts to the recommended torque. | Follow the tightening order shown in the figure. |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Tappet cover | Bolt | - | 1.0 | 3.2 JTS |
- Place the ignition coils back in their housings and fasten them using the bolts.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Ignition coils | Bolt | | 1.0 | 3.2 JTS |
- Place the air chamber gaskets in their housings.1. Fit the air chamber (1a) in its housing and secure it using the bolts (1b).| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Air chamber | Bolt | - | 2.3 | 3.2 JTS |
- Refit the engine wiring- Connect the earth lead and secure it using the bolt.- Connect the electrical connection to the throttle casing.- Connect the electrical connections to the cam angle sensors for the right cylinder head.- Connect the electrical connections to the phase transformer electromagnets for the right cylinder head.- Connect the electrical connections to the cam angle sensors for the left cylinder head.- Connect the electrical connections to the phase transformer electromagnets for the left cylinder head.- Connect the intermediate couplings for the engine electrical wiring.- Connect the electrical connection to the engine oil pressure warning light switch.- Connect the electrical connection to the left detonation sensor.- Connect the earth lead and secure it using the bolt.- Connect the electrical connection to the engine coolant temperature sensor.-- Connect the electrical connections to the left cylinder head ignition coils.- Connect the electrical connection for the engine rpm sensor.- Connect the electrical connection to the engine oil level sensor.- Connect the electrical connection to the right detonation sensor.- Refit the electrical wiring mouting bracket and secure it using the bolts.- Refit the cable duct and secure it using the clips.-- Connect the electrical connections to the right cylinder head ignition coils.- Connect the earth lead and secure it using the bolt.- Place the engine oil vapour recovery pipe in position and connect the rapid connectors.- Connect the electrical connection to the absolute pressure sensor.- Connect the electrical connection to the shut-off solenoid valve.- Connect the electrical connection to the fuel vapour solenoid valve.- Connect the electrical connection to the fuel pressure sensor on the fuel manifold pipe.- Connect the electrical connection to the fuel pressure regulator on the pressure pump.- Place the left rear and right front engine lifting brackets in their housings fastening them using the bolts.- Place the air conditioning compressor mounting in its housing and secure it using the bolts.
- Place the air conditioning compressor in its housing and secure it using the bolts.- Connect the electrical connection for the air conditioning compressor.- Place the power steering pump mounting in its housing and secure it using the bolts.- Refit the power steering pump and secure it using the bolts.- Place the alternator mounting in its housing and secure it using the bolts.- Position the alternator and fasten it using the bolts.- Connect the electrical connection and the alternator supply lead using the nut.- Adjust the belt tensioner and fit the engine components single drive belt.- Place the timing side power unit rigid support in position and secure it tightening the bolts to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Lower rigid support to timing side upper support | Bolt | M10 | 5.4 ÷ 6.6 | 3.2 JTS |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Timing side upper rigid support to engine | Bolt (to be replaced) | M12 | 6.3 ÷ 7.7 + 90° | 3.2 JTS |
Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE
