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. Fit the tool on the crankshaft.

Tool	Description	Function	Validity
1860815000	Flange	Crankshaft rotation

2. Lock the crankshaft using the tool fitted previously for undoing the (left) bolt (2a) and remove the toothed drive pulley (2b).3. Undo the bolts (3a), (3b) and remove the crankcase front cover with the oil pump incorporated (3c) complete with intake (3d).4. Undo the bolts and remove the support (4a) complete with moving timing belt tensioner (4b).

1. Undo the bolts (1a) and remove the engine oil filter mounting (1b) complete with heat exchanger (1c).

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 assembly4. 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.

Tool	Description	Function	Validity
1860815000	Flange	Crankshaft rotation

5. Undo the bolts (5a) and remove the crankcase rear cover (5b) with the oil seal incorporated.- 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	1.9 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.6. Undo the bolts (6a) and remove the bearing caps (6b).7. Remove the lower main journal half-bearings.8. Remove the crankshaft.9. Remove the upper main journal half-bearings.10. Remove the thrust washers.11. Undo the bolts (11a) and remove the jets (11b) from the crankcase.12. Undo the bolt (12a) and remove the rpm sensor (12b).

- Rotate the crankcase through 90° on the overhaul stand.- Undo the bolts and remove the crankcase from the mounting, then place it on a special workbench. Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING - Undo the bolts and remove the intake duct from the oil pump. Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT 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 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.

Measurement	Value		Validity
Cylinder head support surface flatness	< 0.1 mm		1.9 JTD 8V1.9 JTD 16V

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

1. 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.

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

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).

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 8V

Measurement	Value	Validity
Main journal diameter - Category B	59.987 - 59.993 mm	1.9 JTD 8V

Measurement	Value	Validity
Main journal diameter - Category C	59.982 - 59.986 mm	1.9 JTD 8V

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

Measurement	Value	Validity
Main journal diameter oversize	0.127 mm	1.9 JTD 8V

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.

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.

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).

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

1. Remove the bearing caps 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	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 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. Op. 1028H58 CONNECTING ROD SMALL END BUSH (ONE) - REPLACE

Measurement	Value	Validity
Small end bush inner diameter	26.006 - 26.012 mm	1.9 JTD 8V

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

Measurement	Value	Validity
Gudgeon pin housing diameter in piston	25.999 - 26.004 mm	1.9 JTD 8V1.9 JTD 16V

- Check that the outer diameter of the piston pins is within the recommended limits; if not, replace the worn piston 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 8V

Measurement	Value	Validity
Cylinder compression 2nd piston ring gap	0.25 - 0.50 mm	1.9 JTD 8V

Measurement	Value	Validity
Piston oil scraper ring gap	0.25 - 0.50 mm	1.9 JTD 8V

- Check that the piston ring seat is within the recommended values.

Measurement	Value	Validity
Piston ring seat in piston - 1st groove	2.080 ÷ 2.100	1.9 JTD 8V

Measurement	Value	Validity
Piston ring seat in piston - 2nd groove	2.020 ÷ 2.040	1.9 JTD 8V

Measurement	Value	Validity
Piston ring seat in piston - 3rd groove	2.020 ÷ 2.040	1.9 JTD 8V

- Check that the thickness of the piston rings is within the recommended limits.

Measurement	Value	Validity
Cylinder compression 1st piston ring thickness	1.970 - 1.995 mm	1.9 JTD 8V

Measurement	Value	Validity
Cylinder compression 2nd piston ring thickness	1.970 - 1.995 mm	1.9 JTD 8V

Measurement	Value	Validity
Piston oil scraper ring thickness	1.970 - 1.990 mm	1.9 JTD 8V

- 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, 8 mm from the lower edge of the skirt.

- Check that the axial clearance between the pistons rings and the seats corresponds to the recommeded figures.

Measurement	Value	Validity
Cylinder compression 1st piston ring endfloat	0.085 - 0.130 mm	1.9 JTD 8V

Measurement	Value	Validity
Cylinder compression 2nd piston ring endfloat	0.025 - 0.070 mm	1.9 JTD 8V

Measurement	Value	Validity
Engine piston oil scraper ring endfloat	0.030 - 0.070 mm	1.9 JTD 8V

1. Fit the caps (1b) on the connecting rods (1a) and secure them tightening the 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

- Use the tool for the angular tightening of the connecting rod cap bolts.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 - Fit the intake duct on the oil pump and secure it using the bolts.- Fit the crankcase on the overhaul stand and secure it using the bolts.- Position the rpm sensor in its housing and secure it using the bolt.- 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 IDENTIFICATION- Main journal grade A (normal), diameter 59.994 - 60.000 mm, RED paint mark, numerical code 1 (94 00)*- Main journal grade B (normal), diameter 59.987 - 59.993 mm, BLUE paint mark, numerical code 2 (87 93)*- Main journal grade C (normal), diameter 59.982 - 59.986 mm, YELLOW paint mark, numerical code 3 (82 86)*- 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 59.860 - 59.866 mm, GREEN paint mark, numerical code 7 (60 66)*- Main journal grade F (0.127 mm undersize), diameter 59.855 - 59.859 mm, BLACK paint mark, numerical code 8 (55 59)*- (*): 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: 0.025 mm - Maximum: 0.052 mm; this value can be measured, as a final check, using the calibrated wire (Plastigage).- Place the bearing caps complete with half-bearings in their seats.

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).

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

- Fit the tool.

Tool	Description	Function	Validity
1860815000	Flange	Crankshaft rotation

- Rotate the crankcase through 90° on the overhaul stand.- Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C.- Refit the piston-connecting rod assemblies (1a) in their seats with upper connecting rod bearing halves using 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 are fitted in the cylinder block/crankcase so that the combustion chamber in the piston is facing the intake side.

1. Test the crankpin clearance by applying plastigage to measure crankpin installation clearance. - Place the crank pin caps complete with half-bearings in their seats.

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).

1. Tighten the bolts (1a) to torque, using the angular tightening tool (1b).

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 nuts and remove the bearing caps tightened previously.- Check that the thickness of the connecting rod half-bearings is within the recommended limits.

Measurement	Value	Validity
Crankpin half-bearings - Category A (red)	1.527 - 1.531 mm	1.9 JTD 8V

Measurement	Value	Validity
Crankpin half-bearings - Category B (light blue)	1.530 - 1.534 mm	1.9 JTD 8V

Measurement	Value	Validity
Crankpin half-bearings - Category C (yellow)	1.533 - 1.537 mm	1.9 JTD 8V

1. Use an appropriate graduated measuring tool (1a) to measure the clearance indicated by the plastigage (1b).

Measurement	Value	Validity
Clearance between crankpins - crankshaft bearings	0.030 - 0.056 mm	1.9 JTD 8V1.9 JTD 16V

- 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 cap complete with half-bearing and secure it without tightening the bolts.

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).

- Tighten the connecting rod cap bolts to the recommended torque using the angular tightening tool.

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 tool.

Tool	Description	Function	Validity
1860815000	Flange	Crankshaft rotation

- Place the crankcase rear cover with built in oil seal in its housing.- Tighten the crankcase rear cover 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

- Undo the cover and replace the oil filter cartridge.- Place the engine oil filter mounting complete with heat exchanger in position and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Water/engine oil heat exchanger support	Bolt	M10	4.5 ÷ 5.5	1.9 JTD 8V

- Fit the front crankcase cover with built-in oil pump complete with intake chamber and secure by tightening bolts to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Crankshaft oil seal front cover	Bolt (pretreated to be replaced)	M6 x 1 x 22	0.8 ÷ 1.0	1.9 JTD 8V

Component	Fastening	dia	Value (daNm)	Validity
Crankshaft oil seal front cover	Bolt	M6 x 1 x 35	0.8 ÷ 1.0	1.9 JTD 8V

- Place the seal in its housing on the oil pump using the tool.

Tool	Description	Function	Validity
1860816000	Fitting tool	Fitting oil pump seal	1.9 JTD 8V

- Position the toothed timing drive pulley in its housing and tighten the bolt (left hand 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

- Place the mounting complete with timing belt moving tensioner back in its housing and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing tensioner moving support	Bolt	M12	2.8 ÷ 3.1 + 40° +/- 2°	1.9 JTD 8V

- Clean the residues of sealant from the mating surfaces between the engine block and the crankcase sump.- Apply a strip of silicone sealant to the contact surfaces between the crankcase sump and the engine block.

The sealant strip must be unbroken.

- Place the oil sump back in its housing.

When fitting the crankcase sump, take care not to damage the sealant strip.

Finish the installation operation within 10 minutes of applying the sealant.

- Tighten the side bolts fixing the crankcase sump.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump	Bolt	M8	(engine block side) 2.3 - 2.8	1.9 JTD 8V1.9 JTD 16V

- Tighten the bolts securing the sump to the crankcase, camshaft side and gearbox side, to the specified torque with the tool.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump	Bolt	M6	(front and rear cover side) 0.8 - 1.0	1.9 JTD 8V1.9 JTD 16V

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

- Rotate the engine through 180° on the overhaul stand.- Place the air conditioning compressor complee with mounting back in its housing and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
COMPRESSOR MOUNTING	Bolt	M10x1.25x75	4.5 ÷ 5.5	1.9 JTD 8V 1.9 JTD 16V

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 between of the averages of the projection for each individual piston.

Measurement	Value		Validity
Cylinder head gasket size with average maximum piston projection	projection 0.014 - 0.104 mmthickness (no reference) 0.770 - 0.870 mm

Measurement	Value		Validity
Cylinder head gasket size with average maximum piston projection	projection 0.105 - 0.205 mmthickness (one reference) 0.870 - 0.970 mm

Measurement	Value		Validity
Cylinder head gasket size with average maximum piston projection	projection 0.206 - 0.294 mmthickness (two references) 0.970 - 1.070 mm

- Place the cylinder head centering bushes on the cylinder block.- Place the cylinder head gasket selected in position.

The cylinder head gasket is 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:- keep the gasket sealed in its casing until it is fitted;- not lubricate the gasket or the contact surfaces with oil.

- Position the cylinder head on the cylinder block/crankcase.1. Tighten the cylinder head bolts (1a) to the recommended torque using the angular tightening tool (1b).

Component	Fastening	dia	Value (daNm)	Validity
Cylinder head	Bolt	M12	(engine crankcase side) 2 + 4.5 + 90° + 90° + 90°	1.9 JTD 8V2.4 JTD 20V

Achieve the figure of 6.5 daNm by a pretightening of 2.0 daNm subsequently increased by a torque of 4.5 daNm to achieve a nominal value of 6.5 daNm

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

- 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) 0.8 - 1.0	1.9 JTD 8V

- Place the pressure pump mounting complete with alternator back in its housing and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Pressure pump mounting	Bolt (pretreated to be replaced)	M8	2.3 ÷ 2.8	1.9 JTD 8V

- Place the pipe from the pressure pump to the fuel return manifold pipe back in its housing and secure it using the bands.- Place the new rigid pipe between the pump and the fuel manifold back in its housing and secure it tightening 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

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 the tool.

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. Rotate the driven toothed pulley until the timing references are aligned.2. Fully fit the toothed timing drive belt.3. Use a screwdriver for leverage on the tensioner arm until the reference (3a) for the tensioner is in the maximum tension position and tighten the tensioner bolt (3b) to the recommended torque in this position.

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

- Remove the timing tool.- Rotate the crankshaft through two revolutions.1. Loosen the moving timing tensioner nut.2. Use a screwdriver for leverage on the tensioner arm until the reference (2a) for the tensioner is in line with the reference opening (2b) and tighten the tensioner bolt (2c) to the recommended torque in this position.

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

- Rotate the crankshaft through two revolutions and check that the reference for the tensioner remains in line with the reference opening.- Check the correct timing again, refitting the timing tools and checking the timing references are aligned.- If not, repeat the tensioning/timing procedure.- Tighten the bolt fixing the crankcase front cover removed previously.- Fit the power unit rigid support and tighten 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

- Position the auxiliary drivebelt fixed tensioner in its housing and secure it tightening the bolt to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine components single belt fixed tensioner	Bolt	M8	2.2 ÷ 2.7	1.9 JTD 8V

- Position the crankshaft pulley in its housing and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Services pulley on crankshaft	Bolt	M8	(drive pulley side) 2.3 - 2.8	1.9 JTD 8V1.9 JTD 16V

- Place the engine components single belt in its housing using a spanner on the moving tensioner.- Place the exhaust manifold gasket in its housing.- Place the exhaust manifold - turbocharger assembly complete with precatalyzer back in its housing and secure it tightening the nuts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Turbocharger and exhaust manifold assembly	Nut	M8	(cylinder head side) 2.2 - 2.7	1.9 JTD 8V

- Connect the engine oil return hose from the turbocharger to the crankcase and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil supply pipe from turbocharger	Bolt	M8	(engine block side) 2.2 - 2.7	1.9 JTD 8V1.9 JTD 16V

- Connect the engine oil turbocharger supply pipe to the crankcase and tighten the bolts 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 E.G.R. exhaust gas intake hose to the exhaust manifold and secure it using the bolts.- Place the oil dipstick pipe back in its housing and fasten it to the oil sump using the bolt.- Place the water pump rigid return in position and secure it using the bolts.- Connect the hose to the rigid pipe and securing it using the band.- Place the timing belt side guard in its housings and secure it using the bolts.- Fit the timing belt protective cover and secure it using the bolts.- Place the support complete with vacuum reservoir in position, seucre it using the bolts and connect the two pipes.- Place the duplex pipes in position and connect them to the water-oil heat exchanger.- Connect the heater coolant supply and return pipes to the thermostat.- Refit the electrical wiring- Connect the electrical connection for the fuel pressure sensor.- Connect the electrical connection for the throttle casing.- Connect the electrical connection for the coolant temperature sensor.- Connect the electrical connection for the excess pressure sensor.- Connect the electrical connection for the E.G.R. solenoid valve.- Connect the electrical connections for the injectors.- Connect the electrical connection for the fuel pressure regulator.- Connect the glow plug electrical connections.- Connect the electrical connection for the engine oil level sensor.- Connect the electrical connection for the rpm sensor.- Connect the electrical connections for the alternator.- Connect the electrical connection for the minimum engine oil pressure switch.- Connect the electrical connection for the air conditioning compressor engagement solenoid. Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE