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

Operation 1004E20 · ENGINE ASSEMBLY INSPECTION AND REPAIRS

1.9 JTS, 2.2 JTS

Removing

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).

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.

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

- 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.

- Check that the diameter of the main journals corresponds to the recommended figures.

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

- 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.

- 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.

- The size of the seals is given below.

- 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.

- The clearance between the pistons and the liner/bore is given below.

- 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.

- 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.

- 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.

- 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).

1. Remove the connecting rod caps and check the crankpin clearance. Use an appropriate gauge to measure the width of the plastigage.

- 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.

- 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.

- Preload the hydraulic tensioner for the counter-balance shaft chain and fit it at the recommended torque.

- Fit the chain lubrication jet.

- Place the heat exchanger in its housing with the mounting and tighten the bolts to the recommended torque.

- 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.

- Position the power assisted steering pump in its housing and secure it tightening the bolts to the recommended torque.

- 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.

- Place the tappet cover complete with gasket back in its housing and secure it by tightening the bolts to the recommended torque.

- Place the electronic power module in its housing and secure it tightening the bolts to the recommended torque.

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.

- Place the crankshaft front oil seal cover in its housing and secure it tightening the bolts to the recommended torque.

- 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.

1.9 JTD 16V

Removing

1. Undo the bolts (1a) and remove the air conditioning compressor (1b) from the mounting.

2. Undo the bolts (2a) and remove the air conditioner compressor mounting (2b).

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

2. Undo the bolts (2a) and remove the alternator (2b).

1. Undo the bolts (1a) and (1b), then remove the pressure pump support assembly (1c).

- Remove the locating pins.

1. Undo the bolt (1a) and remove the rpm sensor (1b).

- Undo the bolts and remove the flywheel side oil seal cover.

1. Fit the tool for rotating the crankshaft.

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

2. Undo the bolt (2a) and remove the timing toothed drive pulley (2b).

3. Undo the bolts (3a) and remove the crankshaft oil seal front cover (3b).

1. Undo the bolts (1a) and remove the fixed timing tensioners support (1b).

Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C.

1. Undo the bolts (1a) and remove the connecting rod cap (1b).

2. Remove the lower connecting rod half-bearing.

3. Remove the connecting rod-piston assembly.

4. Remove the upper connecting rod half-bearing.

Carry out the same operations to remove the pistons and connecting rods for the remaining cylinders.

Remove the tool.

- Check that the crankshaft endfloat corresponds to the recommended figures using a magnetic base and dial gauge.

If the value for the crankshaft endfloat does not correspond with the recommended figures, when refitting, regrind the crankcase seat and use suitable oversize thrust washers.

1. Undo the bolts (1a) and remove the connecting rod caps (1b).

2. Remove the lower main journal half-bearings.

3. Remove the crankshaft.

4. Remove the upper main journal half-bearings.

5. Remove the thrust washers.

6. Undo the bolts (6a) and remove the jets (6b) from the crankcase.

- Remove the cylinder block/crankcase from the support tools, then place on a workbench.

1028H60 SERIE PISTONI, PERNI e ANELLI - Sost. a pistoni con bielle al banco - Comprende quadratura ed equilibratura

1084B18 POMPA OLIO MOTORE, staccata - Verifica al banco

Drill and remove the water/oil sealing plugs from the crankcase to allow for washing the ducts.

Refitting

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.

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

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

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

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.

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).

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

Check that there are no deposits or blockages in the crankshaft lubrication ducts.

Check that the diameter of the main journals is within specified limits.

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

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.

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

Crankpin undersizes higher than the value mentioned will adversely affect the structural resistance of the crankshaft (following contact between the tool and rolled connectors). As far as the above is concerned, if the regrinding requires undersizes greater than 0.127 mm, then the crankshaft must be replaced and a new one ordered from the Parts Dept. The half-bearings used for undersizes of more than 0.127 mm should not be ordered from the Parts Dept. (even if the number is still quoted).

Check the main bearings, noting that the half-bearings should not be adapted. Replace them if scoring or signs of binding are noted.

Fit the half-bearings making sure they are scrupulously clean.

If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions.

Fit the crankshaft in the crankcase.

1. Fit the calibrated wire (plastigage) for measuring the bearing clearance.

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

1. Fit the main bearing caps complete with half-bearings.

The bearing caps have progressively numbered references (from zero to four starting from the front of the engine) which define the fitting position.

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

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

If the figure measured is outside of the tolerance, replace the half-bearings with ones of the correct size and category.

Measure the clearance for all the bearings taking care to take the measurements one at a time without moving the crankshaft at any time.

Check that the small end bush internal diameter is within the recommended limits; if not, replace the worn small end bush.

1028H58 BOCCOLA PIEDE di BIELLA (una) - Sost.

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

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

Fit the piston rings in the cylinder liner and check that the opening between the ends is within the recommended values; if this is not the case, replace the circlips.

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.

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

1. Check that the backlash (1a) between the first-second ring (1b) and the seats in the piston (1c) corresponds to the recommeded figures.

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

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

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.

1028H60 SERIE PISTONI, PERNI e ANELLI - Sost. a pistoni con bielle al banco - Comprende quadratura ed equilibratura

1084B18 POMPA OLIO MOTORE, staccata - Verifica al banco

Check that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it.

Place the engine block on the overhaul stand using the mounting bracket.

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 59.988.59.994 mm, BLUE paint mark, numerical code 2 (88 94)*

Main journal grade C (normal), diameter 59.982.59.998 mm, YELLOW paint mark, numerical code 3 (82 88)*

Main journal grade D (0.127 mm undersize), diameter 59.867.59.873 mm, BROWN paint mark, numerical code 6 (67 73)*

Main journal grade E (0.127 mm undersize), diameter 59.861.59.867 mm, GREEN paint mark, numerical code 7 (61 67)*

Main journal grade F (0.127 mm undersize), diameter 59.855.59.861 mm, BLACK paint mark, numerical code 8 (55 61)*

(*): Last two numbers (thousandth part) of the main journal dimensions.

- In the case of the usage of a crankshaft where the maximum undersize for the bearings is 0.127 mm through grindings, the grade should be selected through the measurement of the diameter of the bearing using the above as a reference.

Having defined the grade and the colour of each new or reground crankshaft bearings, it is necessary to select the thickness of the bearings that should be the same colour as the corresponding bearing; the pair of half-bearings required can be ordered from the Parts Dept. by quoting the order no.

The above is designed to guarantee the optimum operational clearances for all the bearings.

Lastly, we wish to point out that, generally, the clearance between the main journal and the half-bearing, obtained through the selection method indicated above, should be within the following values: Minimum: 0.011 mm - Maximum: 0.071 mm; this value can be measured, as a final check, using the calibrated wire (plastic gauge).

Place the upper main bearing half-bearings in their seats in the engine block.

Place the crankshaft in its housing in the crankcase.

- Place the bearing caps complete with lower half-bearings in position.

The bearing caps have progressively numbered references (from zero to four starting from the front of the engine) which define the fitting position.

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

- Fit the tool.

Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C.

1. Place the piston and connecting rod assembly (1a) in its housing complete with half-bearing using a suitable tool (1b).

For the selection of the connecting rod half-bearings, follow the procedure described previously for the main journal half-bearings.

The piston-connecting rod assemblies should be fitted in the cylinder block/crankcase so that the drain on the piston skirt is aligned with the oil jet on the engine block.

Carry out the same operations to fit the pistons and connecting rods for the remaining cylinders.

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).

- Tighten the bolts to the recommended torque, using the angular tightening tool.

Undo the nuts and remove the connecting rod caps with the half-bearings fitted previously.

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

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.

- Remove the tool.

Place the crankshaft front cover in its seat complete with gasket and tighten the bolts to the recommended torque.

- Position the engine oil intake duct in its housing and secure it using the bolts.

1. Place the crankshaft front cover (1a) in its seat using the tool (1b).

Place the engine rpm sensor in its housing and secure it by tightening the bolt to the recommended torque.

- Place the timing tensioners support assembly in position and secure it tightening the bolts to the recommended torque.

1. Place the flywheel side cover in its housing and secure it tightening the bolts to the recommended torque.

Place the air conditioning compressor mounting (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

- Place the air conditioning compressor in its housing and secure it tightening the bolts to the recommended torque.

Apply silicon sealant to the entire perimeter of the crankcase sump.

1. Place the crankcase sump in its housing.

2. Tighten the side bolts securing the crankcase sump to the recommended torque.

3. Tighten the front and rear bolts securing the crankcase sump to the recommended torque.

4. Tighten the bolts securing the air conditioning compressor mounting to the crankcase sump to the recommended torque.

- Fit the flywheel lock.

- Position the toothed timing drive pulley in its housing and secure it tightening the bolt to the recommended torque.

Remove the flywheel lock.

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.

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

Position the first cylinder at T.D.C.; rotate the crankshaft a further two teeth of the toothed timing drive pulley to lower the pistons thereby preventing any interference with the valves whilst fitting the cylinder head.

- Position the cylinder head locating bushes on the crankcase as shown in the figure.

The locating bushes between the crankcase and cylinder head are shorter (12.5 mm) than the bushes between the cylinder head and the cylinder head extension. Take great care not to reverse them as this could impair engine operation.

Fit the new cylinder head gasket selected.

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).

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

- Refit the glow plugs and tighten them to the recommended torque.

- Fit the pressure pump mounting complete with pressure pump back in its housing and secure it tightening the bolts to the recommended torque.

1. If not already carried out during cylinder head overhaul, remove plugs (1a) and fit camshaft timing adjustment tools (1b) to the cylinder head extension.

Check that the tools are correctly fitted in the housings in the camshafts.

Remove the intake camshaft timing tool and tighten the plug.

- Place the camshaft housing centering bushes on the cylinder head.

The centering bushes between the cylinder head and the camshaft housing are longer (16.0) than those between the engine block and the cylinder head; take care therefore not to mix them up because this could adversely affect the operation of the engine.

- Place the valve rockers in their housings.

- Place the camshaft housing gasket in position.

- Position the camshaft housing and secure it tightening the bolts to the recommended torque.

If this has not already been done during the overhauling of the cylinder head, loosen the bolt fixing the exhaust side camshaft drive pulley fixing bolt.

1. Undo the bolt fixing the crankcase front cover shown in the diagram.

Temporarily fit the toothed timing drive belt on the 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.

1. Fit the toothed timing belt completely taking care to ensure that the yellow references on it are aligned with the references on the toothed pullies.

2. Use a screwdriver for leverage in the opening (2a) until the reference for the tensioner (2b) is in the maximum tension position and tighten the bolt (2d) for the tensioner to the recommended torque in this position.

Tighten the bolt fixing the exhaust side camshaft toothed pulley to the recommended torque using the tools for counter-torque.

Remove the timing tools.

Remove the exhaust side camshaft template as the inlet side one has already been removed.

Rotate the crankshaft through two revolutions.

- Loosen the bolt retaining the timing moving tensioner.

- Use a screwdriver for leverage on the tensioner arm until the reference for the tensioner is in line with the reference opening and tighten the tensioner bolt to the recommended torque in this position.

Recheck the timing by refitting the timing tools.

nly fit the exhaust side camshaft template because the intake side template seat is not accessible.

Tighten the bolt fixing the crankcase front cover removed previously.

Tighten the plug on the cylinder head extension for fitting the exhaust side timing tool.

1. Fit the injectors (1a) in their seats complete with brackets (1b) and tighten the nuts (1c) to the recommended torque.

Start the refitting beginning with the injector for cylinder no. 4 and continue with the injectors for cylinders 3, 2, and 1.

- Place the alternator in position and secure it tightening the bolts to the recommended torque.

- Place the heat exchanger and engine oil filter mounting in position and secure it using the bolts.

- Fit the pipe from the injectors to the fuel recovery manifold and connect to the fuel recovery manifold.

- Connect the pipe from the injectors to the fuel manifold, injector side pushing it home until the clips click into place.

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

- Connect the return pipe from the fuel manifold, fuel return manifold side and tighten the band.

- Place the pipe from the pressure pump to the fuel manifold back in its housing and secure it tightening the connectors to the recommended torque.

- Place the pipes from the fuel manifold to the injectors in their housings and secure them tightening the connectors to the recommended torque.

- Place the throttle control shaft valve for the inlet ducts back in its housing and secure it tightening the nuts to the recommended torque.

- Connect the linkage of the intake duct throttle spindle control valve.

- Place the bracket complete with engine oil vapour separator and vacuum reservoir in its housing and secure it using the nuts.

- Connect the engine oil vapour recovery pipes and the engine oil recovery pipe and secure them using the bands.

- Place the vacuum pipes in their housings, connect them and secure them using the bolts.

- Connect the engine oil vapour recovery pipe to the engine oil filler and secure it using the band.

- Place the duplex engine oil heat exchanger rigid supply and return pipe back in its housing, then tighten the bands and the bolts.

- Connect the pipes to the thermostat and tighten the bands.

- Place the exhaust manifold gasket in its housing.

- Place the turbocharger and exhaust manifold assembly complete with catalytic converter back in its housing and secure it tightening the nuts to the recommended torque.

- Connect the engine oil return pipe from the turbocharger, engine crankcase side, and secure it tightening the bolts to the recommended torque.

Connect the engine oil delivery pipe to turbocharger, engine crankcase side, and tighten the connector to the specified torque.

- Connect the exhaust gas intake pipe from the exhaust manifold to the E.G.R. heat exchanger, exhaust manifold side, then secure it using the collar and tightening the bolts to the recommended torque.

- Place the exhaust manifold heat shield back in its housing and secure it using the nuts.

- Place the engine oil dipstick pipe back in its housing and fasten it with the bolts.

- Place the turbocharger air inlet pipe complete with engine oil vapour recovery pipe in its housing, then secure it using the bands and the bolts.

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

- Position the engine components single belt fixed tensioner in its housing and secure it tightening the bolt to the recommended torque.

- Fit the timing belt covers and secure them using the bolts.

- Position the services pulley in its housing on the crankshaft and secure it tightening the bolts to the recommended torque.

- Adjust the mobile tensioner with a wrench and fit the auxiliary drive belt.

- Connect the electrical connection to the thermal coupling signalling the overheating of the catalytic converter.

- Connect the electrical connection to the air conditioning compressor engagement solenoid.

- Tighten the bolts securing the electrical wiring.

- Connect the electrical connection to the cam angle sensor.

- Connect the electrical connections to the heater plugs.

- Connect the electrical connections to the injectors.

- Connect the electrical connection to the fuel pressure regulator on the injector single manifold.

- Connect the electrical connection to the fuel pressure sensor.

- Connect the electrical connection to the throttle casing.

- Connect the electrical connection to the engine temperature sensor.

- Connect the electrical connection to the fuel pressure regulator.

- Connect the electrical connection to the air temperature and pressure sensor.

- Connect the electrical connection to the E.G.R. solenoid valve.

- Connect the electrical connection to the throttle control shaft valve for the inlet ducts.

- Connect the electrical connection to the engine oil pressure switch.

- Connect the electrical connection to the engine oil level sensor.

- Connect the electrical connection to the rpm sensor.

- Tighten the drain plug in the crankcase sump to the recommended torque.

When the refitting of the power unit is completed, refill the engine lubrication system.

Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE

1.9 JTD 8V

Removing

1. Fit the tool on the crankshaft.

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 assembly

4. Remove the upper connecting rod half-bearing.

- Carry out the same operations to remove the pistons and connecting rods for the remaining cylinders.

- Remove the tool.

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.

- 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

- 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.

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

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

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

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.

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).

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

- 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.

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

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.

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

Crankpin undersizes higher than the value mentioned will adversely affect the structural resistance of the crankshaft (following contact between the tool and rolled connectors). As far as the above is concerned, if the regrinding requires undersizes greater than 0.127 mm, then the crankshaft must be replaced and a new one ordered from the Parts Dept. The half-bearings used for undersizes of more than 0.127 mm should not be ordered from the Parts Dept. (even if the number is still quoted).

- Check the main bearings, noting that the half-bearings should not be adapted. Replace them if scoring or signs of binding are noted.

- Fit the half-bearings making sure they are scrupulously clean.

If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions.

- Fit the crankshaft 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).

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

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

- 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.

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

- 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.

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

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

- 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.

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.

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

- 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.

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).

- Fit the tool.

- 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).

- 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.

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

- 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.

- Remove the tool.

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

- Tighten the crankcase rear cover bolts to the recommended torque.

- 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.

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

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

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

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

- 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.

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

- 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.

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.

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

- Place the cylinder head centering bushes on the cylinder block.

- Place the cylinder head gasket selected in position.

- 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).

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.

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

- 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.

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.

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.

- 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.

- 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.

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

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

- 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.

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

- Connect the engine oil turbocharger supply pipe to the crankcase and tighten the bolts to the recommended torque.

- 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

3.2 JTS

Removing

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.

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.

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

- 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.

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

- Check that the diameter of the main journals corresponds to the recommended figures.

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

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

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

- Check that the inner diameter of the small end bushes corresponds to the recommended figures.

- 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.

- Fit the sealing rings in the cylinder liner and check the gap between the seal ends is within specified limits.

- Check that the outer diameter of the pistons is as specified.

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.

- 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).

- 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.

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

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.

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.

- 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.

- 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.

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

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.

1. Place the rpm sensor (1a) in its housing and secure it using the bolts (1b).

2. Place the detonation sensors (2a) in their housings and secure them using the bolts (2b).

1. Place the thermostat (1a) in its housing complete with pipe (1b) and secure it using the bolts (1c).

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).

2. Place the fixed pad (2a) in its housing on the oil pump and secure it using the bolts (2b).

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).

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.

- Place the engine oil filter mounting and heat exchanger in position complete with a new gasket and secure it using the bolts.

- 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.

- 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.

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.

- 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.

2. Place the fixed pad (2a) in its housing and secure it using the bolts (2b).

3. Place the moving pad (3a) in its housing and secure it using the bolt (3b).

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.

- 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.

3. Place the fixed pad (3a) in its housing and secure it using the bolts (3b).

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.

- 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.

2. Place the fixed pad (2a) in its housing and secure it using the bolts (2b).

3. Place the moving pad (3a) in its housing and secure it using the bolt (3b).

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.

- 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).

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.

1. Place the phase transformer electromagnets (1a) in their housings on the cylinder head and secure them using the bolts (1b).

- 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.

1. Position the engine components single belt moving tensioner (1a) in its housing and secure it using the bolts (1b).

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.

1. Remove the tool used for counter-torque for the bolt fixing the services pulley on the crankshaft and for rotating the crankshaft.

1. Place the water pump rigid inlet pipe (1a), complete with gaskets, in position and secure it using the bolts (1b).

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.

- 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.

- Place the ignition coils back in their housings and fasten them using the bolts.

- Place the air chamber gaskets in their housings.

1. Fit the air chamber (1a) in its housing and secure it using the bolts (1b).

- 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.

Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE

2.4 JTD 20V

Removing

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

- Fit the tool for rotating the crankshaft.

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.

- 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

- 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.

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

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

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

- 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.

- 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).

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

- 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.

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

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.

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

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 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.

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).

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

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

- 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.

- 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.

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.

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

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

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

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 crankpin

2. - 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 IDENTIFICATION

Bearing 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 dimensions

In 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.

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.

- 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.

- 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).

- 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.

- 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.

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

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

- 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.

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

- Fit the tool for rotating the crankshaft.

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

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.

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

- 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.

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.

- 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.

- 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.

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.

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

- 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.

- 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.

- 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.

- 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.

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

- 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.

- 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.

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

- 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.

- 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.

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

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

- 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.

1.8

Removing

1. Remove the toothed drive pulley

1. Undo the bolts (1a) and remove the alternator (1b).

1. Undo the bolt (1a) and remove the detonation sensor (1b).

1. Undo the bolt (1a) and remove the rpm sensor (1b).

- Undo the bolts and remove the connector holder bracket.

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

- Place the engine oil filter mounting complete with heat exchanger in a vice fitted with protective jaws.

1. Undo the bolts and remove the water-oil heat exchanger (1a) from the engine oil filter mounting (1b).

- Remove the gaskets.

1. Undo the plug (1a) and remove the oil filter cartridge (1b).

1. Undo the bolts (1a) and remove the rigid return pipe (1b) to the water pump complete with O-ring.

2. Undo the bolts (2a) and remove the air conditioner compressor (2b).

3. Undo and remove the engine oil pressure warning light switch.

1. Undo the bolt (1a) and remove moving tensioner (1b).

2. Undo the bolt (2a) and remove fixed tensioner (2b).

3. Undo the bolts (3a) and remove the crankshaft oil seal front cover (3b).

- Remove the gasket.

- Place the crankshaft oil seal cover assembly in a vice fitted with protective jaws.

1. Undo the bolts (1a) and remove the water pump pulley (1b).

2. Undo the bolts (2a) and remove the cover (2b) complete with water pump impeller.

- Remove the gasket from the water pump cover.

- Remove the centering pins.

Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH

- Rotate the crankshaft using the tool fitted previously until the piston concerned is at B.D.C.

- Mark the connecting rod cap and the connecting rod to be removed.

1. Undo the bolts (1a) and remove the connecting rod caps (1b) and lower half-bearings.

2. Remove the pistons complete with connecting rods and upper half-bearings.

The arrow (a) on the piston crown facing the timing side indicates the fitting direction. The connecting rod-cap matching is the "BREAK" with a compulsory position. The projection (b) on the connecting rod and the cap should be facing the flywheel with the arrow on the crown pointing towards the timing side to ensure the correct piston-connecting rod matching.

Op. 1028H54 PISTON WITH CONNECTING ROD - DISMANTLING AT THE BENCH

Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING

- Release the rpm sensor support ring and remove it.

- Remove the crankshaft rear seal.

- Check that the crankshaft endfloat is within specified limits.

- If the value is not within the recommended limits, replace the half-bearings for main journal 3 and repeat the checking operation.

1. Undo the bolts (1a) and remove the main journal caps (1b) and lower half-bearings.

The bearing caps are numbered from 1 to 5 starting from the timing side.

2. Remove the crankshaft from the cylinder block/crankcase.

3. Remove the upper main journal half-bearings.

4. Remove the thrust washers from the centre support.

5. Undo the bolts (5a) and remove the engine oil jets (5b).

1. Place the crankshaft in the cylinder block/crankcase on the supports and check that the radial clearance is within the recommended limits.

- Remove the crankshaft from the cylinder block/crankcase.

Op. 1020A46 CRANKCASE OIL SUMP PARTITION - R.R. WITH CRANKCASE SUMP REMOVED

Op. 1084A40 ENGINE OIL LEVEL SENSOR - R + R

- Drill and remove the water/oil sealing plugs from the crankcase to allow for washing the ducts.

Refitting

- Clean the residues of sealant from the mating surfaces between the cylinder head and the engine block.

- Clean the residues of sealant from the mating surfaces between the oil sump and the engine block.

- Clean the parts removed thoroughly and check their condition visually.

- Fit the water/oil sealing plugs in the engine block using suitable fitting tools.

- Place the engine oil jets in their housings and tighten the bolts.

- Lubricate all the mechanical components with engine oil.

- Check that the cylinder head support surface does not have cracks or grooves.

1. Using a calibrated metal rule and a feeler gauge, check the flexible yield, widthwise and lengthwise and the diagonal defromation of the upper engine block surface.

1. The following information is stamped on the engine block: production date (1a), cylinder liner/bore grade (1b), main journal bearing grade (1c).

1. Measure the inner diameter of the cylinder bores as illustrated in the diagram below using a gauge for the interior.

- If the cylinder bore internal diameter is not within the recommended limit, ream the cylinder bores following the recommended oversizes.

In the case of reaming, all the cylinder bores must have the same oversize.

After reaming the original code must be invalidated and the new oversize code stamped on the engine block.

- Check that the diameter of the main journals corresponds to the recommended figures.

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

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

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

- Check that the length of main journal "3" (guide bearing) is within the recommended values.

- If the diameter of the main journal 3 is not correct, it should be reground to the recommended undersizes.

- Check the crankshaft and connecting rod bearings bearing in mind that no adjustment operations should be carried out on the half-bearings. Replace them if scoring or signs of binding are noted.

- Fit the upper half-bearings on the engine block making sure that they are perfectly clean and have been lubricated with engine oil.

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.

- Fit the lower half-bearings on the connecting rod caps making sure that they are perfectly clean and have been lubricated with engine oil.

If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions.

- Fit the bearing caps following the fitting position marked on them and tighten the bolts to the recommended torque.

The fixing bolts removed previously can be reused just to check the bearing clearance.

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

Check the clearance for all the main journals taking care to do it one bearing at a time without ever moving the crankshaft.

- If the values are not within the recommended limits, replace the half-bearings and repeat the operation of checking the clearance.

- The size of the main journal half-bearings is given.

- Apply adhesive putty in the side splining of main journal cap number 5 (flywheel side) and place it in position.

- Fit the remaining main journal caps following the position marked on them.

- Tighten the new connecting rod cap fixing bolts to the specified torque.

- Clean any carbon residues carefully from the pistons.

- Check that the outer diameter of the pistons perpendicular to the gudgeon pin axis 14.5 mm from the lower edge is within the recommended values.

- If these values do not correspond to the recommended figures, replace the piston complete with piston rings and gudgeon pin.

- The clearance between the piston and the liner/bore is given below.

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

- Check that the clearance between the gudgeon pin and the housings in the connecting rod and piston are within the recommended values.

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

- Fit the piston rings in the cylinder bore and, using a feeler guage, check that the gap between the two ends is within the recommended values, or else they must be replaced.

1. Check that the backlash (1a) between the circlips (1b) and the housing in the piston (1c) corresponds to the recommeded figure; if this is not the case, replace the circlips.

Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING

Op. 1028H54 PISTON WITH CONNECTING ROD - DISMANTLING AT THE BENCH

1. Fit the piston complete with connecting rod (1a) and half-bearings using the tool (1b) for compressing the circlips and then fitting them in the cylinder liner/bore.

2. Position the piston with the arrow (2a) facing the timing side and the projection (2b) facing the flywheel.

1. Fit the calibrated wire (plastigage) for measuring the bearing clearance.

2. Fit the lower connecting rod half-bearings on the caps making sure that they are perfectly clean and have been lubricated with engine oil.

If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions.

3. Fit the connecting rod caps matching them with the connecting rod using the references made during the dismantling and tighten the bolts to the recommended torque.

The fixing bolts removed previously can be used just to check the bearing clearance.

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

If the values are not within the recommended limits, replace the half-bearings and repeat the operation of checking the clearance.

- Fit the connecting rod caps and secure them by tightening the fixing bolts to the recommended torque.

- Remove the tool for rotating the crankshaft.

1. Place a new flywheel side oil seal (1a) in the housing using the tool (1b).

- Fit the rpm sensor support seal on the oil seal fitted previously.

- Position the rpm sensor in its housing and secure it to the support seal using the bolt.

Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH

- Place the crankshaft oil seal front cover in a vice fitted with protective jaws.

- Fith the water pump cover with a new gasket and tighten the bolts to the recommended torque.

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

- Fit the crankshaft oil seal front cover centering bushes on the crankcase.

- Fit a new crankshaft oil seal front cover gasket.

- Place the crankshaft front oil seal cover in its housing and secure it tightening the bolts to the recommended torque.

- Place the engine oil pressure switch in position and tighten it to the recommended torque.

- Place the water pump rigid return pipe, complete with new gasket, in position and tighten the bolts.

- Place the oil filter mounting in a vice fitted with protective jaws and replace the gaskets.

- Place the water-oil heat exchanger in position on the engine oil filter mounting and secure it using the bolts.

- Place a new oil filter cartridge in position and tighten the cover to the recommended torque.

- Remove the engine oil filter mounting assembly from the vice, place it in position on the left side of the crankcase and secure it tightening the bolts to the recommended torque.

- Position the detonation sensor in its housing and secure it tightening the bolt to the recommended torque.

- Place the connector holder bracket in position and fit the rpm sensor connector.

- Place the alternator in position and tighten the bolts to the recommended torque.

- Place the toothed drive pulley in its housing on the crankshaft.

- Apply a bead of silicon sealant about 2 mm thick to the contact areas between the engine block, 5th main bearing cap (flywheel side) and the crankshaft oil seal front cover.

1. Apply a bead of silicon sealant about 3 mm thick to the edge of the sump and around the oil recirculation and inlet connectors as illustrated.

- Refit the oil sump in its seat and tighten the bolts to the recommended torque.

- Rotate the overhaul stand through 180 °.

- Fit the locating bushes for the engine block.

- Fit a new cylinder head gasket.

- Place the cylinder head in position and tighten the fixing bolts to the recommended torque, following the order illustrated in the diagram.

1. Fit the tool (1a) in the special splining on the camshafts (1b).

1. Fit the tool (1a) on the toothed driven pullies (1b).

Fit the inlet side template first and then the exhaust side one.

- Using the special tool, rotate the crankshaft and place the reference on the toothed drive pulley in line with the reference (triangle) on the crankshaft oil seal front cover.

- Using a spanner, rotate the timing belt moving tensioner in a clockwise direction until the tensioner locking pin can be placed inside the opening.

- Fit a new timing belt in place, taking care not to move the crankshaft timing references.

1. Check the crankshaft timing by checking that the references illustrated in the diagram are aligned.

- Fit the timing belt definitively adjusting the moving tensioner to remove the locking pin.

- Remove the templates used for timing the camshafts.

- Place the cam cover in position and secure it by tightening the bolts to the recommended torque.

- Place the ignition coil module in its housing and secure it tightening the bolts to the recommended torque.

- Place the ignition coil cover in its housing and secure it using the retaining clips.

- Fit the timing belt lower protective cover and secure it using the bolts.

- Place the auxiliary belt pulley and washer in position and tighten the bolt to the recommended torque.

Prevent the crankshaft from rotating using the flange fitted previously on the crankshaft.

Check that the timing reference on the auxiliary drive pulley is aligned with the reference on the timing belt lower protective cover.

- Place the water pump rigid rear return pipe, complete with new seals in position and secure it to the thermostat tightening the bolts to the recommended torque.

- Fit the new exhaust manifold gasket on the cylinder head studs.

- Place the exhaust manifold - catalytic converter in its housing with the mounting bracket on the crankcase and tighten the fastenings to the recommended torque.

- Place the exhaust pipe heat shield in its housing and secure it using the bolts.

- Place the oil dipstick pipe back in its housing and fasten it to the cylinder head using the bolt.

- Place the modular intake chamber in its housing and secure it to the cylinder head tightening the bolts to the recommended torque.

- Place the injection control unit in its housing on the modular intake chamber and tighten the bolts to the recommended torque.

- Place the throttle body in position and secure it tightening the bolts to the recommended torque.

- Connect the water supply and return pipes to the throttle body and secure them using the bands.

- Connect the corrugated oil vapour hose to the tappet cover and to the throttle body and secure it using the retaining clips.

- Connect the rapid connector for the throttle body coolant supply pipe, thermostat mounting side.

- Place the wiring in its housing on the engine and secure it using the retaining clips.

- Connect the electrical connection for the injection control unit.

- Connect the electrical connections for the injectors.

- Connect the electrical connection for the phase transformer solenoid, inlet side.

- Connect the electrical connection for the fuel vapour flow enablement solenoid valve.

- Connect the electrical connection for the throttle casing.

- Connect the electrical connection for the modular intake manifold control actuator solenoid valve.

- Connect the electrical connection for the rpm sensor.

- Connect the electrical connection for the detonation sensor.

- Connect the electrical connection for the engine oil level sensor.

- Place the starter motor in its housing and secure it tightening the bolts to the recommended torque.

- Connect the earth lead to the cylinder head and secure it using the bolt.

- Connect the electrical connection of the ignition coil module.

- Connect the electrical connection for the water temperature sensor on the thermostat.

- Connect the electrical connection for the water temperature regulator on the thermostat.

- Connect the electrical connection for the inlet side timing sensor.

- Connect the electrical connection of the exhaust side timing sensor.

- Connect the electrical connection for the upper Lambda sensor and secure it to the mounting bracket.

- Fasten the wiring retaining duct to the tappet cover using the clips.

- Connect the electrical connection for the phase transformer solenoid, exhaust side.

- Connect the electrical connection for the minimum engine oil pressure switch.

- Connect the electrical connection for the air conditioning compressor.

- Place the intermediate timing belt protective cover in position.

- Fit the upper timing belt protective cover and secure it using the bolts.

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

- Position the auxiliary drive belt moving tensioner in its housing and secure it tightening the bolt to the recommended torque.

- Adjust the moving tensioner with a wrench and fit the auxiliary drive belt.