1. Place the piston/connecting rod assemblies (1a) for cylinders 2 and 3 complete with half-bearings (1b) in their housings using a suitable fitting tool.

The piston-connecting rod assemblies should be fitted so that the arrows stamped on the piston crown are facing the exhaust side.

1. Place the connecting rod caps (1a) for cylinders 2 and 3 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.

	Fastening	Component	Ø	Value (daNm)
1c	Bolt	CONNECTING ROD CAPS	M9	2.4 ÷ 2.6 +60?

Fastening

Component

Value

(daNm)

Bolt

CONNECTING ROD CAPS

2.4 ÷ 2.6 +60?

Use the tool for the angular tightening of the connecting rod cap bolts.

	Description	Code
	Torque wrench	1.860.942.000

Work in the same way to fit the piston/connecting rod assemblies for cylinders 1 and 4.

Proceed with the refitting

Op. 1020A20 CRANK CASE OIL SUMP - R + R CLEAN SEALS FOR SEALANT APPLICATION.

Proceed with the refitting

Op. 1016C10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL.

Proceed with the refitting

Op. 1080B62 CATALYTIC CONVERTER - R + R.

Proceed with the refitting

Op. 1076A48 CATALYTIC CONVERTER HEAT SHIELD - R R.

Proceed with the refitting

Op. 5040A26 COMPRESSOR MOUNT - R R.

Proceed with the refitting

Op. 5040A20 AIR CONDITIONER COMPRESSOR - R+R - INCLUDES FLUID LEVEL CHECK AND TOP UP IF NECESSARY.

Proceed with the refitting

Op. 1016A40 IGNITION COIL COVER ON CYLINDER HEAD- R+R.

Proceed with the refitting

Op. 7055B54 UNDER-ENGINE GUARD - R R.

Proceed with the refitting

Op. 4450B04 RIGHT FRONT WHEEL R R.

Refill the air conditioning refrigerant circuit

Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE.

Connect the negative battery terminal (-).

Refill the engine cooling system

Remove the vehicle from the lift.

1.9 JTD 16V

Removing

Position the vehicle on a lift.

Make sure that the ignition key is in the OFF position, then disconnect the negative battery terminal (-).

	Description	Connector
	Battery	See A1B BATTERY ( BATTERY NEGATIVE )

Proceed with the removal

Op. 1008C10 POWER UNIT UPPER REACTION LINK R R.

Proceed with the removal

Op. 1060G80 DS ELECTRIC INJECTION CONTROL UNIT - R R.

Proceed with the removal

Op. 4450B04 RIGHT FRONT WHEEL R R.

Proceed with the removal

Op. 7055B54 UNDER-ENGINE GUARD - R R.

Proceed with the removal

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R..

Proceed with the removal

Op. 1092G10 SINGLE ENGINE BELT R R.

Proceed with the removal

Op. 1092A10 CRANKSHAFT SERVICES PULLEY - R.R..

Proceed with the removal

Op. 1092G20 ENGINE COMPONENT SINGLE BELT FIXED TENSIONER - ONE - R + R.

Proceed with the removal

Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R.

Proceed with the removal

Op. 5530B10 BATTERY - R+R.

Proceed with the removal

Op. 1016C10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL.

1. Undo the plug and drain the engine oil.

Collect the engine oil in a suitable container. The engine oil used contains substances that are harmful to the environment. Place these substances in containers designed for oil collection and disposal.

1. Undo the bolt connecting the intermediate driveshaft bearing support to the crankcase sump.

2. Undo the bolts fixing the manual gearbox-differential unit to the crankcase sump.

1. Undo the front and rear bolts (1a) fixing the crankcase sump using the tool (1b).

	Description	Code
1b	Spanner	1.860.833.001

2. Undo the side bolts (2a) fixing the crankcase sump using the tool (2b).

	Description	Code
2b	Spanner	1.860.834.001

3. Cut the crankcase sump sealant using the tool.

	Description	Code
3	Blade	1.870.718.000

4. Remove the crankcase sump.

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

1. Release and remove the piston/connecting rod assemblies (1a) complete with half-bearings (1b).

Refitting

1. Place the piston/connecting rod assemblies (1a) in their housings complete with half-bearings (1b) using a suitable fitting tool (1c).

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.

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.

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

	Fastening	Component	Ø	Value (daNm)
1c	Bolt	CONNECTING ROD CAPS	M9	2.4 ÷ 2.6 + 60?

Fastening

Component

Value

(daNm)

Bolt

CONNECTING ROD CAPS

2.4 ÷ 2.6 + 60?

Use the tool for the angular tightening of the connecting rod cap bolts.

	Description	Code
	Torque wrench	1.860.942.000

Thoroughly clean traces of sealant of the mating surfaces between the crankcase sump and engine block.

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

1. Place the crankcase sump in its housing.

When positioning the crankcase sump, avoid significant sideways movements that could remove the sealant.

2. Tighten the side bolts (2a) fixing the crankcase sump to the recommended torque using the tool (2b).

	Fastening	Component	Ø	Value (daNm)
2a	Side bolts	OIL SUMP	M8	(Engine crankcase side) 2.3 - 2.8

Fastening

Component

Value

(daNm)

Side bolts

OIL SUMP

(Engine crankcase side) 2.3 - 2.8

	Description	Code
2b	Spanner	1.860.834.001

3. Tighten the front and rear bolts (3a) fixing the crankcase sump to the recommended torque using the tool (3b).

	Fastening	Component	Ø	Value (daNm)
3a	Front and rear bolt	OIL SUMP	M6	(Front/rear cranckase covder side) 0.8 - 1.0

Fastening

Component

Value

(daNm)

Front and rear bolt

OIL SUMP

(Front/rear cranckase covder side) 0.8 - 1.0

	Description	Code
3b	Spanner	1.860.833.001

1. Tighten the bolts fixing the manual gearbox-differential unit to the crankcase sump to the specified torque.

	Fastening	Component	Ø	Value (daNm)
1	Bolt	OIL SUMP	M10	(Manual gearbox side) 5.0 - 6.1

Fastening

Component

Value

(daNm)

Bolt

OIL SUMP

M10

(Manual gearbox side) 5.0 - 6.1

2. Tighten the bolt connecting the intermediate driveshaft bearing support to the crankcase sump.

Fit a new engine oil drain plug complete with gasket and tighten it to the recommended torque.

Fastening

Component

Value

(daNm)

Proceed with the refitting

Op. 1016C10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL.

Proceed with the refitting

Op. 5530B10 BATTERY - R+R.

Proceed with the refitting

Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R.

Proceed with the refitting

Op. 1092G20 ENGINE COMPONENT SINGLE BELT FIXED TENSIONER - ONE - R + R.

Proceed with the refitting

Op. 1092A10 CRANKSHAFT SERVICES PULLEY - R.R..

Proceed with the refitting

Op. 1092G10 SINGLE ENGINE BELT R R.

Proceed with the refitting

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R..

Proceed with the refitting

Op. 7055B54 UNDER-ENGINE GUARD - R R.

Proceed with the refitting

Op. 4450B04 RIGHT FRONT WHEEL R R.

Proceed with the refitting

Op. 1060G80 DS ELECTRIC INJECTION CONTROL UNIT - R R.

Proceed with the refitting

Op. 1008C10 POWER UNIT UPPER REACTION LINK R R.

Refill the engine oil lubrication system

Op. 0010T11 ENGINE OIL CHECK LEVEL AND TOP UP.

Refill the engine cooling system

Op. 0010T20 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY.

Connect the negative battery terminal (-).

Remove the vehicle from the lift.

1.8 T.SPARK

Removing

Position the vehicle on a lift.

Make sure that the ignition key is in the OFF position, then disconnect the negative battery terminal (-).

	Description	Connector
	Battery	Vedere A1B BATTERIA ( CABLAGGI )

Proceed with the removal

Op. 4450B04 RIGHT FRONT WHEEL R R

Proceed with the removal

Op. 7055B66 ENGINE COMPARTMENT DUST SHIELD PROTECTION IN RIGHT FRONT WHEEL ARCH - R.R.

Proceed with the removal

Op. 1016A40 IGNITION COIL COVER ON CYLINDER HEAD- R+R.

Proceed with the removal

Op. 5510C14 ROCCHETTI/BOBINE DI ACCENSIONE - S.R.

Proceed with the removal

Op. 1016A20 SINGLE CAM COVER - R + R AND REPLACE GASKET.

Proceed with the removal

Op. 1056B60 TUBO COLLETTORE COMBUSTIBILE UNICO, COMPLETO DI ELETTROINIETTORI - S.R.

Proceed with the removal

Op. 1072D10 MODULAR INLET MANIFOLD - R+R.

Proceed with the removal

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD ON BULKHEAD - R+R.

Proceed with the removal

Op. 1092G10 SINGLE ENGINE BELT R R.

Proceed with the removal

Op. 1092G20 ENGINE COMPONENT SINGLE BELT FIXED TENSIONER - ONE - R + R.

Proceed with the removal

Op. 1092A10 CRANKSHAFT SERVICES PULLEY - R.R..

Proceed with the removal

Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R.

Proceed with the removal

Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT.

Proceed with the removal

Op. 1016C10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL.

Proceed with the removal

Op. 1080B40 CATALYTIC PRE-CONVERTER - R R.

Proceed with the removal

Op. 1008A44 REAR RIGID MOUNT - R R.

Proceed with the removal

Op. 1020A20 CRANK CASE OIL SUMP - R + R CLEAN SEALS FOR SEALANT APPLICATION.

Turn the crankshaft until the pistons of the 1st and 4th cylinder are set to BDC.

1. Undo the bolts (1a) and remove the connecting rod caps (1b) complete with half-bearings (1c) for cylinders 1 and 4.

1. Withdraw and remove the piston/connecting rod assemblies (1a) complete with half-bearings (1b) for cylinders 1 and 4.

Work in the same way to remove the piston/connecting rod assemblies for cylinders 2 and 3.

Refitting

1. Place the piston/connecting rod assemblies (1a) for cylinders 2 and 3 complete with half-bearings (1b) in their housings using a suitable fitting tool (1c).

The pistons and connecting rods are fitted in the cylinder block/crankcase with the large grooves (for the inlet valves) on the piston crown facing the inlet side.

1. Place the connecting rod caps (1a) for cylinders 2 and 3 in their seats complete with half-bearings (1b) and secure them by tightening the bolts (1c) to the recommended torque.

Fit the connecting rods so that the number stamped on each rod faces towar the same side as the number stamped on the big end.