COMPONENTS TRANSFER for lighter engine

Operation 1004E60 · ENGINE ASSEMBLY INSPECTION AND REPAIRS

Removing

- 1004D40 engine - position on stand and remove

- 1004E30 COMPONENTS TRANSFER for half-finished engine

1. Loosen the nut fixing the automatic belt tensioner.

2. Remove the timing drive belt.

1. Using locking tools (1a) and (1b), undo the bolts (1b) fixing the pullies.

2. Remove the inlet and exhaust camshaft drive pullies.

1. Undo retaining bolts

2. Remove the fixed timing belt tensioner.

3. Undo the bolts (3a) and remove the timing belt rear protection (3b).

1. Undo the fixing nuts (1a) and remove the mounting bracket (1b) for the ignition coils.

1. Undo the retaining bolts.

2. Remove the inlet and exhaust side camshaft housings.

Recover the gasket underneath.

When removing the camshaft housings, take care not to let the hydraulic tappets drop. Slightly raise the camshaft housing to release it from the centering pins, then turn it over, taking care to check that the hydraulic tappets are in their housings.

Disconnect the coolant hose to the water pump rigid pipe.

3. Using a suitable spanner, undo the bolts fixing the cylinder head to the cylinder block/crankcase.

4. Remove the cylinder head.

5. Recover the cylinder head gasket.

Refitting

Remove the half complete engine to be replaced from the overhauling stand.

Remove the engine mounting brackets and transfer them to the new half complete engine.

Using a suitable tool, lift the engine and fix it to the rotating stand to fit the missing component.

Position the piston for cylinder no. 1 approximately at T.D.C.

Clean the cylinder head and crankcase contact surfaces.

Position the cylinder head gasket with the wording 'ALTO [TOP] facing you.

Before fitting the cylinder head, rotate the crankshft until the piston for cylinder no. 1 is approximately at T.D.C.

Position the cylinder head on the crankcase.

1. Tighten the cylinder head bolts, following the order shown in the figure below.

2. Using the tool, tighten the cylinder head fixing bolts to torque, following the order illustrated previously.

Fit a new cylinder head gasket.

Fit the camshaft housing, taking care not to let the hydraulic tappets drop.

Tighten the cylinder head fixing bolts to torque.

Position the new inlet side camshaft housing gasket.

Fit the camshaft housing, taking care not to let the hydraulic tappets drop.

Tighten the cylinder head fixing bolts to torque.

Fit the timing belt rear protection.

Fit the timing belt fixed tensioner, tightening the fixing bolt to torque.

Fit the camshaft pullies, without tightening the fixing bolts.

Remove the camshaft rear covers from the camshaft housing.

1. Position camshaft timing adjustment tools.

2. When fitting the tools, align shaft seat (2a) with key (2b) on the tools.

3. Tighten the tool retaining nuts.

The tools are stamped with the letters 'A (intake) and 'S (exhaust) to facilitate correct positioning on the shafts. The tools are not interchangeable.

Remove the spark plugs from their sockets on the cylinder head.

1. Position a dial gauge (1a), supported by a pointer (1b) in the housing for the spark plug for cylinder no. 1. Turn the crankshaft with small, even movements until the dial gauge shows the cylinder no. 1 piston is at TDC.

1. Proceed with fitting the timing drive belt, fitting it initially on the crankshaft gear (1a), the oil pump gear (1b), the fixed pulley (1c), the inlet camshaft pulley (1d), the exhaust camshaft pulley (1e) and, lastly, on the automatic tensioner (1f).

1. Undo retaining bolts

2. Position the toothed belt tensioning tool.

1. Adjust the tool until the belt is as taut as possible, i.e. when the moving belt tensioner pointer is at the end of its travel.

2. Tighten the tensioner retaining nut.

Use the pulley tightening tool to tighten the camshaft pulley retaining bolts to the specified torque.

Remove the camshaft timing tools.

Remove the dial gauge together with the probe.

Rotate the crankshaft through two revolutions in its normal direction of rotation.

1. Loosen the belt tensioner retaining nut and use tool (1a) to slightly release belt tension until moving reference (1b) is aligned with fixed reference (1c) on the tensioning device.

2. Tighten the tensioning device retaining nut to the specified torque.

Remove the tool and tighten the retaining bolt removed previously to the specified torque in order to fit the tensioning tool.

It is good practice to check timing again by refitting the tools to the camshafts and adjusting the engine until cylinder no. 1 is set to TDC, measured using the dial gauge and probe. If the engine timing is not correctly adjusted or the timing belt is found to be faulty, the removal-refitting and engine timing adjustment operation must be repeated.

Fit the camshaft rear covers.

- 1004E30 COMPONENTS TRANSFER for half-finished engine

- 1004D40 engine - position on stand and remove