‘PA48568 1000000 I) REPAIR MANUAL e ENGINES -Engine 1995 cm® (code AR 67202) Engine 1773 cm® (code AR 67102) -Engine 1749 cm? (code AR 67103) Hid GROUP 01 - ENGINE MAIN MECHANICAL UNIT Matching of pistons - rods and crankshatt . + Refiting cylinder head . - Checking engine timing = Cylinder compression test 01-58 01-58 01-59 01-61 1-61 01-63 01-64 1-64 01-65 01-66 01-67 01-88 -01-70 -01-70 01-70 -01-72 01-72 01-74 01-74 01-74 01-75 01-78 01-80 01-89 HGINE MAIN MECHANICAL UNIT CHECKING ELECTRICAL COMPONENTS = Engine oil pressure meter — Engine oil temperature sensor O1- 01-84 01-84 - 01-84 = Minimum engine oil pressure warning light sensor . — Minimum engine oil level warning light sensor “ON VEHICLE” OPERATIONS — Removalirefitiing of oil sump ~ Removaliefitting of engine pulley 01-85 01-85 01-86 - 01-86 01-90 TECHNICAL CHARACTERISTICS AND SPECIFICATIONS — Engine technical characteristics . = Complete engine block — Rod -piston assembly .... = Cylinder head . ~ Angular values of the real timing diagram . . = Fiuids and kbricarts — Sealants and fixatives . . ~ Abrasives — Tightening torques ... SPECIFIC TOOLS FAULT DIAGNOSIS AND. CORRECTIVE INTERVENTIONS - 01-92 01-92 01-93 = 01-96 01-99 01-103 ~ 01-104 - 01-104 01-104 01-105 01-107 01-108ILLUSTRATED INDEX ENGINE REMOvALREFITTING | Pag. 0 ENGINE DISASSEMBLY AND REASSEMBLY pes Pag, 01-28 | DISASSEMBLY OF CYLINDER __ CYLINDER HEAD CHECKS AtIO INSPECTIONS Pag, 01-50 | PSeS 42C000D ENGINE BLOCK CHECKS AND INSPECTIONS. Pag. 01-58 INDICATIONS FOR (reaaoigo| REASSEMBLY Pag. 01-70 CHECKING ELECTRICAL COMPONENTS | Pag. 01-84 71991 ENGINE GENERALITIES ‘The engine is of the 4 cylinder in line type in light alloy with a double on-head camshatt, timing variator and doubla static ignition and injection controlled by 2 single BOSCH MOTRONIC 1.7 control unit The clutch - gearbox - differential group is connected behind the engine and forms an integral pant of the engine unit, The engine itset is front mounted and set transversally with a 13° inclination forwards. Iti installed on the frame by suspension type mounts and fixed by two elastic damping supporss. A third sup- port of the compass type secures it to the suspension ‘crossmember, ‘A tod between the engine and the body prevents ex- cessive shaking of the engine. ‘The engines described below contorn to the "USA 83" exhaust emissions regulations. STRUCTURE Engine block: this is a single biock in light alluminium and silicon with @ high mechanical resistance and heat dissipation, ‘The crankshatt is supported by five main supports. Grooving in the walls o! the engine block permit the Circulation of engine coolant and lubricating oi For AR67202 (1865 cc.) engines only, oll spray jets which cool the pistons are located at the base of the cylinders Cylinder liners: tmese are incastiron and are of the low est lappez.cn tha outsce by the cesli more rational hat dissioation we! The size of the cam is such that itis rst Geis fs thus able meg fora O1-4 The cylinder liners are supplied already coupled with their relative pistons and are divided into tnvee dimen- sional classes Front cover: this is in die-cast in alurinium alloy and completing the forward part of the engine block, pro‘ects the timing chain. ‘The ol pump boay is tocatad in the lower part and the volute for the insigllation of the water pump rotor is located on the urper part. Cylinder head: In is of the monolth type, compact and chil-cast in aluminium and siicium alloy with a double camshaft with rect action valves arranced in a “V" of 46". There ave two ignition spark plugs tor each cylinder. The contor- mation of the combustion chambers is optimal due tothe postion of the valves; at the same time the rectinear intake ducts have a cortained loading loss and permit maximum exploitation of the resonance, a distinct ad vantage with regard to volumetric perfermance this is a structural part of the engine with mechanical functions in adkition to that of containing the engine oil ficone It is made of die-cast aluminium wit: tiguis sealingHi ENGINE MAIN MECHANICAL UNIT. MOVING PARTS Crankshaft: this is forged in high resistance bonded steet is soft nitride. This treatment decreases wear and increases reliability (resistance to fatigue). I rests on five main supports and shouklers on the central main support Eight countenweights arranged through 180° accurately balance the rotating masses. ‘Achannel runs inside the shatt for the lubrication of ne ‘main and rod journals, Main and rod bearing halves these are of the three-metal, thin shell type are divided into three dimensional classes to contain the radial play ‘There are two holes and a circumference groove for the Passage of oll locatedon ne tront, central and rear main bearing haves, Flywheel this is in cast iron, balanced, and with a ring gear in tempered steel Pistons - rods: the pistons are in siicium-aluminium alloy with sef-heat ing inserts and are divided into three dimensional classes. To ensure correct installation an arrow is stamped onto the piston ceiling which indicates the direction of retation of the engine The rods are in hardened and tempered alloy, with @ ‘bushing in copper alloy inserted for the coupling with the ‘gudgeon pin of the piston. ‘The piston - rod assembly has been lightened to reduce the moving masses PA4655B1000000 01-5 AUXILIARY ORGANS Timing Giract drive by double chain with cemented and tem: pored on-head camshaits in steel alloy. A reference notch for correct timing has been engraved onto the central journal of the camshaft and relative cap, ‘The lightweight tappets, of the mechanical type, are ‘composed of a valve cup in alloy steel in contact with the cam, “The control of the valve cup is transmitted to the valve bby a cap, in tempered carbonitrided steel, used to regu: late the vaive clearance, Particularly important is the introduction of sodium into the exhaust valve which improves the dissipation of the heat to which they are subjected, ‘The valve seats are sintered in material suitable for operation with unleaded petrol. Timing variator: This is of the simpilied type which ensures great precl- ‘sion of timing, rapid intervention and high mechanical reliabilty Im order to reduce the size of the engine, the actuation valve has been inclided in the intake manifold with suitable channeling, also present on the cylinder head, which regulates the flow of clo the vz ~ This device varies the intake valve timing on the basis of engine loading, This parameter is received ‘and processed by the MOTRONIC control unit in the form of an electric signai sent by the airflow meter 8 a command, to the solenoid, by way of a relay, 7.1991 Hk ENGINE MAIN MECHANICAL UNIT = When the quantity of air taken in by the engine is ower tan a pre-set value, the solenoid (1) is deac- tivated.and tne valve box (2) pushed by tne counter- Spring (3) i tad up allowing the passage of oilfrom the channeling (A) to reach the variator. In this case the timing of the intake valves is not changed. — Ifthe quantity ofintake air exceeds the pre-set value the solenoid (1) Is activated and pushes the valve box (2) downwards. In this position the oil artiving from the channeling (A) enters the piston chamber (8) and passes through a hole into the internal channel (C} in the piston. ‘The oil can only exit this channel through the upper hole (leading to the cilto-variator delivery duct (D)) a the lower hole no longer opens onto the exhaust duct (E) as the valve box (2) is lowered. ‘The oil passes through the channeling (0) and (F) ‘and reaches the chamber (G) moving the piston (4) axially towards the engine. P4.48558 1000000 O1-6 “The piston is excerally equipped with neta teen and as a result ofthe axlal movement is forced 10 rotate clockwise (as seen tom ine timing se), Thig rotation is tranemeted te the pinion through @ stiaight toothed groovedproie. The pinion (5) which is rotated by the threaded tug of the camshait (6) transmits the rotation othe shat andinthis way he Liming ofthe intake valves is varied by 30°, When the solenoid is deactivated, the valve box (2) retuins to the inal poston, iterrupting the flow of pressurized ol to the piston (8) but permitting ihe retuin ofthe cil 0 the outlet due to the thrust trom the counter spring (7). ‘The channeling (L) enables the camshaft joumal to be lubricated under the various operating conci- tons. The ollwhich leaks into he solenoid chamber ) is cischarged through the drainage hole (E). 7.1991LUBRICATION The pump located on the front cover of the engine block is actioned directly by the crankshaft through a coupling. The oil, taken from the sump by the pump, is fitered on imake by the gauze filter and then sent under pressure through the channeling to the the total flow cartridge ail ‘iter, The titer is equipped with a safety by-pass valve which permits the oil to pass if the titer becomes. clogged. ‘The maximum lubrication pressure is regulated by a selie! valve installed on the pump, After being fitered, the oll passes into the main lubrica~ tion duets, which run longitudinally along the engine block and into the vertical ducts which run along both the engine block and the cylinder head. From the main ducts, passing through the three trans- versal ducts, the oil is sent to the lubrication channeling of the crankshatt main and red supports From the vertical ducts, the oil is sent to two ducts located longitudinally on the head and these lubricate the camshatt supports and valve cups. On the lubrication duct relative to the camshaft, intake side, there are two channels which permt the passage of cil to actuate the timing variator. The recovery citcuit is composed of two ducts located lengitudinally on the cylinder head. These collect the oil originating from the outlets located under each valve cup PAL 1000000 01-7 and rom the rear sumps, and discharge it romthe head, by gravity, into ine sump. The gears of the timing chain inthe engine block are in this way lubricated. A riciculation system with vapour separator permits the recovery of the oil vapours coming from the oil sump. The lubrication pressure is indicated by 2 pressure gauge located on the instrument panel. AA warning lamp alerts the driver to an excessively low oil pressure. The pressure signals are supplied by a sender andaa thermecontact located in the engine block The oil temperature is indicated on the instrument panal and receives the signal from a sender installed on the oilfiter suppor. ‘An il level sensor located to one side of the oil dipstick supplies the input signal forthe Mlumination of a warning light on the instrument panel which comes on it the of {alls below a certain lovel Only for ARE7202 engine: — The lubrication system is equipped with an oll cool ing radiator and a thermostat valve located in the fiter support. When the temperature falls below 78" +2°C the oilis sent directly to the cartidge fiker from where i reluins to the engine. When the tem- perature exceeds 83.5°C the thermostat valve ‘opens to permit the cil to pass to the oil cooling radiator in order to reduce the temperature. = Inorder to coo! the piston skint more eiticiently, jets are located in the engine block. These jets incorpor ate a ball vale which opens at a pressure of 1.25 101.75 bar. 71991 LUBRICATION CIRCUIT Suctien device Qi sump Oil pump, Pressure reliet vaive Ou ractator Olt titer suport Thermostat valve - voo00¢0 ENGINE MAIN MECHANICAL UNIT 8 10. Bypass vane 1 Oilpressure r Oi fites Minimum o evel sensorHl ENGINE MAIN MECHANICAL UNIT. ENGINE REMOVAL/REFITTING ‘The information and ilustrations given below permit the rapid removal of the engine trom its housing in the engine compartment and its successive reiiting, PA+€558 1000000 O1-9 ‘The bench disassembly of the single components is described in a separate chapter. This chapter should be taken as a single, complete procedure though parts may be used as required. For lurther information and delails refer to the chapters relative to the components or specific groups. 71991 REMOVAL, 1, Place the vehicle on a two columa itt and release the pressure in the fuel supply system as follows: — disconnect the fuel pump supply tuse; = start the engine and run untiit stops. = Drain off the freon from the air conditioning system in accordance with the current regulations (see GROUP 60). 1. Remove the battery alter first disconnecting the negative clamp (-) and then the positive (+). PA#65581000000 01-4 1. Empty the power steering fluid reservoir using a suitable syringe. 1. Disconnect the electrical connection from the air tow meter. 74991a 1. Disconnect the air intake pipe trom the constant idle speed actuator. Disconnect the oil vapour recirculation hose fromthe corrugated sleeve. 2. Loosen the clamp and separate the corrugated sleeve from the air intake box. PAs655e ./00000 01-11 1. Remove the air cleaner cover, air flow meter and corrugated sleeve assembly. 2 Itnecessary remove the fiter element. 1. Disconnect the spark plug cables from the two igni- tion coils. 2. Disconnect the electrical connections supplying the ignition coils. * 3. Disconnect the electrical connections from the two ‘gnition modules. 71991 Hi ENGINE MAIN MECHANICAL UNIT 1. Raise the vehicte on the itt 2. Loosenthe lower screw securing tha battery support to the vehicle body. PA465981000000 1. Lower the vehicle. Unscrew the remaining screws securing the battery ‘Support to the body and raise it slightay. Remove the relay box bracket from the battery by unscrewing the two screws. Remove the battery support together with the coils, ‘and ignition modules. 7.1991Hid Remove the cap from the expansion tank, discon ine coolant inlet sleeve fromtive pump an drain ‘lant into a suitable container CAUTION The antifreeze mixture used as an engine coolant damages paint: avoid all contact with painted surtaces. Disconnect the engine coolant delivery sieeve from 2 the expansion tank, as6590 1000000 ENGINE MAIN MECHANICAL UNIT. 01-13 1, Disconnect the engine to coolant delivery sleeve {rom the thermostatic cup. 2. Disconnect the engine coolant to heater delivery sleeve from the thermostatic cup. 3. Disconnect the engine coolant retum sleeve from the heater. = Disconnect the engine coolant to expansion tank Golvery sleeve from the throttle valve 1, Disconnect the electrical connection trom the throttle valve potentiometer. rigor 1. Disconneetthe electrical connection tromtne engine coolant temperature sensor (NTC) 2. Disconnectthe electrical connection fromthe engine oil pressure meter. 3. Disconnectthe electrical connection fromthe engine coolant maximum temperature warning ight sensor. 4, Disconnectthe electrical connection tromtne engine coolant temperature sender. tm body. PA46556 1000000 ENGINE MAIN MECHANICAL UNIT 01-14 1. Remove accelerator cable suppor bracket and ‘move it to the left-hand side of the engine compart ment, 1. Disconnect the earth point from the negative (-) terminal of the battery. 7-198)Hie] ENGIN wa WECHANCAL UT 1. Unscrew the screws, and move the bracket to one ith the hydraulic clutch control with- ing the cil inlet pipe 1. Disconnect the electrical connection trom the re- versing tight switch PAs€5581000000 01-15 1. Disconnect the two electrical connections from tha engine cooling fan. 71991 Hid 1. Remove the airintake cuct tromtne cleaner together with the brackets, Geen : Trl: — \ VDSS | 1, Remove the engine cooling fan, PA#65581000000 ENGINE MAIN MECHANICAL UNIT 01-16 1, Disconnect the cable from the odometer sensor. Disconnect the electrical connection rom odometer sensor, a — ws (1 0h AeHy Remove the earth cables from the timing cover. Disconnect the electrical connection from the timing variator. . Disconnect the oll vapour recovery hose fromthe oil vapour separator Unserew the two screws securing oll vapour separ- ator to the air intake box and move it to one sice. PA465581000000 ENGINE MAIN MECHANICAL UNIT 1 01-17 Disconnect the excess fuel fo tank retum hose from the pressure reguletor. Disconnect the fusl prassuro regulator vacuum In- take hose trom the air intake box. Disconnect fuel vapour recirculation hose trom the air intake box. Disconnect the servo brake vacuum intake hose from the air intake box. 7-191 Ht 1. Unscrew the nut securing the impulse dashpot the the support bracket. 2. Disconnect the fuel delivery hose from the impulse dashpot 4485581000000 ENGINE MAIN MECHANICAL UNIT 1 1 O1-t Disconnect the electrical connection trom the rp.m. ‘and timing sensor. Disconnecttne electrical connection fromthe engine ol minimum pressure warning light sensor. 71991Disconnect the oil to power steering pump intake and delivery unions. Orain off the engine oil (see GROUP 00). Specific procedure for AR67202 (1995 ¢.c.) engines. Gisconnect the engine cil to relative cooling racialor Intake and delivery unions from the oi fiter support 419558 1000000 01-19 1, Remove the engine damping rod, 1, Move the air conditioning hoses in order to discon- rect the upper gears selection rod. 71991 1. Raise the vehicle on the lit. 1. Working from the front left wheel aren. remove the bracket supporting the inteligent sussension and ABS sensors without aisconneeting them 1. Disconnect brake pad wear sensor connection.Hy | a Gs 8 orj 1, Remove the starter motor together with the rear ‘support bracket. to the support ENGINE MAIN MECHANICAL UNIT Withdraw the intermediate shaft Remove the custband. 1. Remove the intermediate shatt support 01-29 Argat REMOVAL OF GEARBOX-DIFFERENTIAL GROUP 1. Inctab the two brackets N’ 1.820.145.000 (R.4.0178) onto the engine block ready for positioning the over- haul stand. es se y iy lo, \ Ai 1.820.148,000 (R.4.0178) e 1 a ol PAs€5581000000 {GINE MAIN MECHANICAL UNIT O1-: 1. Raise the engine using a hydraulic lit and releasing it trom the supponing jack. Place it on a rotary ‘overnaul stand and secure it using brackets N’ 4,820.145,000 (R.4.0178) 1.820.145.000 (R.4.0178)Remove tools N* 1.820.225.9000 and N° 1,820.233.000 used to remove the engine from the engine compartment. _ = A y 1. Remove the tlywneel cover. O1-31 id 1. Using a hydraulic crane remove the gearbox-dit- ferential group trom the engine. NOTE: For the complete overhaul of the gearbox reler to GROUP 13. F-1991 ENGINE HAI MECHANICAL UT 01-32 CLUTCH PLATE REMOVAL 1. Remove the disk pressure plate booy. 2. Remove the clutch disk. NOTE: For further details regarding the clutch anc its components refer to GROUP 12. 71991Hq 7 j ENGINE nAIN| MECHANICAL UNTT 01-33 uf enGINE MAIN MECHANICAL UNIT 01-3. REMOV. AIR | 1. Disconnect the el vapour hose from the eyknder /AL OF AIR INTAKE BOX Gesonnedt ' 1. Remove the fuel supoly manifold complete wih | 1. Wandraw ine tons and remove the power stering 2._ Disconnect the ol recirculation hose fromthe engine Injectors and supporting bracket with fuel pressure pump. HOTE: For additional disassembly and inspec- tions regarding the fuel supply system refer to GROUP 04. block. regulator and impulse dashpot. 3. Disconnect the water to throttle body delivery hose from the thermostatic cup. Remove the strut supporting the air intake box. Loosen the clamps holding the sleeves connecting tne intake box to the cylinder head. 6 Remove the complete air intake box. 1. Remove the snark plug cover 2 Disconnect the leads trom tne spark plugs and remove them togather with their clamps, REMOVAL OF POWER STEERING PUMP. REMOVAL OF ALTERNATOR: . Loosen the two bolts securing the power steering pump. 1. Loosen the bolts securing the aiternator. 2. Remove the water pumplponer steering pump drive bett 74991 PA465551000000Hi 1, Loosen the drive belt by acting on the micrometeric tensioner and withdraw it trom ine alternator pulley, 1. Witheraw the pins and remove the alternator together with belt tensioner brackets, a18556 1000200 ENGINE MAIN MECHANICAL UNIT 01-35 REMOVAL OF AIR CONDITIONING COMPRESSOR Unscrew the two pins and remove the compressor. Remove the alternator and compressor support. Remove the guide pulley. Remove the front engine support bracket. Remove the p.m. and timing sensor. Remove the airconditioning compressor alternator rive belt. 71991 Hid REMOVAL OF WATER PUMP 1 2 3, 4 5. 6 Remove the engine coolant to pump intake hose. . Remove the water pump, |. Remave the weter pump gasket. Remove the oil filler support assembly. 3. Remove the O-ring. Remove the oll dipstick, 7.65—5.45 Nm 0.70 ~ 0.96 kom 12.75 > 15.75 im 1.3+1.8 kgm ENGINE MAIN MECHANICAL UNIT O1-36 REMOVING CYLINDER HEAD 1. Fiemove the timing variator controlling solencic, 2 Remove the liming vatiator control valve and spring Remove the intake maniiolds and right-hand engine support bracket,1. Remove the spark plugs 2. Remove the timing cover. 3. Remove the gasket 4. Remove the leti-nand engine support bracket. ES 15.75 Nm 1.0- 1.6 kgm, ~ PAs6558 1000000 01-37 — Rotata the crankshatt until the connecting chain link is at the top, 1. Unlock the belt tensioner screw and push the chain cownwards. Lock the belt tensioner in this position bby rectightening the relative screw 1. Remove the connecting link from the timing chain, 71991 4. Using too! N* 1.€20.080,000 (A.2.0451), release the cylinder head and remove i 2. Remove the gasket. 1.820.080.000 (82.0351) PA#65561000000 01-3. 41. Install the cylinder liner fixing tools N 1.820.004.000 (A.2.0117) with wasners N° 1.820.052,000 (2.0362). 2. Install a suitable tool fo permit rotation of the crank- shaft. 9. Withdraw the tining chainby rotating the crankshaf, 0@ 1.820.004.000 ae 1.820.052.000 (42.0362) To refit he cylinder nead reter to the rele- fcc} vant paragraph.REMOVAL OF COMPONENTS FROM THE ENGINE BLOCK = Release the rotary standand rotate the engine block 180°. Remove the oll sup. Remove the oil pump suction body. Remove the gasket. Remove the engine oil minierum pressure warning light sensor. Remove the engine oil pressure meter. 6 Remove the engine oil level sensor 645+ 60Nm 6.6 +8.2 kgm :8 1000000 01-39 REMOVAL OF CYLINDER LINERS AND PISTONS = Rotate the crankshaft so that the first and fourth pistons are at B.0.C. Remove the rod cap from the first piston. Remove the relative rod haif-bearing, Remove the red cap trom the fourth piston. Remove the relative rod half-bearing, 71991 Hi = Release the rotary stand and rotate engine block 180" 1. Remove the cylinder liner fixing tools N* 1.820.004.000 (A.2.0117) and washers N° 1.820.082.000 (2.0362) 1.820.004.000 (a2o17) sazocoto 2 (a.2.0117) S 1 = 3 a 2 | 1.820.052.000 (4.20269) L-13:0.082.000 (8.20362) PAse5SS 1000000 ENGINE MAIN MECHANICAL UNIT O1-40 2. Withdraw the cylinder ner with piston from the first cylinder. Remove the relative rod hat bearing 3. Witharawtne eylindertiner andpiston fromthe tourth cylinder. Remove the relative rod hatl-bearing — Rotate the engine block 180° and proceed in tne same way for the second and third cylinders,Witharaw the liner Remove the O-ring Using a suitable tool, withdraw the seal rings and oil scraper ring from the piston. CAUTION Proceed with care in order to avoid broak- ing the rings which may otherwise be re- used. PA4655B1000000 01-41 When refitting, install the seal rings so that the word «TOP» stamped onto them faces upwards. Withdraw the two flexible rings securing the gud- eon pin, Withdraw the gudgeon pin and separate the piston from the rod. To retit, follow the Indications given in the relative paragraph. 71991 A =GINE MAIN MECHANICAL UNIT 01-4. REMOVAL OF COMPONENTS FROM THE ENGINE BLOCK (Contined) Remove the previously installed tool for rotating the flywheel. 1. Install ool N* 1.820.228.000 to prevent rotation of the flywheel 2. Remove the crankshatt pulley. 3. Remove the oll seal ring When refiting use inserting toot N° 1.820.007,000 (2.0146), 203+ 237 Nm 21.3-+ 23.55 kgm =z 3 4 bg) o al jou Remove the washer. Remove the tront cover. Remove the seal ring, Remove the gaskets between the front over and the engine block 8. Remove the ol pump control pinion. 9. Withdraw the toothed wheels and relative chain, 10. Remove the the shoulder. 02> 125 Nm 1.04 + 1.28 kgm 1.820.228.000Ht ENGHE WAN MECHANICAL UAT 01-43 HM ENGINE Main MECHANICAL UNIT O1-44 4, Remove he DISASSEMBLY/OF OIERUMR parce wens REMOVAL OF COMPONENTS FROM 2. Remove the satety washer. ssanassve wowsrrerscne fa panete at love nue pr tases ot vob: ENGINE BLOCK (Continued) 3. Remove he oi sel / B Ferewathe wetted wheels 7. Remove the timing chain shoe. When tefting use inserting tol 1.623,010,000 3. Withdraw the cotter pin. tn Remave.te five! ae 4. Remove the ear cover, Fram: ‘Wea isacaning:tekaie ase crannaNak wian’ | $¢ Remove ne quaker omsisen rear ester ana énsina der is at TD.C; position ine tywneot ana | 8 Remove the tool N’1.820.228.600 which was pre- check that tha small ele located on the viously instaled to leck the flywiee! outer edge ts at 31°30" in relation to the vertical. 6+8Nm Before applying the specified fixative to the threads of the flywheel retaining screws, remove all traces of the old fica tive, 06+ 0.8kgm 1.821.010.000 1.820.228.000 (43.0178) ‘000000 7199101-45 NOTE: Mark the position of the various compo- nents In case they are to be reused. REMOVING THE CRANKSHAFT 1. Remove the main journal caps using # suitable tool 2. Remove the the main nall-pearings from the main journal caps. Remove the lower thrust hall-rings Remove the crankshatt. Remove the upper thrust haif-rings. Remove the main hal-beatings trom the supports. To refit the crankshaft follow the indica- tions given in the relative paragraph. PA465581000000 71991 HM -GINE MAIN MECHANICAL UNIT DISASSEMBLY OF CYLINDER HEADS PRELIMINARY OPERATIONS 1, Lock the moveable suppor N° 1.820.012,000 (A.2.0195) into a vice. 2, Install fork N° 1.820.013.000 (4.2.0196) and lock it to the support 3, Insert the cylinder head onto the rods of the fork and lock it into position. 1.820.013.000 (A.2.0198) 1.820.012.0009 (2.0195) REMOVING THE CAMSHAFTS 1. Remove the camshaft caps NOTE: Arrange the caps in order in case they are to be reused. 2. Remove the camshatts. 3. Remove the rubber pads, PA465581000000 1. Remove the bett tensioner. 2. Remove the spring, 3. Remove retaining plate. CAUTION Restrain the belt tensioner when releasing the retaining screw and release the spring. 4, Remove the engine coolant temperature sender. §. Remove the engine coolant maximum temperature sensor.DISASSEMBLY OF VALVES Operate on one cylinder at a time. withdraw the valve cup trom the intake side. Remove the valve clearance adjustment cap intake side. Withdraw the valve cup - exhaust side. Remove the valve clearance adjustment cap - ex- hhaust side. 581000000 01-47 NOTE: Arrange the components in order in case they are to be reused. 5. With the tool illustrated below, remove the exhaust and intake side cotters. 41.821.058.000 (A.3.0324) 1.821.124.000 (43.0522) 1 1.821.122.000 (A.3.0520) 1,820.011.000 (A2.0192) 71991 Hid ENGINE MAIN MECHANICAL UNIT 01-48 1. Remove the previusly installa tools. vinen retlting use inserting toot Nt 3. Witcraw the exhaust vate, = Operate on he exhaust sido, 8. Ramove the spring retaicing ing. 4. Remove the upper cap. 9. Remove the lower cap. 5. Remove the inner spring. Proceed likewise for !he camponents on the exhaust 8. Remove the outer sping side, 7. Using puller N° 1.621.162.000 (A.3.0621), remove Following the same procedure and using the same the oil seal 41.821.162.000 (A.3.0821) 1.821.110.00 {A.3.0469) i PA26558 1000000 tools, operate on the other cylinders, 1.821.124.000 (a3.0822) 1.820.049.000 (A2.0359) . S g ? .s20.041.000 | (Azorsa)HN DISASSEMBLY OF THE CAMSHAFT -INTAK = SIDE 1, Unscrew the three screws and remove tne satety plate Remove the timing gear. Remove the body. Remove the piston Remove the piston return spring When reassembling: = ensure that the sealant does not block the oil channels. = Do not tighten the three retaining screws So that the timing can be adjusted if necessary. = Wait for approximately two hours before installing the shaft on the cylinder head. 446558 1000000 ENGINE MAIN MECHANICAL UNIT 1 01-49 Remove the support using tool N’ 1.822.110.000. 104.5 > 115.5 Nm 10.7 + 11.8 kgm \,_ve22.10.000 7.1991 Hy DISASSEMBLY OF CAMSHAFT - EXHAUST SIDE 1. Remove the ott. 2. Remove the nut. 3, Remove the satety retainer. 4, Remove the washer. 5. Remove the timing gear. 6. Remove the flange. 7. Remove the feather. CYLINDER HEAD CHECKS AND INSPECTIONS CHECKING LOWER PLANE OF CYLINDER HEAD 1. Ensure that the lower plane is level and retace it necessary. 7 | {Maximum head iower plane flatness error | l 0.05 mm. PA465531000000 SINE MAIN MECHANICAL UNIT 1. After resurfacing check that the height of the head ‘exceeds the permitted minimum, CAUTION Do not exceed the permitted minimum valuo as this may cause serious engine malfunction. = Check that the surlacing of the lower plane of the head is of the required quality. Minimum permitted height of the head per ig latter facing 134.900mm 71991VALVE CUP SEATINGS AND VALVE CUPS 1. Check that the diameter of the valve cup seats is within the specified limits, [| oiametar of valve cup seating Intake ang exhaust 36.000 to 35.025 mm 01-51 CAMSHAFT SUPPORTS 1, Install the caps, tighten the lubricated nuls to the prescribed torque and check thal the ciameter of he ‘Supports is within the prescribed limits. 1. Check that the outer diameter of the valve cups is within the prescribed limits. Diameter of camshaft supports 27.000 to 27.033 mm anim | 2.04 + 2.24 kgm | ‘Diameter of valve cup 2) | take: | 34.973 to 34.989 mm. [am exhaust a PAs6558 1000000 7-1981 ENGINE MAIN MECHANICAL UNIT 4. Check that the width of the camshafi support shoulder is within the prescribed limits. 01-52 1. Check that the height of the cams exceeds the prescribed minimum KH ironed | E41) [oninumum eam height Tees OTS we inake Taam exoos ‘oie Welles @ SY a AO LSIC. 1. Check that the diameter of the camshaft jcurnals is within the prescribed limits. am rote it 1. Check that the width of the camshaft shoulders is within the prescribed limits, Q | Jovamoter ot camshatt journals | ‘Width of camshaft shoulders C 26.959 10 26 660 mm | 810 8.022 mm soncacnHid VALVE SEAT REPLACEMENT 1 he 1 Extract worn valve seats using suitable equipment, Check that the diameter of the valve seat housings 4s within the prescribed limits. 581090000 ENGINE MAIN MECHANICAL UNIT 1 01-53 Check that the outer diameter of the new valve seat is within tne prescribed limit. |Outer diameter of valve seat «B> | 1. Heat the head to a temperature of about 100°C and Installine new valve seatsusing the special inserting tools. (A3.0622) +) (42.0826) (3) make _ 45.100 10 45.116 mm [exhaust 39.095 te 29.111 mm 71991 100 ~ 120°C CLEARANCE BETWEEN VALVE GUIDE AND STEM 1, Measure the inner ciameter of the valve guide and ccheck that itis within the prescrived limits. Internal diameter of valve guide «d» 8.000 to 8.015 mm UL csmsapprsnconnennseineael PA465581000000 ENGINE MAIN MECHANICAL UNIT 1. Measure the diameter of the valve stem in at least thee places and at right-angles to each other. = Calculate the clearance and check that itis within the prescribed limits. I not, replace the worn parts. [Radial clearance between valve stem | land inner dlamoter of valve guide intake 6.015 to 0.045 mm [Tr as0ie 070 mn) exhaustHid Scie ein eee 01-55 Ad 01-56 ENGINE MAIN MECHANICAL UNIT REPLACING VALVE GUIDES 1. Insert the new valve guides using inserting tool N° 1.821.164.000 (&.3.0625) which will also ensure 1. Ream the new valve guides to tree them from bur- 1. Exttaet the wom valve guides using puller N° correct protrusion. fing and calibrate the holes to the prescribed 1.821.053,000 (43.0311). diameter Q iH] Valve guide protrusion SB Se _ Inner diameter of valve guides 1.821.053,000 inte Teco tbaet > 10 10.150 my F (A3.0311) land exhaust intake rtd ethaudi 8.00010 8.015 mm tha 1.921.164.000 5 (A.3.0625) TURNING OF VALVE SEATS. 1. necessary carry out valve seat tuming using a suitable too! NOTE: Taper "C" can be obtained by positioning = Measurre the diameter of the valve guide seats and the hand lathe tool at an angle of 45". the outer diameter of the new valve guide: the instal- lation interference must be within the prescribed tollerances. A fame sa pe mcesnd nes (oer 1 | |otamotor ot vate guide soars VALVES 15.000 to 16.018 mm ee - jo 1. Check that the diameter of the stem and the 2: Tal! Garreterofthe neat are witntna poserbediens. So =. 2 External diameter of valve guides i 75.039 t0 15.050 mm Te —- ee route costae P| os hast Taste 7een | D) | |Diameter ot valve head «B= | peace exhaust [intake 43,850 10 $4008 mm | oO exhaust 37.850 10 38.000 mm | PAI855B 10. 000 7.1991 PASSS5810000001. After turning, grind each valve in its relative seat as follows: = spread the stop limit surtaces of the valves and seats with abrasive paste (SIPAL AREXONS Cartosil: cium for valve). — Lubrisate the valve stem with engine oil = Fixthe lower surface of the valve head to the suction cup of a pneumatic lap = insert the valve into tne relative guide and arin = Afier grinding, thoroughly clean both the valves ang their seats, ENGINE MAIN MECHANICAL UNIT 01-57 tA Length of tree spring “outer spring) be inner spring. bo | Jj zinm_| ‘2mm | ee jouter spring ——$—— VALVE SPRINGS — Check that the length of the «tree~ springs is within the prescnbed tits NOTE: The terminal planes must be parallel to ‘each other and perpendicular to the axis of the spring with a maximum error of 2°, 1. Using a oynamometer check that the charactenstic ata of the springs are within the prescribed limits. PAs€55B 1000000 [Lenatn | contotoasing lor the sping Neo) valve A aE Bie wo 220 closed (21.6 to 22.4) Valve A 452 to 470 25.5 #5 open (46.110 47.9) a nner spring enath [contr scr | lot ane spang nu | valve A 11510 120 jclosed us (11.8 t0 12.2) 1 patio se 22 (24.9 to 25.7) ee T 71991 Ht ENGINE BLOCK CHECKS AND INSPECTIONS = Visibly check the engine block for signs of cracking and excessive wear of the sliding surfaces: check ‘hat the threads are all intact. ~ Remove the caps trom the main engine lubrication ‘and coolant channel andclean with 2 suitable deter. ‘gent. Blow off with compressed air and install naw caps = Thoroughly clean the engine biock faces of alltiaces of old gasket. MAIN BEARING CAPS 1. Install the main bearing caps in the position and irection identified by the numbering on the caps themselves. 2. Tighten the lubricated nuts to the correct torque and check that the diameter of the main suppoms is within the preserized limits, 3. Check that the length *S" of the central main support shoulder is within the prescribed limits, | [ovamerer or man suppons 83.652 10 63.664 mm 4485581000000 ENGINE MAIN MECHANICAL UNIT 01-5» 4 [Length of central main support shoulder "S” 25.15 to 25.20 mm 9ty ENGINE MAIN MECHANICAL UNIT CYLINDER LINER PROTRUSION Carry out the check without the seal rings NOTE: Procedure to be jollowed during the bench overhaul asa preliminary check of the cor- rect coupling of the cylinder liners and engine biock. 1. Apply two centesimal dial gauges to tool N° 1,825,003.000 (C.5.0148) and reset them on a sur lace plane. 1.825.003.000 (c.8.0148) 1, Iniroduce the cylinder liners into the engine biock vithout the seal rings. PAs88581000000 : 01-59 1. Place tool N° 1.825.003.000 (C.6.0148) on the en- gine block ¢o that the probes rest on the edge of the cylinder liner, then check that the protrusion is within the prescribed tollerances. [cylincer liner protrusion from engine Iblock F- 0.01 to 0.08 mm, 1.825,003.000 (€.6.0148) 7-191 ot ENGINE MAIN MECHANICAL UNIT Check with seal rings NOTE: Procedure to be carried out when refitting, 1. Insert the seal rings in tho cylinder liners. Insert the cylinder liners into the engine block. 1, Lock the cylinder ners using cylinder liner tizing tools N* 1.820.004.000 (A.2.0117) and washers N° 1.820.082.000 (A.2.0362) andtightening the relative ~ nuts to the prescribed torque. 2, Place tool N’ 1.825.003.000 (C.6.0148) on the en gine block so that the probes rest on the edge of the cylinder iners and check that the protrusion is within the prescribed rollerances. [a] [evince ner proteusion trom engine | | [block __ 0.01 190.06 mm 01-60 76> 8aNm 75 + 8.56 kom 1.820.004.000 1.825.003.000 (6.0148) 1.820,052.000 (4.2.0362) 71991Hr era an mecacas ur Ot-s: HW SHOE WAN UEoUANCAL UAT 01-6. MA! “ND ROD BEARING HALVES AND 1. Check that the ovalzation of the main and rod | ~ Check eccentricity between main journals TH. T HALF-RINGS journals is within the prescribed limits 2. Check that the taper of the rod and main journals is vehi the prescribes its. a 8. Check that the length of the ceniral main journal is = > within the prescribed limits. BOND ens ~ Check paralisiism between main and rod journals | ain journals maximum ezarvety - main and rod bearing halves and the crankshaft ¢ atlbe coupled by matching the parts of the same nensional class, eniitied by dots of the same sigur on the side of the bearing hall and on the | [Main ansttedJourats maximum elevant crankshat journal jovalization error | Check that the thickness of the bearing halves is, Ts 7 /| [azn paatslsm ero Betwaen ] within tne prescribed limits, nt main and rod journals A Main and rod Journals maximum taper CRANKSHAFT error Main and rod journals = = Check the deviation between the axes of the two 10 rem : ‘i i jis of fod journals and th the main jour F—4] |ciass | Thickness of bearing halves Fn ee eng ean Re y i J | - Thecrenkshaitjourais are divisedintotwo classas ) JA | RED 1.830 10 1.835 mm) and marked with a blob of paint: RED, BLUE or t) Length of central main journal eee eee aioe neeetnanermaaes Bleue | wain{ 183510 1.839 mm| YELLOW depending on the manulacturing toleren- Maximum derivation between the Shak of the two |vELLoW| Testo 1 B44 mm mz "30.000 t9 30.035 mm pairs or rod Journals and the shatt of the main [al RED. 4.832 10 1.836 mm 1. Check that the diameter of the main and rod journals journals Bleue | Rod [183610 1841 mm! fs within the prescribed limits, 0.300 mm ic [YELLOW 1641 to 1.845 mm | [ ! Diameter of main journals Bi} 5 iRED 59,970 10 69.976 mn (elue 159,963 10 59.970 mm YELLOW 159.956 to 59.969 men PEEL Wn... ORAS 19 99968 rim} ) 2 ED D | |piameter of rod journats Ga.s02 0 «9098 mm : 49,985 10 49.992 mm YELLOW - | 49.978 to 49.985 mmn| l\ A within the prescribed limits. wits Zin wham | w/ PA465581000000 7.1991 ase5581000000co] Cleaning lubrication channels 1 Unscrew the cylindrical eaps closing the ends of the lubrication channels. Bal Loctite Opn = Thoroughly clean the luorication channels using warm diesel oil and blow-ott = Close the holes of the lubrication channeis with new caps. CYLINDER LINERS = The cylinder liners are selacted according to their inner diameter and are divided into three categories AB and ©. These categories are Wentitiad by ELUE, PINK and GREEN dots located on the outer surtace 1. Check that the inner diameter, taper and ovalization of the cylinder liners are wimin the prescribed limits. \pAsé558 1000000 ENGINE MAIN MECHANICAL UNIT 01-63 Diameter of cylinder liners (a) Tees A(Bluy | 2298510 68.994 mn (1) Cass Ae) | 83,385 10 83.394 mm (2) Bepiny [P2951 84.004 mm (1) cass BRED 183,395 10 63.404 mm (2) [24.005 to 64.014 mm (1) 123.405 to 83.414 mm (2) (1) For AR67102 and AR67202 engines (2) For engine AR67103 Class C (Green) fxn taper (M-N) 0.01 mm, ‘Maximum ovalization (X- Y) 0.01 mm | i Mon | tt 6 H H = area for dimensional control 7-1991 REPLACING THE ENGINE FLYWHEEL RING GEAR = When replacing the ring gear ot ine engine flywheel, proceed as follows: + remove the old ring gear. + thoroughly clean the mating sudtaces of the new ring ‘gear and the flywheel. + Unitcrmiy heat the new ring gear to 120- 140°C and fit ito the engine flywheel + leave the parts to coo! naturally to ambient tempera~ ture: do not force the cooling of the parts. PISTONS AND GUDGEON PINS — Like the cylinder liners, the pistons are civiced into three classes according to their manutacturing tol lerances: These classes are identified by the letters A, Band C and are differentiated by cots located on the piston ceiling, 1. Chack that the outer diameter o the piston is within saroocco0 O1-64 (Outer diameter «a» (3) Class A 83.995 to 83.945 mm (1) (eve) 83.305 10 83.355 mm (2) [cizss 8 {83.945 to 83.955 mm (1) (Pink) 183.355 10 83.365 mm (2) [cies C 83.955 to 83.965 mm (1)| (Green) 183.385 10 83.375 mmm (2) (1) For ARG7102 and ARG7202 engines (2) For engine ARS7103 {3} to be measured perpendicularly to the gudgeon pin hole at a distance of: [ane7202 [ MONDIAL [| g= 10.3 mm (4) aneriog | MONDIAL [ t= 165 mm 5) BORGO | g=17mmi4) ‘ane7i03 | BORGO | g=15mm/(4) trom the lower edge of the skirt Irom the gudgeon pin shaftHi = Both the gudgeon pins and relative mating holes on the piston are divided into two classes according to the manufacturing tollerances. These classes are identified by BLACK or WHITE dats on the inner surface of the pins and on the outer surface of the piston hub, 1, Check that the outer diameter of the gudgeon pin is within the prescribed limits, D | [outer famotero! guageon pin Bax Iwnte J 21.994 19 21.997 mm. 21.997 to 22.000 mm 1. Check that the diameter of the mating hole on the piston is within the prescribed li 5] Diameter of the gudgeon pin mating hole on the piston Black 22.000 to 22, White 22.002 to 22.005 mm PA46558 1000000 ENGINE MAIN MECHANICAL UNIT 01-65 PISTON RINGS AND OIL SCRAPER RING 1. Check that the thickness “S" of the piston rings and the oil scraper ring is within the prescribed limit. | Thickness rings «S» Hi 41. Insert the rings in the control ring or in the eyinder 1.478 to 1.490 mm Goetze | 1.47510 1.430 mm Borge [1.478 to 1.490 mm| jOilscaper | Goetze [9.475 to 3.490 mm {ring Borgo | 3.478 to 3.490 mm 71991 liner and check thet gap "L" is within he prescribed ‘ims KH] |cap «t» First ring (0.30 10 0.59 mm] [Second ring [ 0.30 to 0.59 mm| (Oil scraper Borgo | 0.25 to 0.49 mm {ring Goetze] 0.25 16 0.50 mm| ¢ ANE MAIN MECHANICAL UNIT O1-6¢ RODS 1. Check that the diameter of the bushing of the rod ‘small end is within the prescribed limits. 1. Check that the axial play between tne piston rings angoil scraper ring with their relative seatings onthe piston is within the prescribed limits. ] |Axial play between oil rings and sealing | [Fest ring 0.035 to 0.067 mm) ‘Second [ Borgo [00095 190087 ml {ring Goetze [0.035 to 0.070 mm) fou scraper [Borge | 0.025 to 0.057 mm ng Goetze | 0.025 t0 0.060 mm PA465521000000 GQ | [Piameteret ne roa sma end bushing hole 22.005 to 22.015 mm. 71g91Hid en Nan HECHAMCAL UIT fod cups and tighten the lubncated nuts e prescribed torque, Check tnat the diameter of the rou big end 1s within the prescribed sims, diner Uiatneter oF rod big end (") For engine aR67202 3 BE asim “@y / 555 kgm | 7 / ‘Check tnat the rods are perpendicular. 13 /000ce 01-67 CHECKING WEIGHT DIFFERENCE BE- TWEEN THE SINGLE PISTONS AND THE SINGLE RODS 1 Gruxyp the yudgeun jans did pistons according to te dimansional class (BLACK or WHITE) Ingert the gudgeon pins in the pistons and lock than wath the flexible rings. Install the oiston rings and the oll scraper ring. Check that the difference in weight between the pistons is within ine prescribed limis. 1. Simitarly check tnat ine ditference in weightbetween the rods, together with the bearing halves, caps and, bbolts is within the prescribed limits. ab ‘Weight rence between rods TIMING SYSTEM IDLE GEAR BUSHING 4. Using a plug gauge {passes-doasn't pass) N 126. WOF-OUU (C8 O13), Check the Hier weet ot the timing contrcl idle shaft housing bush. 1.626.001.000 (C.8.0103) 1. Also check the corresponding bushing on the tront cover. 1.826 161.000 ce 3 PAs6555 1000000 01-638 1, Temporarily instal the front cover, Remove tw cover and relative gasket 3. Using tool N° 1.826.001 Nan (C4) 0403, check the al oF te tase Lari -826.001.000 (c.8.0103) — = If the two bushings are excessively worn, replace them proceeding as follows: 1, Remove the engine block bushing using tool N° 1.821.015.000 (A.3.0210) 1.821.015.000 (A.3.0210)Ht 1 install a new bushing using a suitable inserting tool. Remove the oushing on the front cover and install a new one using suitable tools Temporarily install the front cover orto the engine block and ream the two bushings al the same time, using guide tool N’ 1 620.114,000 (A4.0172) and reaming tcol N° 1 828,001/2.000 (U.2.0040/1) ENGINE MAIN MECHANICAL UNIT 01-69 1.828.001/2.000 1.820.114.9000 (A.4.0172) = Remove the tools and using plug gauge N’ 1.826,007.000 (©.8.0103) check that the inner diameter of the two bushings is correct, ‘When replacing one bushing, the other must also be replaced. 7.1991 Ha INDICATIONS FOR REASSEMBLY For the reassembly operations, follow the procedure used for disessembly in the reverse order unless otherwise indicated below. CHECKING VALVE LEAKAGE = Insert the spark plugs in their seatings. 1, Pourasmall quantity of fuelin one of the combustion chambers so that it just covers the valve heads 2. Blow low pressure air into the intake and exhaust ports and check that no bubbles form. ! ere are bubbles check for correct assembly and grind the valve seats again it necassary (see specilc proce: cure). PA#65581000000 = -SINE MAIN MECHANICAL UNIT 01-7. REASSEMBLING CAMSHAFTS, ADJUSTING VALVE CLEARANCE Locking the nuts of the camshaft caps ‘when the timing marks do not correspond means that the valves overlap and strike each other leading to irreparable damaged. It is therefore necessary to scrupulously follow the refitting procedure given below. 1. Position the camshatts. = Position the caps and tum them in accorcance with the numbering marked on them. 2. Tighten the lubricated camshett cap nuts on the intake side to the prescribed torcue. | 20+ 22Nm 2.08 + 2.24 kom 7.19911 Check that the clearance between the cam heel radius and corresponding valve cup is within the prescribed limits, otherwise replace the intake valve caps with others of a suitable thickness. co lIntake side valve clearance 0.380 t0 0.450 mm ] 1.825.018,000 (c.6.0197) = Unleck and remove the intake side camshatt cap Pals, 1 Tighten te lubocated eshaus! side eap nuts to the rect torque: ENGINE MAIN MECHANICAL UNIT 01-71 Gil 20; 28 Hin [ 204 + 2.28 kgm | 1. Check that the clearance between the cam heel radius and corresponding cup is within the pres- crived limits, otherwise replace the exhaust vaive caps with others of a suitable thickness. — (0.420 to 0.500 mm 1.825.018.000 (c8.0197) figat Hid 1. Rotate the exhaust side camshaft unil the cam cf the first cylinder faces outwards and the timing mark corresponds with that an the central cap (first cylin. der in firing phase). 2. Rotate the intake side camshatt until the cam of the first cylinder faces outwards and the retarence not cches are staggered by 3 to 4 mm in advance so that the marks will be perfectly aligned aiter the timing chain has been tensioned pot ieseatlls 20+ 22Nm 2.04 + 2.24 kgm CHECKING AXIAL PLAY OF THE CAMSHAFTS: 1. Apalyacentesimal dial gauge and measure the axial play of the camshatts. Check that the vaiue is within the prescribed tollerances CAUTION Do not rotate the camshafts: the valves which are overlapping may strike cach other and cause irreparable damage ENGINE MAIN MECHANICAL UNIT REFITTING CRANKSHAFT 1. Set the main bearing halves onto the relative sup- ports NOTE: The assembly onto the crankshaft must be carried out by matching the parts of the same dimensional class marked with col- ured dots on the side of the bearing halt and relative cranshatt journal. 2 Install thrust ring halves into their seatings and en- sure that the lubrication grooves tace the crankshatt shoulcers. 3. Position the crankshatt after abundantly lubricating the main bearing haives.: bi Set the main bearing halves into the main bearing caps 2 Sal the thrust ring halves onto the central main cap. 3, Install the central main caps setting themin accord: ance with the numbering markedon them (the salely ‘mark must be on the same side as the correspond: ing mark on the engine block) tighten but do not lock the retaining nuts. = In the same way install the remaining main caps without locking the nuts. PA46559 1000000 ENGINE MAIN MECHANICAL UNIT 01-73 4. In two or three operations starting from the central main eap, tighten the lubricated nuts securing the main caps. 20Nm + 15" 2.04 karin + 115" 71991 Hid CHECKING CRANKSHAFT AXIAL PLAY 1. Using a certesimal dial gauge mounted on a mag- netic platform, check that the axial play ofthe crank shatt is within the prescribed limits. ICrankshatt axial play 0.076 to 0.263 mm REFITTING CYLINDER LINERS, PISTONS, RODS, COUPLING OF RODS AND PISTONS 1. Coupling must be carried out by matching the parts of the same dimensional class marked with paint of the same colour, A (Bie), B (Pink) or (Green), onto the piston calling and on the outside of the cylinder liner. AINE MAIN MECHANICAL UNIT 01-7, [Ciearance between cylinder liner and [piston \ (0.040 10 6.059 mm | AV, MATCHING OF PISTONS AND GUDGEON PINS 1. Match parts of the same dimensional class, identi- fied by dots of the same colour: BLACK or WHITE ‘onthe inside of the gudgeon pins and on the outside of the relative piston hub. (Clearance between piston hole and igudgeon pin Black 0.00310 0.008 mm _| [white 0.002 to 0.008 mmMATCHING OF PISTONS, RODS AND CRANKSHAFT 1. The rods must be set with the attset tured towards the crankshaft intermediate supports. 2. The pistons must be positioned so that the arrow stamped onto the ceiling points in the direction of engine rotation. Each rod has the cylinder numberto which it refers stamped onto the big end. [Clearance betwoen rod small end [bushing and gudgeon pin T.o08100.92tmm | {nite 0.008 10 0.018 mm 01-75 & ESS XG & Install the cylinder liners and seal rings onto the engine block. ‘Check tne cylinder ner protrusion as described in the relative paragraph. — = Rotate the crankshaft until the position correspond Ing to the 8.D.C. of the first and tour cylinders is reached. 1. Set the bearing halves onto the rod big ends NOTE: The asembly onto the crankshaft must be carried out by matching the parts of the same dimensional class indicated by blobs of colour, RED or BLUE on the side of the bearing half and RED and LIGHT BLUE on the relative crankshatt journal. 2. Place the piston rings on the pistons with the gaps slaggered by 120° 3. Usinga suitable too}, install the pistons and rods into the first and fourth cylingers. CAUTION ‘The arrows stamperd onto the piston cail- ing should indicate the direction of rota- tion, Position the rods with the offset facing the crankshaft intermediate supports. 4. Installthe cylinder liner fixing toots N* 1.820.C04.000 [A.2.0117) and supplementary washers N° 1,820.052.000 1A.2.0362} PAdG956 100000 ENGINE MAIN MECHANICAL UNIT. 1.820.004.000 (a20117) \ 1.820.052.0900 (A2.0362) 01-76~ Rotate the engine block 180°, 1. Set NOTE: the rod bearing halves onto the rod caps ‘The assembly onto the crankshaft must be carried out by matching the parts of the same dimensional class indicated by blobs of colour, RED or BLUE on the side of the bearing halves and REO or LIGHT BLUE on the relative crankshatt journal 58 1000000 ENGINE MAIN MECHANICAL UNIT 01-77 Insiall the rod caps of the first and fourth cylinders and set the saiety notches so that they are facing the corresponding notches on the rod big end. Lu- bricate but do not tighten the retaining bolts. cauTION ‘The number of the cylinder townich tne rod caps refer is stamped onto tho side of the caps. Hl In the same way, refit the pistons and rods of the second and third cylinder. Before locking the bolls of the rod caps, use @ thickness gauge to check thatthe axial play benween crankshaft shoulder and 10d-cap profile are within the preseribad limits. [Axial play between crankshaft shoulder land rod-cap protile 0.2100.3 mm | 7.1991 Tighten the lubricated rod cap bolts to the correct torque, 49+ 54Nm INE MAIN MECHANICAL UNIT 01-7 REFITTING THE CYLINDER HEAD 1. Position the timing chain, = Rotate the crankshaft until the piston ofthe first anc fourth cylinders is at TD.C. 2. Position the cylinder head gaset.ENGINE MAIN MECHANICAL UNIT ly eycve ma econ 01-797 01-80 1. Ensure that the cams of the first cylinder face the 1. Tighten and lock the two screws securing the lower CHECKING ENGINE TIMING outside and that ihe timing marks on the camshaft side of the cylinder head exhaust side) are aligned and on the intake side, 2. Install the timing chain and tension it 1. Install probe N* 1.825.019.000 (C.6,0189) with diat staggered by 3 to 4 mm in advance. gauge into the spark plug seat of ihe first cylinder. = Rotate the crankshaft until the piston of the fist cylinder is at 7.0.C. inthe tring phase. 2. Cheek that the marks engraved on the camshatts 21@ aligned to these of the rlative central caps. 4 = tt the marks en the camshatis era not aligned with the reletive caps, operate as desciibad below. 4 1.825,013.000 (c6.0183) ‘When refitting torque gradually following 76 to 84Nm the sequence indicated: 7.75 to 8.56 kgm 1. Install the cylinder head on the engine block. After bench testing and 2. Lubricate the threads, nuts and washers with engine trials Coil and tighten, in two or three operations, the ten when the engine is cool » 2a01e ‘Second tii \areenent) 53.695 + 53.708 Second ting * Thickness of rings (a) _ 1.475 + 1.490 (3) L - Inner diamter of rod big end wy 53.695 + 53.705 (") Saleen! 1 Weight difference between rods: <2 a Olserapering | 3.475 9.490 0) FR — - oisce 0.008 + 0021 Fist in 030+ 050 - na eee. ciate ce Clearance between rod small 0.009 + 0.024) Ringgen (ye) — recomend | /end bushing and gudgeon pin 0.005 + 0.018 Oil scraper ting wee eer “ poneenetC) 0.25 + 0.50 (9) (7) Only eelaive to ARG7202 engine First ting 0.035 + 0.067 0.085 + 0067 @) ) asta lay boweon | son aing piston rings and 0.035 + 0.070 (3) seatings 0085 + 0. , ni Oi soraper ing mageatied Rod bearing halves Unit: mm 0.025 + 0.060 (3} - A Rea 1832+ 1696 (1) Tobe measured in tho checking ring nul or in the oylindar finer eo a ena Poe see te (2) Borgo (3) Goetze. — — ee : e-Yetow | toate t045 0,025 + 0,052 JA- Red z 0.025 + 0.049 ¢) Raciatplaybewweenpineara| 0.021 + 0,051 - Blue ros bearings 0,021 + 0,088 (7) 0,020 + 0,048 Gudgeon pin Sean Ic - Yellow 2199421997 0,020 + 0,045 () Black A - (ia? Aaecierolaiug66n 21.991 + 21.994 () axial play of rod head 02-03 pin (a) a 21.997 + 22.000 () Only relative to ARG7202 engine me, 21.994 + 21.997 (*) ‘a 0.003 + 0.008 al Black ! asi aniows pica 0.005 + 0.014 () hole and gudgeon pin z we, 9002 = 0.008 0.005 + 0.011 () (*) Only relative to AR67202 engine ) Zt PA465581000000 7.1991Hy CYLINDER HEADS Heads Valve guides PA65561006. ENGINE MAIN MECHANICAL UNIT 01-99 HH ENGINE MAIN MECHANICAL UNIT 01-100 sri Unit: mm Valve seatings “om Diameter of valve guide seating (a] 15.000 + 15.010 Outer diameter of ee Sees Valve guide protrusion (| _9.850+ 10.150 i bined Esreast 39.095 + 39.111 Diameter of valve cup seating (e)| 35000+35.025 [ . Valve seat taper (a) 90" + 20" Diameler of vane seat [axe 75.0007 45028 Ez rerterence between valve] ake oars +om6 | housing ( Eraust 39,000 + 39.025 Zo «oS \seat and housing Exhaust 0070+0.111 5 cylinder nead shrink temperawre tor | Minimum permissable height of the +120" ca ate ang ” to 18.900 installation of valve seatings MOeIENS, head atte tacing ngs | 3 paraliel ni Maximum error et parallelism between head a planes Maximum error of flatness of head lower 005 plane Valve Une ey Diameter of valve ‘wae 7S70 + 7.985 a = Unit: men semi Exhaust 7.985 « 7.960 Outer diameter of iriake 15.039 15.050 Diameter of valve intake 43.850 + 44.000 valve guide @ Ba eo} __| ee JExhaust 15.050 + 15.068 Exhaust 37.850 + 38.000 inner diameter of valve guide (bore) (b) 3000-8015 Radial play between vatve | intake 0.015 + 0.045 finerterence between valve [intake ‘0.021 + 0.050 stem and guise Exhaust 0.040 + 0.070 Jguide and seating Exhaust 0.032 + 0.068 7.1991 PA46558 1000000dy ENGINE NAN MECHANICAL UNIT 01-101 HY _AGINE MAIN MECHANICAL UNIT 01-40 Valve springs on Length of valve spring Outer spring 48.7 a atrest (Li) Trner apring 462 Camshatt —— 10 2 ameter of camshatt journal (a)| 26.958 + 26.980 ive | Outer 5 — ee Length of closed vaive Diameter of camshait journal seating (b) | _ 27.000 «27.033 spring (Le) inner spring 345 Sane cenennnsninea rere | Radial play between weight and Length of spring with | Outer spring Bs pee aie 0.020 + 0.074 ‘open valve (La) inner spring 25 |Camshatt axial play 0.080 + 0.124 Load corresponding to| Outer spring | 212 + 220 N (21.6 + 22.4kg) spring length with valve closes inner spring | 115+ 120N (11.8 + 122 kg) Load corresponding to| Outer spring | 452+ 4701N (46.1 + 47.9 kg) springlongtrwatn vane] J open Inner spring | 244 »252N (24.9 + 25.7 ka) Valve cups Vit een Unit: mm Diameter of valve cups (a) 34.973 +34.989 Valve clearance intake (0.380 + 0.450 6) Radia play between valve cups and seat.ng| 0.011 + 0.052 {cold engine) ©) esha 0.430 « 0.500 a intake 115 Nominal height Exhaust 96 ‘Anguarvalue ef timing intake =30" reference marks on caps Exhaust 1315" PA4555B 1000000 71991 Pa46558 1000000 71991| | | | Hy ANGULAR VALUES OF ACTUAL TIMING DIAGRAM Clockwise rotation of crankshaft seen from front side (1) Exhaust (a) TOC PA465581000000 (2) Intake (@) BOC 71991 ENGINE MAIN MECHANICAL UNIT 01-103 bi ENGINE MAIN MECHANICAL UNIT 01-104 FLUIDS AND LUBRICANTS. pana tow TOS) a as Application type | Classitication Namo Quy titres Intake Closing (ater 800) © [se 660) Engine 08 or | aPISG | SELENIA SPECIAL ene ‘al me = Total capacity comes |FORMULAALFAROMEO| 55:6" ai ree — Partial capacity (filter and pan) for routine SAE 10W/40 | 10W/40 5 Opening (oefore BDC) © potiee Exnaust [Closing (aier TOO) | 3 = Fiter os intake angular value | arse — Camshatt sumps ae ___._ eae angitatvalis OB {5 Vaues measured wi tining varalor engages Etc oad es tone . Intake and exaust valve cups = Camshaft supports - Oil pump shait . Outer surface of crankshaft ol seals : ‘Crankshaft oil seal lip Grease ISECO . Spark plug threads oi SECO Maiyncte A z (*) Only for AR 67202 engine SEALANTS AND FIXATIVES ‘Application Type Name uy Cylinder head screws (lower side) Mastic | DIRING Curil - Upper head cover plane Masi [DIRING Hetate . Timing variator solenoid support flange ‘Screws securing flywheel to crankshaft Mastic |Lociite 270 (green) Camshaft shank for instalation of timing variaor Gasket between flexible support pads and Mastic | DIRING Heldte supply manifold DOW CORNING Hermetite Contact sudaces between ol sump and Wasi | MASCHERPA engine block 037091 (black) ABRASIVES Application Type Name Quy Grinding of valve seats ‘Abrasive SIPALAREXONS Carbosiicium for valves PA465561000000IGINE MAIN MECHANICAL UNIT 01-46 HH { ENGINE MAIN MECHANICAL UNIT 01-105 Hid TIGHTEN TORQUES Tightening nuts securing cylinder head to engine block Engine block Tightening sequence Phase Nm kgm Pan Nm kom — ‘When refitting: Huts securing main caps to suppo% biock (inci) 24s 20885 oreaiamy iran tonswne| sacar | saecaee ‘Screws securing flywheel to crankshaft (with fixative) 116441286 | 1187+191 the indicated sequence Nut securing erankshatt pulley (in i) 2004231 | 218-2055 Screws securing bek tensioner shoe to front cover 6+8 06+08 After trials and bench Nuts securing font cover to engine block 10.2 + 126 1.04 + 1.28 oe scl cosanina ‘Nuts securing watar pump to font cover 765+945 | 076+096 nuts by one turn following] e2.65491.95 | 849+93 ‘Nuts securing water pump to engine block 1275+1575 | 19-16 the sequence indicated, Screws secunng thermostat unt to ovine head 85+105 0.87 + 1.07 figmae i ae coonenca Fits securing rod caps +58 5455 eas Oil sump drainage cap 345 +80 66+82 ‘Screws and nuts securing ol sump oot 08+ ta Cylinder head Part Nm kom Screws securing timing cover 975 = 15.75 10416 Screws securing eyinder head to tront cover 142541575 | 145416 Nuts securing camshaft caps (in ol 20+ 22 2.046224 Spark plug tightening (in ISECO Molykate Aoi) 26+0465 | 285+ 359 Engine coolant temperature sender 406494 41450 Engine minimum oll pressure sensor 95.74 444 264645 Engina ol pressure motor 85~105 0.87 + 1.07 Nat securing exhaust side timing gear 51+ 63 52-64 Engine coolant maximum temperature warning light sensor 38-47 0.58 0.48 Support securing timing variator to carnshalt (with fbative) 106541155 | io7+18 Screws securing tiring gear to timing varialor 2950325 30+33 Engine ol temperature sensor 213-263 22027 Zngine ofl minimum level waming ight sensor a 25 PAs65561000000 7-191 PAs65581000000Hy ENGINE MAIN MECHANICAL UNIT 01-107 iy ENGINE MAIN MECHANICAL UNIT 1.820.013.0060, (A 2.0196) Cylinder head suppor yoke 1.820.049.000 {A2.0359) 41.820,052.000 (A2.0362) 1.820.080.000 (A.2.0451) ‘Special nut for valve suppor tool Toot for locking cylinder lines ‘Tool tor removing head from engine block 1.820.114.000 i (aa2.0172) ‘Guide for reaming front cover and engine block bushings 1.820.145.000 (R.4.0178) Engine support bracket 1.820.225,000 ‘Support for removalirefiting engine group 1.820.228.000 Tool for locking flywheel | | i | 11820.233.000 Bracket for removing!retiting engine group i 1.820.240.000 Tool for locking flywheel 1,821,007.000 (43.0148) Crankshatt front cil seal inserting tool i 1.821,010.000 (A3.0178) Crankshatt rear oil seal inserting too! 1.821.015.0009, (43.0210) | Totfor removal busting on engine eck PA465581000000 (CONTINUES) 7-199 SPECIAL TOOLS (CONTINUED) 1.820.008.000 1.821.053.000 Tool for locking eynder liners : i oun ol ingoy one Valve guide pul 1.820,011.000 1.821.068.000 (42.0192) Nabe sper. ‘aan Lever for valve disasserbiylassembly | ! 1820.012.000 | 1.824.110.000 Base for cyinder head support tool Inserting tot for valve guide pads (20195) " "— (43.0468) 9 oun 1.821.122,000 Cage for valve disassembiy/assemply (A3.0520) 1.821.124.000 : toa Suppor for valve disassemblyicssembly 1.821.162.000 ide seal cov sh tasoeen, Poller for valve guide seal cover (intake and exhaust) 1.821.164. ese Inserting tool for valve guides (intake and exhaust) 1.822.001.000 aaa Spanner for rotation of camshat isassembly/reassembly and greasing of camshaft ting varator~ 222 110.000 | 122! fordsassembiyreassembly and greasing of camshat ting varia intake side 1-825,093.000 Toot for checking cylinder liner or piston protrusion trom engine block Pei checking cy piston p fom engine 1.825.010.000 ines Tool for checking TOC 1.825.018,000 Feeler gauge for checking valve clearance (c.6.00197) "ERID209 rear et cea bo sg 8000 Tan cea eng cigs PA4655810C0000ke Hild . : ENGINE MAIN MECHANICAL UNIT Ui-109 in + hi GINE MAIN MECHANICAL UNIT O1-1 PROCEDURE FOR FAULT RECTIFICATION OILLoss | Testa TEST STEPS RESULTS REMEDY Z T TEST FAULTS AND SYMPTOMS FAULT ISOLATION | nereRence FOREWORD: t Ik is absolutely necessary to accurately identify the engine component or area causing the leak. If the cause OIL LEAKS. | Visual detection of oil leaks causing drips or solling of A cannot be visualy identitied, it is advisable to wash the engine with water, dry it, and then start it on a level the engine surface or perform a short test cycle and wait until the leaks become evident. Following this, act on the attected component and tackle the other components at a later date. Loss OF O1L ‘The pressure gauge on the instrument panel indicates B PRESSURE ‘a decrease {sudden or gradual) of engine oll pressure: al very low pressure the relevant warning lamp comes ) Be At | CHECK DRAIN PLUG = ch aan piocerentpe ecto aans] (on) pe [cavowspan NOTE: It Is advisable to first ascertain that the damage prossure gauge on the instrument panel, pressure meter and minimum pressure Je | Torque or replace plug t ‘sensor are operational, checking the ac- recessary tual engine oll pressure with a pressure gauge refer to WIRING DIAGRAMS AND ‘2 | CHECK OIL SUMP ELECTRICAL DIAGNOSIS = IN + the oll sump for damage, distortion or micro-cracks _ + sealing of gasket between sump and engine block EXCESSIVE OIL il consumation will increase notably in relation to the Cc * » Sees secuilag sume fe. comer) teres Levy > eee simppior restore CONSUMPTION stated values and those noted during the life of the | g2sket i necessary. | Tighten the sump screws vehicle. ) to the correct torque NOTE: High oil consumption during the first 8000 miles must not be considered 3 | CHECK OIL FILTER abnormal as this is dueto the engine setting = Check for absence of leaks in the oil fter area; check (ox) > Carry out step At that the seal i tight ATTENTION: fiter to the correct torque + Engine oil is harmtull to the skin: reduce all contact, stains or drops of oll on your skin to a minimum: wash off oil with soap and water. + Do not dispose of used oil in the environment: find out where used cil is collected in your area. (CONTINUED) PA65551000000 1991 PA485581000000 71991| | i | i i i | ENGINE MAIN MECHANICAL UNIT O1-111 OlL Loss. | TESTA Hy ENGINE MAIN MECHANICAL UNIT 01-112 shaft and camshatt oll seals: check for leaks in these| LOSS OF OIL PRESSURE | TESTB { TEST STEPS RESULTS REMEDY TEST STEPS RESULTS REMEDY Ad | CHECK OIL SEALS Bt | CHECK OIL LEVEL | 7 amave ie covers nrGer to gain acess tothe car pe [ary out step as 7 Uaing te pst cheok tat he calavalls omen Carry out step 82 pe [Replace detective oi Gof Top-up ot level seals no | cHECK MISCELLANEOUS COMPONENTS 2 | chek QUALITY OF OI AND FILTER TGhesk for teaks rom any other component nt istedin (oxy pe | Ropicecetecive corpo — check nae Cary cut stop 3 the previous test steps. Correct the fault on the basis of nents ‘+ the engine oilis of the prescribed type | the remedies mentioned above. + thatthe oil fitteris of the prescribed type and correctly, isaled Lexy Service withthe pres: cibed otto the proper W necessary replace the finer | | | — | 33 [cHEGK OW FUN | = Ghescol pur ler vases of nding, eveealng os Cary eu step 8a | congeners . | ex) farac dtectv pats | | | | | 1 Lecce Enaotiest A 865501000000 71901 PA465581000000Hy ENGINE MAIN MECHANICAL UNIT LOSS OF OIL PRESSURE TESTB ‘TEST STEPS RESULTS | REMEDY ba | CHECK PRESSURE RELIEF VALVE = Check: + pressure relief valve for correct seal, integrty and cleanliness. ‘+ the vaive spring for yielding or breakage (&) > CY > Carry out step BS | Replace detective compo- nents BS | CHECK OIL PASSAGES. Only relevant to complete engine overhaul: - Check the passages in the engine block and cylinder heads for obstructions caused by oil residues or foreign matter. = Check plugs on cranckshat for sealing and integrty. Gy > Thoroughly clean affected parts and replace them t necessary. uy =NGINE MAIN MEC! HANICAL UNIT. EXCESSIVE OIL CONSUMPTION ‘TEST STEPS RESULTS. REMEDY FOREWORD: ‘Check that excessive cll consumption is not caused by la sakage. Reter to Test A. CHECK FOR SEEPAGE THROUGH sa VALVES: = Remove the cylinder heads and check for traces cf ol in ‘the combustion chambers. inthis case check: + Dimensions and clearances between the valve stem and the relevant valve guide, and between the vaNve ‘guide and the valve guide seats in the cylinder head: + theintegrty ofthe seal padlocated onthe valve stem + the valve stem for traces of binding or scoring, (&) > ey > Carry out step C2 Roplace detective parts CHECK FOR SEEPAGE THROUGH PISTON © | pines = Check for seepage through piston rings. if this is dis- ‘covered check the piston rings for: + breakage or damage: + correct installation (TOP mark facing upwards) * correct distribution of clearance around the circum. ference (gaps located at tnree aitferent angles): + binding in their seats or excessive wear. 3 | CHECK CYLINDER LINERS. PA465581000000 End of test B 7-1991 = Check: + the roughness of the cylinder tiners (excessive wear| could cause excessively smooth surtace); + that the main dimensions are within limits. Carry out step C3 Replace the faully rings Replace the faulty cylinder| liners if necessary PA485581000000 End of test CHi] ENGINE MAIN MECHANICAL UNIT 01-415 Hid ENGINE MAIN MECHANICAL UNIT 01-116 PROCEDURE FOR FAULT RECTIFICATION PROCEDURE FOR FAULT RECTIFICATION | ENGINE - NOISY OPERATION ENGINE - NOISY OPERATION | FOREWORD: i Discover i the noises are really caused by the engine and not by other components Ike: FAULTS AND SYMPTOMS FAULT ISOLATION ce | + Coolant pump ~ + Akemator BACKGROUND BEATING (DUE | Abackground beat that canbe heard when the engine D + Power steering pump TOINBALANCE) is under load or noise coming trom tha red: crankshaft i + Air condtioning compressor and piston-eylinder liner couplings j Note whether the noise is mainly present when the engine is cool or at normal running temperature, when engine is at | idle speed or if the noise increases as the revs increase. NOTE: Before performing the tests indicated below, check the oil level, grade of oil and cil filter. If Noise is produced by the engine i necessary change engine oll and filter using the prescrined quantities and grades. + noise is present when the vehicle is at rest and during travel + noise is present when the clutch is engaged and disengaged E FAULTS AND SYMPTOMS FAULT ISOLATION TEST i REFERENCE i BEATING WHEN THE ENGINE —_| Moreor less constant noiseis present when the engine A ' 1S IDLING is at ile speed, at normal punning temperature; noise | Jcomes trom the timing system cover area, BEATING WHEN THE ENGINE | Continuous beating of varying intensity coming from B Is COLD ne or more of the cylinders NOTE: Beating disappears when tne engine is at ‘oral running temperature. The atfacted cylinder can esasily be identified by dis- | t ‘connecting the spark pugs one at a time. | INTENSE AND INCONSTANT —_| Very intense beating which can be heard during ctatch c | [BEATING ‘engagement and disengagement and during sudden | seceleration, | l | — | | PA465581000000 7-1991 PAS6558 1000000 74009Hy ENGINE MAIN MECHANICAL UNIT 01-117 BEATING WHEN ENGINE IS AT IDLE TESTA TEST STEPS RESULTS REMEDY 1 | CHECK VALVE CLEARANCE = Check that the clearance between the cam heel radius and the top of the valve cup is within the specified limits. Q® Carry out step A2 ‘cups for wear, scoring, binding ote. Adjust clearance ng_| VISUALY CHECK CAMS AND curs — Visually check the cuspid of the cams and the top of the Carry out step AS Replace detective tems 43. | CHECK AXIAL PLAY = Check that camshaft axial play is within the specified limits. Carry out step Ad Replace defective cam-| shalt ‘Ad | CHECK CUPS AND SEATINGS = Check the outer diameter of the cups and the diameter| of the'relevant seatings; also check for scroing, binding ete. ® QO |@O Replace affected cups| and/or relevant cylinder| heac PA46551000000 End of test A 71991 uy =sGINE MAIN MECHANICAL UNIT O1-11 BEATING WITH ENGINE COLD TESTB TEST STEPS RESULTS REMEDY CHECK PISTON-CYLINDER LINER Bt COUPLING — heck that the clearance between cylinder liner and piston is within the prescribed limits. Carry out step B2 Replace affected cylinder liner and piston 82 | CHECK GUDGEON PIN = Checkthat clearances between piston hole and gudgeon pin, and between rod small end bushing hole and gud ‘geon pin are within the specttied limits, Replace atfected items P4465581000000 End of tost B 71991Hy ENGINE MAIN MECHANICAL UNIT 01-119 fi ENGINE MAIN MECHANICAL UNIT 01-120 loose. ~ Check that the nut securing the crankshatt pulley is not INTENSE AND INCONSTANT BEATING TESTC TEST STEPS RESULTS REMEDY c1r_| CHECK CRANKSHAFT PULLEY ATTACHMENT fauts Carry out step C2 Tighten the nut to the cor- rect torque or replace @ 2 | CHECK FLYWHEEL ATTACHMENT shatt are not loose, = Check that the screws securing the tiywheetto the crank Tighten screws tothe spe- sitied torque of replace @] damaged. Use locking| ‘compound LOCTITE 270 + main and rod bearings for traces of overheating, flaking etc. + crankshaft journals for damage BACKGROUND BEAT (DUE TO INBALANCE) TESTD TEST STEPS RESULTS REMEDY p1_ | CHECK CASTING OF MAIN AND ROD BEARINGS, = Check: Carry out step D2 @ » Lay > Replace crankshaft. Wash engine block tubri cating system and over- haul or replace oil pump it necessary. CHECK CONNECTING ROD AND BACKGROUND BEATING 2 = Check: + clearances between redbig end and crankshaft jour- nals and relevant bearings + tightening torques of main bearings and rod big end are within prescribed limits, Carry cut step D3 Replace crankshaft and/or affected rod. Tighten to prescribed torque D3_ | CHECK CRANKSHAFT BEATING PAas655e...00000 End of test C 1991 = Check that crankshaft axial play is within the specitied limits Q®| ®@ Carry out step 04 Replace the thrust half riogs PA385561000009HH ENGINE MAIN MECHANICAL UNIT 01-121 r BACKGROUND BEAT (DUE TO INBALANCE) TESTD TEST STEPS RESULTS REMEDY D4 | CHECK PISTON BINDING BEATING — Vtaualy check the mating sutaces ot te eyinde ners pe |cany cut step 8 and pistons for overheating, binding, scoring ete. andthat the piston rings move freely in the relative grooves onthe ay p> | Replace cylinder jiner ana piston of aftected cylinder piston End of test D ji | IMPORTANT NOTE: Forany anomalies which interfere with the correct operation of the engine refer to FAULT RECTIFICATION included in Group 04. For example + engine does not start + engine stumbles + irregular engine idle speed + excessive fuel consumption + excessive percentage of CO + et. Pages 1000000