CRANKSHAFT
• Step 1: TURBO ONLY: Before fitting the crankshaft,
install the four piston sprays (a) and stake the retaining plates
(arrowed).
Q Step 2: Locate the main bearing shells so that they are
firmly seated and their tabs engage with the slots in the
journal webs.
• Step 3: Apply some grease to the smooth side of the
thrust washers and 'stick' them in position on both sides of
the rear main bearing web (at the flywheel end).
• Step 4: Oil the shells liberally with fresh engine oil and
lower the crankshaft into position.
• Step 5: Fit the remaining halves of the shells into the
bearing caps. Oil the journals and position the caps the right
way round and in the correct order.
• Step 6: Screw the bolts in finger-tight and check that the
crankshaft rotates freely and smoothly.
Q Step 7: Tighten the bolts evenly and progressively until
the specified torque setting is reached, see Chapter
3,
Facts
and Figures. Check again that the crankshaft rotates
smoothly.
• Step 19:
Lift
the crank-
shaft clear of the
cylinder block,
retrieve the
other halves of
the
bearing
shells...
• Step 20:
...and
the two
thrust
washers
from
the rear
main bearing
web.
• Step 21:
TURBO
ENGINES ONLY.
Unbolt and
remove
the four
piston cooling
sprays
(a) from
the
cylinder
block oil gallery.
The
bearing shell
positions are
arrowed.
Job 24. Diesel engine -
reassembly.
Before starting work, read the notes at the beginning of
Job 6 for petrol engine reassembly
-
the checks and
preparation being basically the same for diesel engines.
H INSIDE INFORMATION! TURBO ENGINES ONLY. The
piston cooling sprays must be checked for serviceability
before refitting. Each spray contains its own valve which
must
open at between 1.25 and 1.75 bar. Below this
figure could cause excessive oil burning and low oil
pressure. Above this figure might result in the piston
overheating and its subsequent failure. Have your FIAT
dealer carry out this check, and replace any faulty units if
necessary. Q
• Step 9: Fit new oil
seals to the two seal
carriers.
• Step 10: Fit the
rear oil seal carrier (with
its new seal), using a
new gasket. Lubricate
the seal (illustration Job
24-9,
part b) and
lightly oil the gasket (a).
• Step 11: Position Nos. 1 and 4 crank pins at Top Dead
Centre (TDC), then fit the flywheel with its TDC mark facing
the cylinder head surface. Screw in the fixing bolts and tighten
to their specified torque. See Chapter
3,
Facts and Figures
Job 23-21
Q Step 8: Turn and lever the crankshaft tight against the
timing end and check the crankshaft end float by using a
feeler gauge between the thrust washer on the timing side of
the web and the crankshaft. Thicker washers are available if
required. See Chapter
3, Facts and Figures.
gjpjgjjl 'READING' YOUR SPARK PLUGS
Champion explain how the condition of spark plug firing ends can act as a guide to the state of tune and general condition of the engine. The examples shown are assumed to be the correct grade for the engine.
NORMAL
Core nose lightly coated with grey-brown deposits. Electrodes not burning unduly
-
gap increasing by about 0.01 mm every 1,000 miles approximately (with the use of unleaded fuel). Spark plugs correct for engine.
OIL FOULING
Deposits can short-circuit firing end, weakening or eliminating spark. Causes: worn valve guides, bores or piston rings, or while new engine is running-in. Replace spark plugs. Cure oiling problem.
SPLIT CORE NOSE
(May first appear as hair-line-crack). Probably caused by: Over-advanced ignition timing. Faulty distributor advance mechanism. Use of low octane fuel. Weak mixture. Manifold air-leaks. Cooling system problems. Incorrect gap-setting technique.
HEAVY DEPOSITS
Possible causes: Fuel or oil additives. Excessive upper cylinder lubricant. Worn valve guides. Unvarying speed (stationary engine). Replace spark plugs.
OVERHEATING
Likely causes are: Over-advanced ignition timing, or faulty distributor advance mechanism. Use of low octane fuel. Weak mixture. Discard spark plugs showing signs of overheating, and cure the cause.
CARBON FOULING
Look for dull black sooty deposits. (Unleaded fuel carbon fouling can appear similar to oil fouling). Deposits can short circuit the firing end, weakening or eliminating the spark. Check for: Over-rich mixture, faulty choke or clogged air filter. Replace spark plugs.
INITIAL PRE-IGNITION
Caused by serious overheating. Causes are those listed for overheating, but may be more severe. Corrective measures are urgently needed before engine damage occurs. Discard plugs in this condition.
FACT FILE: CORRECT INSTALLATION
• Make sure seating areas are perfectly clean.
• Insert plug finger tight to seat. Ensure plug 'spins' freely.
• PLUGS WITH SEATING GASKET: Tighten to relevant torque setting.
• PLUGS WITH TAPER SEATS: Tighten a further l/16th turn ONLY - no further!
• Overtightening can damage cylinder head or make taper seat plugs impossible to remove.
RECOMMENDED FL LUBRICANTS
FOR YOUR FIAT TIPO ARID TEMPRA
COMPONENT/ TIPO & TEMPRA TIPO SELECTA & TEMPRA SELECTA TIPO & TEMPRA DIESEL CAPACITY 1.4 and 1.6 1.6 and 1.6 i.e. 1.7 D, 1.9 Dand 1.9 TD
ENGINE SELENIA 20K SELENIA 20K SELENIA TURBO DIESEL CAPACITY 3.8 L 3.8 L/4.2 L 5.0 L
MANUAL TRANSMISSION TUTELA ZC80/S -TUTELA ZC80/S CAPACITY 2.0 L -2.0 L
AUTOMATIC TRANSMISSION -TUTELA CVT -CAPACITY -3.5 L (a) -
DIFFERENTIAL(S) FROM GEARBOX FROM GEARBOX FROM GEARBOX CAPACITY ---
STEERING BOX TUTELA K854 TUTELA K854 TUTELA K854 CAPACITY 80 g (b) 80 g (b) 80 g (b)
CONSTANT VELOCITY JOINTS TUTELA MRM2 TUTELA MRM2 TUTELA MRM2 CAPACITY 95 g (each) 95 g (each) 95 g (each)
BRAKE FLUID RESERVOIR TUTELA PLUS 3 TUTELA PLUS 3 TUTELA PLUS 3 CAPACITY (NON-ABS) 0.40
L
(c) 0.40 L (c) 0.40
L
(c)
COOLANT PARAFLU 11 PARAFLU 11 PARAFLU 11 CAPACITY 6.5 L(d) 6.5 L(d) 8.8
L
(d)
WINDSCREEN WASHER TANK AREXONS DP1 AREXONS DP1 AREXONS DP1 CAPACITY 5.0 L 5.0 L 5.0 L
NOTES: (a) DRAIN/REFILL CAPACITY (b) IF MODEL FITTED WITH POWER ASSISTED STEERING USE 0.75 L TUTELA Gl/A (c) IF ABS BRAKING IS FITTED USE 0.52 L TUTELA TOP 4 (d) COOLING SYSTEM AT A CONCENTRATION OF 50% COOLANT TO 50% WATER
CHANGE PERIODS: See Chapter 5, Service Intervals
154