FIAT / DUCATO 244eLearn workshop manual · English · Offline edition
Technical Data

1004E ENGINE ASSEMBLY INSPECTION AND REPAIRS

Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
SubjectValueValidity
CRANKCASE AND COMPONENTSmm2.0 16V
Cylinder head support surface flatness0,03
CRANKCASE AND COMPONENTSmm2.0 16V
Cylinder liner bore86,000 - 86,018
CRANKCASE AND COMPONENTSmm2.0 16V
1st cylinder liner oversize0,25
CRANKCASE AND COMPONENTSmm2.0 16V
2nd cylinder liner oversize0,60
CRANKSHAFTmm2.0 16V
Main journal diameter59,975 - 60,000
CRANKSHAFTmm2.0 16V, 2.0 JTD 8V
Main journal undersize0,300
CRANKSHAFTmm2.0 16V
Crankpin diameter49,984 - 50,000
CRANKSHAFTmm2.0 16V
Crankpin undersize0,300
CRANKSHAFTmm2.0 16V
Width of main bearing no. 225,70 - 25,75
CRANKSHAFTmm2.0 16V
1st oversize on width of main journal bearing no. 20,20
2nd oversize on width of main journal bearing no. 20,30
3rd oversize on width of main journal bearing no. 20,40
Lower main bearing half thicknessmm2.0 16V
Category A1,844
Category B1,857
Lower main bearing half thicknessmm2.0 16V
Category C1,866
Category D1,877
MAIN BEARINGSmm2.0 16V
Upper main bearing half thickness1,847
MAIN BEARINGS2.0 16V
Oversize lower main bearing half thicknessmm
Category A1,994
Category B2,007
MAIN BEARINGS2.0 16V
Oversize lower main bearing half thicknessmm
Category C2,016
Category D2,027
MAIN BEARINGSmm2.0 16V
Oversize upper main bearing half thickness1,997
MAIN BEARINGSmm2.0 16V
Thrust half-ring thickness1,850
MAIN BEARINGSmm2.0 16V
Radial clearance0,039 - 0,080
MAIN BEARINGS2.0 16V
Lower main bearing halvesmm
Category A0,039 - 0,052
Category B0,053 - 0,062
MAIN BEARINGS2.0 16V
Lower main bearing halvesmm
Category C0,063 - 0,074
Category D0,075 - 0,080
CRANKSHAFTmm2.0 16V
End float0,032 - 0,007
MAIN BEARINGSmm2.0 16V
Thickness of thrust half-rings, 1st oversize1,95
Thickness of thrust half-rings, 2nd oversize2,00
Thickness of thrust half-rings, 3rd oversize2,05
ENGINE PISTONmm2.0 16V
Outer diameter85,958 - 85,976
Distance to lower piston edge8
ENGINE PISTONmm2.0 16V
1st oversize outer diameter86,208 - 86,226
2nd oversize outer diameter86,558 - 86,576
PISTON RING SETmm2.0 16V, 2.0 JTD 8V
First ring gap0,20 - 0,40
Second ring gap0,15 - 0,35
CONNECTING ROD ASSEMBLY°C2.0 16V
Heating230 - 250
BIG END BEARINGSmm2.0 16V
Connecting rod bearing half thickness1,832 - 1,842
BIG END BEARINGSmm2.0 16V
Oversize connecting rod bearing half thickness1,982 - 1,992
CYLINDER HEAD GASKETmm2.0 16V
Size1,30
Ground cylinder head-
CYLINDER HEAD GASKETmm2.0 16V
Size1,50
Ground cylinder head-
CYLINDER HEAD RETAINING ELEMENTSmm2.0 16V
Retaining bolt length122,0
TOOTHED TIMING BELTmm2.0 16V
Mass position30
CRANKCASE AND COMPONENTSmm2.0 JTD 8V
Cylinder head support surface flatness0,03
CRANKCASE AND COMPONENTSmm2.0 16V
Cylinder liner bore86,000 - 86,018
CRANKCASE AND COMPONENTSmm2.0 16V
1st cylinder liner oversize0,25
CRANKCASE AND COMPONENTSmm2.0 16V
2nd cylinder liner oversize0,60
CRANKSHAFTmm2.0 16V
Main journal diameter59,975 - 60,000
CRANKSHAFTmm2.0 16V, 2.0 JTD 8V
Main journal undersize0,300
CRANKSHAFTmm2.0 16V
Crankpin diameter49,984 - 50,000
CRANKSHAFTmm2.0 16V, 2.0 JTD 8V
Crankpin undersize0,300
CRANKSHAFTmm2.0 16V
Width of main bearing no. 225,70 - 25,75
CRANKSHAFTmmT2.0 16V
1st oversize on width of main journal bearing no. 20,20
2nd oversize on width of main journal bearing no. 20,30
3rd oversize on width of main journal bearing no. 20,40
Lower main bearing half thicknessmm2.0 16V
Category A1,844
Category B1,857
Lower main bearing half thicknessmm2.0 16V
Category C1,866
Category D1,877
MAIN BEARINGSmm2.0 16V
Upper main bearing half thickness1,847
MAIN BEARINGS2.0 16V
Oversize lower main bearing half thicknessmm
Category A1,994
Category B2,007
MAIN BEARINGS2.0 16V
Oversize lower main bearing half thicknessmm
Category C2,016
Category D2,027
MAIN BEARINGSmm2.0 16V
Oversize upper main bearing half thickness1,997
MAIN BEARINGSmm2.0 16V
Thrust half-ring thickness1,850
CRANKCASE AND COMPONENTSmm2.0 16V
Engine block height234,95 - 235,05
Lower main bearing half thicknessmm2.0 16V
Category A1,844
Category B1,857
Lower main bearing half thicknessmm2.0 16V
Category C1,866
Category D1,877
MAIN BEARINGSmm2.0 16V
Upper main bearing half thickness1,847
MAIN BEARINGS2.0 16V
Oversize lower main bearing half thicknessmm
Category A1,994
Category B2,007
MAIN BEARINGS2.0 16V
Oversize lower main bearing half thicknessmm
Category C2,016
Category D2,027
MAIN BEARINGSmm2.0 16V
Oversize upper main bearing half thickness1,997
MAIN BEARINGSmm2.0 16V
Thrust half-ring thickness1,850
MAIN BEARINGSmm2.0 16V
Radial clearance0,039 - 0,080
MAIN BEARINGS2.0 16V
Lower main bearing halvesmm
Category A0,039 - 0,052
Category B0,053 - 0,062
MAIN BEARINGS2.0 16V
Lower main bearing halvesmm
Category C0,063 - 0,074
Category D0,075 - 0,080
CRANKSHAFTmm2.0 16V
End float0,032 - 0,007
MAIN BEARINGSmm2.0 16V
Thickness of thrust half-rings, 1st oversize1,95
Thickness of thrust half-rings, 2nd oversize2,00
Thickness of thrust half-rings, 3rd oversize2,05
ENGINE PISTONmm2.0 16V
Outer diameter85,958 - 85,976
Distance to lower piston edge8
ENGINE PISTONmm2.0 16V
1st oversize outer diameter86,208 - 86,226
2nd oversize outer diameter86,558 - 86,576
PISTON RING SETmm2.0 16V, 2.0 JTD 8V
First ring gap0,20 - 0,40
Second ring gap0,15 - 0,35
CONNECTING ROD ASSEMBLY°C2.0 16V
Heating230 - 250
BIG END BEARINGSmm2.0 JTD 8V
Connecting rod bearing half thickness1,832 - 1,842
BIG END BEARINGSmm2.0 JTD 8V
Oversize connecting rod bearing half thickness1,982 - 1,992
CYLINDER HEAD GASKETmm2.0 16V
Size1,30
Ground cylinder head-
CYLINDER HEAD GASKETmm2.0 16V
Size1,50
Ground cylinder head-
CYLINDER HEAD RETAINING ELEMENTSmm2.0 16V
Retaining bolt length122,0
TOOTHED TIMING BELTmm2.0 16V
Mass position30
SubjectValueValidity
Crankcase and componentsmm2.3 JTD 16V, 2.8 JTD 8V
Cylinder support surface flatness< 0,10
Cylinder liner boremm2.8 JTD 8V
Category A94,402 - 94,412
Category B94,413 - 94,422
Category C,94,423 - 94,432
Crankcase and componentsmm2.3 JTD 16V, 2.8 JTD 8V
Cylinder liner taper< 0,05
Crankcase and componentsmm2.3 JTD 16V, 2.8 JTD 8V
Cylinder liner ovality< 0,05
Crankcase and componentsmm2.8 JTD 8V
Cylinder liner oversize0,40
Crankshaftmm2.8 JTD 8V
Main journal diameter80,182 - 80,208
Main journal diameter86,182- 86,208 (*)
Crankshaftmm2.8 JTD 8V
Main journal undersize0,254 - 0,508
Crankshaftmm2.8 JTD 8V
Crankpin diameter56,515 - 56,538
Crankshaftmm2.8 JTD 8V
Main journal undersize0,254 - 0,508
Crankshaftmm2.3 JTD 16V, 2.8 JTD 8V
Ovality0,005
Taper0,005
Crankshaftmm2.3 JTD 16V, 2.8 JTD 8V
Main journal misalignment0,05
Crankpin misalignment0,125
Main bearing half thicknessmm2.8 JTD 8V
Category A2,165 - 2,174
Category B2,319 - 2,428
Category C2,573 - 2,682
Connecting rod bearing half thicknessmm2.8 JTD 8V
Category A1,875 - 1,884
Category B2,129 - 2,138
Category C2,483 - 2,492
Crankshaftmm2.3 JTD 16V, 2.8 JTD 8V
Ovality0,005
Taper0,005
Crankshaftmm2.3 JTD 16V, 2.8 JTD 8V
Main journal misalignment0,05
Crankpin misalignment0,125
Crankshaftmm2.8 JTD 8V
End float0,049 - 0,211
Crankshaft bearingsmm2.8 JTD 8V
Radial clearance0,032 - 0,102
Engine piston set2.8 JTD 8V
Piston bush internal diameter32,003 - 32,009
Gudgeon pinmm2.8 JTD 8V
Outer diameter31,996 - 31,999
Outer diametermm2.8 JTD 8V
Category A94,310 - 94,320
Category B94,320 - 94,330
Category C94,330 - 94,340
Piston ring setmm2.8 JTD 8V
First ring gap0,20 - 0,35
Second ring gap0,30 - 0,50
Oil scraper ring gap0,30 - 0,55
Piston ring setmm2.8 JTD 8V
First ring size2,068 - 2,097 (*)
Second ring size1,970 - 1,995
Oil scraper ring size2,470 - 2,490, mm
Piston ring setmm2.8 JTD 8V
First ring end float0,103 - 0,162
Second ring end float0,055 - 0,100
Oil scraper ring end float0,050 - 0,090
Cylinder head gasketmm2.8 JTD 8V
Size1,20
Average maximum piston projection0,40 - 0,50
Cylinder head gasketmm2.8 JTD 8V
Size1,30
Average maximum piston projection0,51 - 0,60
Cylinder head gasketmm2.8 JTD 8V
Size1,40
Average maximum piston projection0,61 - 0,70
Cylinder head gasketmm2.8 JTD 8V
Size1,50
Average maximum piston projection0,71 - 0,80