MP3 400 i.e.

Engine

Removing the intake manifold

- Remove the 3 mounting screws.
- Remove the intake manifold unit.

Removing the rocker-arms cover

- Loosen the 6 special screws with stop and the
relevant rubber gaskets.
- Remove the tappet cover with relevant gasket.

Removing the timing system drive

- Turn the engine to close the intake valves.

ENG - 49
Engine MP3 400 i.e.

- Remove the central screw and the valve lifting

device mass stop bell using the special tool.

Specific tooling
020565Y Flywheel lock calliper spanner

- Remove the return spring and the valve lifting

mass with relevant travel end washer.
N.B.
BE CAREFUL NOT TO ALLOW THE WASHER
AND SPRING TO FALL INTO THE ENGINE
THROUGH THE CHAIN COMPARTMENT.

- Align the reference marks on the timing chain rim

with those on the head.

- Loosen the central screw on the tensioner first.

- Unscrew the 2 fastening screws and remove the
tensioner with relevant gasket.

ENG - 50
MP3 400 i.e. Engine

Remove the inside hexagon screw and the coun-

terweight as shown in the figure.

- Remove the timing belt rim from the camshaft.

- Remove the timing belt rim.

Removing the cam shaft

- Unscrew the 3 fastening screws and remove
camshaft retaining bracket.
N.B.
REMOVING THE FASTENING SCREWS MAY
BE DIFFICULT. BE CAREFUL NOT TO DAM-
AGE THE INSIDE HEXAGON. IF NECESSARY,
SEPARATE THE THREADS IN ADVANCE.

- Remove the cam shaft.

ENG - 51
Engine MP3 400 i.e.

- Remove pins and rocking levers by the transmis-

sion side holes.

Removing the cylinder head

- Remove the spark plug.
- Remove the cooling system outlet sleeve with
thermostat.

- Remove the coolant temperature sensor.

N.B.
THE SENSOR CONTROLS BOTH INJECTION
AND THE ANALOGUE INSTRUMENT ON THE
PANEL. TO CHECK THIS COMPONENT, SEE
THE INJECTION CHAPTER.

- Remove the 2 fastening nuts on the head, on the

exhaust and on the intake side.

ENG - 52
MP3 400 i.e. Engine

- Remove the two M6 screws into the distribution

channel and the M6 screw on the spark plug side
with the thermostat support.

N.B.
THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, ROCKING LEVER PINS AND FITTING
BRACKET IF NECESSARY.
- Loosen the 4 head-cylinder fastening nuts in 2 or
3 times and in a crossed sequence.
- Remove the head, the 2 centring dowels, the
gasket and the lower chain guide sliding block.
N.B.
DO NOT REMOVE THE DOWELS IF THEY ARE
FORCED INTO THEIR SEAT.

CAUTION
WHEN YOU HAVE TO REMOVE THE HEAD, PREPARE A SUITABLE CONTAINER SINCE THE
THERMAL UNIT CONTAINS COOLANT.

Removing the valves

- Using the appropriate tool fitted with an adaptor,
remove the cotters, caps, springs and valves.

Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
020382Y012 bush (valve removing tool)

CAUTION
ARRANGE THE VALVES SO AS TO RECOGNISE THE ORIGINAL POSITION ON THE HEAD (FLY-
WHEEL SIDE AND TRANSMISSION SIDE).

ENG - 53
Engine MP3 400 i.e.

- Remove the oil guards using the special tool.

Specific tooling
020431Y Valve oil seal extractor

- Remove the spring supports.

N.B.
BLOW THE SEATS WITH COMPRESSED AIR
TO FACILITATE THE SPRING SUPPORT RE-
MOVAL.

Removing the cylinder - piston assy.

- Remove the timing chain.
- Loosen the fastening screw and remove the
spacer and the tightening sliding block.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN OR-
DER TO ENSURE THAT THE INITIAL DIREC-
TION OF ROTATION IS MAINTAINED.

- Extract the cylinder with the relevant gasket and

the centring dowel.
N.B.
THE SECOND CENTRING IS ENSURED BY A
PIN SET INTO THE CYLINDER.
CAUTION
TO PREVENT DAMAGES TO THE PISTON,
SUPPORT IT WHILE REMOVING THE CYLIN-
DER.

ENG - 54
MP3 400 i.e. Engine

- Remove the 2 piston pin locking rings by the spe-

cific housings.
- Extract the pin and remove the piston.
N.B.
USE PAPER OR A CLOTH TO CLOSE THE CYL-
INDER HOUSING MOUTH ON THE CRANK-
CASE TO PREVENT SLIPPAGE OF ONE OF
THE PIN LOCKING RINGS INTO THE CASE.

- Remove the piston sealing rings and the oil scra-

per.
CAUTION
NOTE THE ASSEMBLY POSITIONS OF THE
LININGS TO PREVENT INVERTING THE POSI-
TION IN CASE OF REUSE.
N.B.
BE CAREFUL NOT TO DAMAGE THE SEALING
RINGS DURING REMOVAL.

Inspecting the small end

- Using a bore gauge, measure the connecting rod
small end diameter.
N.B.
IF THE CONNECTING ROD SMALL END DIAM-
ETER EXCEEDS THE STANDARD DIAMETER,
EXHIBITS WEAR OR OVERHEATING, PRO-
CEED TO REPLACE THE CRANKSHAFT AS
DESCRIBED IN CHAPTER CRANKCASE AND
CRANKSHAFT.
Characteristic
Standard diameter:
22 + 0.025 +0.015 mm

Inspecting the wrist pin

- Check the pin outside diameter using a micrometer.

Characteristic
Standard diameter:
22 0 - -0.004 mm

ENG - 55
Engine MP3 400 i.e.

- Calculate the coupling clearance between pin

and connecting rod end.

Characteristic
Standard clearance:
0.015 ÷ 0.029 mm

Inspecting the piston

- Measure the capacity diameter on the piston.

Characteristic
Standard diameter:
22 + 0.006 + 0.001 mm

- Calculate the piston pin coupling clearance.

N.B.
THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT
MUST BE MADE ACCORDING TO THE PISTON AXIS.
Characteristic
Standard clearance:
0.001 ÷ 0.010 mm

- Measure the outside diameter of the piston, per-

pendicular to the gudgeon pin axis.
- Take the measurement in the position shown in
the figure.
N.B.
REFER TO THE «SPECIFICATIONS» SECTION
FOR THE SIZES OF THE PISTON AND THE
CYLINDER-PISTON COUPLING CLEARAN-
CES.
Characteristic
A:
10 mm
Piston diameter:
85.8 mm nominal value

ENG - 56
MP3 400 i.e. Engine

- Using a bore meter, measure the cylinder inner

diameter at a given height according to the direc-
tions shown in the figure.

Characteristic
B:
43 mm
Standard diameter:
85.8 mm nominal value

- Check that coating is free from flakes.

- Check that the head matching surface exhibits no deformations or wear.

Characteristic
Maximum allowable run-out:
0.05 mm

- Pistons and cylinders are classified into categories based on their diameter. The coupling is carried
out in pairs (A-A, B-B, C-C, D-D).
N.B.
REFER TO THE «SPECIFICATIONS» SECTION FOR THE SIZES OF THE CYLINDER AND THE
CYLINDER-PISTON COUPLING CLEARANCES.

Inspecting the piston rings

- Alternately insert the three sealing rings into the
cylinder, in the area where it retains its original di-
ameter. Using the piston, insert the rings perpen-
dicularly to the cylinder axis.
- Make sure that each single sealing ring evenly
adheres to the cylinder liner. If it does not, this
means the ring is worn. Replace it.
- Measure the opening (see figure) of the sealing
rings using a feeler gauge.

ENG - 57
Engine MP3 400 i.e.

- If higher values than those prescribed are meas-

ured, replace the linings.

Check the size of the sealing ring opening:

Compression ring: 0.15 ÷ 0.35 mm. Max. value 0.5 mm
Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm
Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm

Rings/housing coupling clearances:

Carefully clean the sealing ring housings.
Place a thickness gauge between the ring and the
housing as shown in the drawing and check the
coupling clearances.
Top ring Standard coupling clearance:
0.01÷0.06 mm
Maximum clearances allowed after use: 0.10
mm
Intermediate ring Standard coupling clear-
ance:0.02÷0.07 mm
Maximum clearances allowed after use: 0.10
mm
Oil scraper ring Standard coupling clearance:
0.01÷0.06 mm
Maximum clearances allowed after use: 0.10
mm
Replace the piston if clearances exceed the max-
imum limits specified in the table.

Removing the piston

- Install piston and wrist pin onto the connecting
rod, aligning the piston arrow the arrow facing to-
wards the exhaust.

ENG - 58
MP3 400 i.e. Engine

- Insert the locking ring into the special tool, with

the opening in the position indicated on the tool.
S = left
D= right

- Place the wrist pin stop ring into position using a

punch

- Install the pin lock using the key shown in the

figure.

Specific tooling
020470Y Pin retainers installation tool

N.B.
THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY.
CAUTION
USING A HAMMER MIGHT DAMAGE THE STOPS' HOUSING.

Choosing the gasket

- Provisionally fit the piston into the cylinder, without any base gasket.
- Install a comparator on the special tool using the short union, as shown in the figure.

Specific tooling
020475Y Piston position checking tool

ENG - 59
Engine MP3 400 i.e.

- Using an abutment plane, reset the comparator

with a preload of a few millimetres.
- Finally fix the comparator.
- Check the perfect sliding of the feeler pin.
- Install the tool on the cylinder without changing
the comparator position.
- Lock the tool using the original head fixing nuts.
- Rotate the crankshaft until TDC (the inverted
point of the dial gauge rotation)
- Measure the deviation from the reset value.

- Identify the thickness of the cylinder base gasket to be used for reassembly by the table below. Cor-
rectly identify the cylinder base gasket thickness to keep the correct compression ratio.
- Remove the special tool and the cylinder.
N.B.
IF DEVIATIONS (OR RECESSES OR PROJECTIONS) CLOSE TO THE CHANGE OF CATEGORY
ARE MEASURED, REPEAT THE MEASUREMENT AT THE OPPOSED SIDE. TO DO SO, REPEAT
THE TOOL INSTALLATION BY INVERTING ITS POSITION.
Characteristic
Recess / Projection measured 1
- 0.185 - - 0.10
Gasket thickness 1
0.4 ± 0.05
Recess / Projection measured 2
- 0.10 - + 0.10
Gasket thickness 2
0.6 ± 0.05
Recess / Projection measured 3
+ 0.10 - + 0.185
Gasket thickness 3
0.8 ± 0.05

ENG - 60
MP3 400 i.e. Engine

Refitting the piston rings

- Place the scraper ring spring on the piston.
- Install the scraper ring keeping the opening op-
posed to the spring junction and with the writing
"top" facing the piston top. The chamfered side of
the oil scraper ring should always be facing the
piston crown.
- Fit the second lining with the identification letter
or the writing "top" facing the piston crown. In any
case, the step must be facing opposite the piston
top.
- Install the first compression lining in the direction
imposed by the housing.
- It is advisable to use a fitter to facilitate the in-
stallation of the linings.
N.B.
THE TWO PISTON RINGS ARE MADE WITH A
TAPERED CYLINDRICAL CONTACT CROSS-
SECTION. THIS IS TO ACHIEVE A BETTER
BEDDING.
- Misalign the lining openings at 120° as shown in the figure.
- Lubricate the components with engine oil.
- The engine uses the first compression lining with an L section.

Refitting the cylinder

- Insert the cylinder base gasket with the thickness
determined above.
- Using the fork and the ring clamp, fit the cylinder
as shown in the figure.
N.B.
BEFORE FITTING THE CYLINDER, CAREFUL-
LY BLOW THE LUBRICATION DUCT AND LU-
BRICATE THE CYLINDER LINER. CHECK THE
PRESENCE OF THE TWO REFERENCE DOW-
ELS.
Specific tooling
020468Y Piston fitting ring
020512Y Piston fitting fork

Inspecting the cylinder head

- Using a trued bar and feeler gauge check that the cylinder head surface is not worn or distorted.

ENG - 61
Engine MP3 400 i.e.

Characteristic
Maximum allowable run-out:
0.1 mm

- In case of irregularities, replace the head.

- Check the sealing surfaces for the intake and ex-
haust manifold.
- Check that the camshaft and the rocker pin ca-
pacities exhibit no wear.
- Check that the head cover surface is not worn.
- Check that the coolant sealing pad exhibits no
oxidation.

Inspecting the timing system components

- Check that the guide shoe and the tensioner shoe
are not worn out.
- Check that the crankshaft pinion and the cam-
shaft timing gear and crankshaft pinion exhibit no
wear.
In case of wear of the sliding blocks, replace them.
In case of wear of the chain or rim, replace the en-
tire unit.
N.B.
IF THE CHAIN HAS DAMAGED THE PINION, REPLACE THE CRANKSHAFT AS DESCRIBED IN
CHAPTER CRANKCASE AND CRANKSHAFT.
Chain tensioner:
- Remove the centre screw with the washer and
the tensioner spring. Check that the one-way
mechanism is not worn.
- Check the condition of the tensioner spring.
- If examples of wear are found, replace the whole
assembly.

Inspecting the valve sealings

- Visually inspect the valve sealing surface.
CAUTION
DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).

ENG - 62
MP3 400 i.e. Engine

- If the sealing surface of the valve is found to be

interrupted at one or more points or is not flat, re-
place the valve.

- Insert the valves into the cylinder head.

- Alternatively check the intake and exhaust
valves.
- The test is carried out by filling the manifold with
petrol and checking that the head does not ooze
through the valves when these are just pressed
with the fingers.

Inspecting the valve housings

- Clean the valve seats of any carbon residues.
- Using the Prussian blue, check the width of the
impression on the valve seat "V".

Characteristic
Standard value:
1 - 1.3 mm
Admissible limit:
1.6 mm

- If the impression width on the valve seat is larger than the prescribed limits, true the seats with a 45°
mill and then grind.
- In case of excessive wear or damages, replace the head.

Inspecting the valves

- Measure the diameter of the valve stems in the three positions indicated in the diagram.

STANDARD DIAMETER
Specification Desc./Quantity
Inlet: 4.987 - 4.972 mm
Outlet: 4.975 - 4.960 mm

ENG - 63
Engine MP3 400 i.e.

MINIMUM ADMISSIBLE DIAMETER

Specification Desc./Quantity
Inlet: 4.96 mm
Outlet: 4.945 mm
- Calculate the clearance between valve and valve guide.

- Check the deviation of the valve stem by resting

it on a "V" shaped abutment and measuring the
extent of the deformation with a comparator.

Characteristic
Limit values admitted:
0.1 mm

- Check the concentricity of the valve head by ar-

ranging a comparator at right angle relative to the
valve head and rotate it on a "V" shaped abutment.

Characteristic
Admissible limit:
0.03 mm

Inspecting the valve stem guide clearance

- After measuring the valve guide diameter and the valve stem diameter, check the clearance between
guide and stem.

ENG - 64
MP3 400 i.e. Engine

INLET
Specification Desc./Quantity
Standard clearance: 0.013 - 0.04 mm
Admissible limit: 0.08 mm

OUTLET
Specification Desc./Quantity
Standard clearance: 0.025 ÷ 0.052 mm
Admissible limit: 0.09 mm

STANDARD VALVE LENGTH

Specification Desc./Quantity
Inlet: 95.0 ± 0.3 mm
Outlet: 94.2 ± 0.3 mm
- Check that there are no signs of wear on the surface of contact with the articulated register terminal.

- If the checks above give no failures, you can use

the same valves. To obtain better sealing perform-
ance, grind the valve seats. Grind the valves gently
with a fine-grained lapping compound. During the
grinding, keep the cylinder head with the valve ax-
es in a horizontal position. This will prevent the
lapping compound residues from penetrating be-
tween the valve stem and the guide (see figure).
CAUTION

ENG - 65
Engine MP3 400 i.e.

TO AVOID SCORING THE CONTACT SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN
NO LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE
VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
CAUTION
DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).

Inspecting the springs and half-cones

- Check that the upper and lower supporting spring
washers, the cotters and the oil seal show exhibit
no signs of abnormal wear. Replace a component
when worn.

- Measure the unloaded spring length.

Characteristic
Standard length:
44.4 mm
Admissible limit after use:
42.4 mm

Refitting the valves

- Place the valve spring support washers on the
head.
- Alternately insert the 4 oil guards using the spe-
cial tool.
- Lubricate the oil guards and the valve guides.

Specific tooling
020306Y Punch for assembling valve seal
rings

ENG - 66
MP3 400 i.e. Engine

- Fit the valves, the springs and the spring retaining

washers. Using the appropriate tool with adapter,
compress the springs and insert the cotters in their
seats.

Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
020382Y012 bush (valve removing tool)
N.B.
DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE VALVE SPRINGS WITH THE REF-
ERENCE COLOUR ON COTTER SIDE (TURNS WITH GREATER PITCH).

Inspecting the cam shaft

- Check that the camshaft ends exhibit no scores or irregular wear.
- Using a micrometer, measure the camshaft capacity.

STANDARD DIAMETER
Specification Desc./Quantity
Bearing A Ø: 42 - 0.060 -0.085 mm
Bearing B diameter: 20 - 0.020 -0.041 mm

MINIMUM ADMISSIBLE DIAMETER

Specification Desc./Quantity
Bearing A Ø: 41.910 mm
Bearing B diameter: 19.940 mm

-Using a gauge, measure the cam height.

STANDARD HEIGHT
Specification Desc./Quantity
intake 33.774 mm
discharge 33.273

ADMISSIBLE LIMITS
Specification Desc./Quantity
intake 33.526 mm

ENG - 67
Engine MP3 400 i.e.

Specification Desc./Quantity
discharge 33.026 mm
Standard axial clearance: 0 - 0.22 mm
Maximum admissible axial clearance: 0.3 mm

- If any of the above dimensions are outside the

specified limits, or there are signs of excessive
wear, replace the defective components with new
ones.
- Check that the retaining plate seat shown in the
figure exhibits no wear.

- Check that the automatic valve lifting device cam,

the travel end roller and the rubber abutment on
the containment bell are free from wear.
- Check that the valve lifting spring has not yielded.
- Replace any defective or worn components.

- Check that the rocking lever pins exhibit no scores or wear.

Characteristic
Standard diameter:
13 - 0.010 -0.018 mm

ENG - 68