1012A23 LOWER ENGINE BLOCK - R R CLEAN MATING SURFACES AND APPLY SEALANT WITH ENGINE REMOVED - Lancia - Ypsilon - eLearn

2429765 - 1012A23 lower engine block - r r clean mating surfaces and apply sealant with engine removed

) - 1004D40 engine - position on stand and remove - 1032B16 toothed timing belt - r r with engine removed - 1020A24 crank case oil sump - r + r clean seals for sealant application with engine removed1. Position the flywheel retainer.

	Name	Country
1	Counter-torque	1.860.846.000

2. Undo the fixing bolts (2a) and remove the clutch plate (2b).

1. Fit the crankshaft gear locking tool as illustrated in the figure.

	Name	Country
1	Counter-torque	1.870.763.000

Work with flywheel retainer 1860846000 fitted.

2. Undo bolts securing crankcase gear and remove.

1. Unscrew the bolts securing the flywheel.2. Remove the engine flywheel together with plate (2a) and the flywheel lock positioned previously.

1. Undo the fixing bolts (1a) and remove the crankshaft rear cover (1b).

Rotate the engine on the overhauling stand.1. Undo the bolts (1a) and remove the crankcase front cover (1b) with built-in oil pump (1b), complete with crankshaft front oil seal (1c), oil pump (1d) and oil filter (1e).2. Remove the gasket from the crankcase front cover.

1. Undo bolts (1a) and (1b) and remove the lower crankcase, which also acts as the main bearing caps.2. Remove the lower main journal half-bearings.

Refitting ( Removing

) Thoroughly clean sealant residues from mating surfaces between lower and upper crankcase.Apply the recommended sealant to the entire perimeter of the crankcase sump in an unbroken strip.

Apply a 2 mm thick, unbroken sealant strip to the lower crankcase surface.

1. Position the main bearing halves to the lower crankcase.2. Fit the lower crankcase to the upper crankcase. check that codes (2a) stamped on both parts of the crankcase correspond because the crankcase components are not interchangeable.

When positioning the lower crankcase, avoid making significant horizontal shifts in position that could remove the sealant.

1. Tighten bolts (1a) and bolts (1b) securing the lower crankcase. Use tool (1c) to for angular tightening.

	Name	Country
1c	Protractor	1.860.942.000

Rotate the engine on the overhauling stand.1. Position a new oil pump gasket.2. Fit the crankcase front cover with built-in oil pump (2a), complete with inlet and oil filter, and tighten bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	ENGINE OIL PUMP	M6 x 20	1

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	ENGINE OIL PUMP	M6 x 32	1

1. Fit a new crankshaft front cover oil seal (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.860.990.000

1. Fit crankcase rear cover (1b) and secure by tightening bolts (1a) to the specified torque.

The rear crankcase cover comes with an oil seal.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FLYWHEEL SIDE COVER	M6 x 20	1

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FLYWHEEL SIDE COVER	M6 x 32	1

1. Fit the gear on the crankshaft.2. Fit the flywheel (2a), complete with retaining shim (2b) and fix it tightening the bolts (2c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2c	Bolt	FLYWHEEL	M8	4.4

1. Fit the gear on the crankshaft.2. Fit the crankshaft locking tool.

	Name	Country
2	Counter-torque	1.870.763.000

3. Secure the crankshaft gear by tightening the bolt to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	TOOTHED DRIVE PULLEY	M12 x 1.25	2 + 90°

1. Line up the driven plate for fitting the clutch assembly (1a), using the centring pin (1b).

	Name	Country
1b	Clutch centering	1.870.418.000

2. Tighten the bolts fixing the clutch to the engine flywheel.Remove the engine flywheel lock applied previously.

- 1020A24 crank case oil sump - r + r clean seals for sealant application with engine removed - 1032B16 toothed timing belt - r r with engine removed - 1004D40 engine - position on stand and remove