1024A10 CRANK SHAFT - R + R WITH ENGINE REMOVED - CHECK MAIN AND CONNECTING ROD BEARINGAND REPLACE IF NECESSARY - Alfa - 156 - eLearn

3239074 - 1024A10 crank shaft - r + r with engine removed - check main and connecting rod bearingand replace if necessary

) 1. Disconnect the earth cable from the left cylinder head tappet cover.2. Disconnect the electrical connection of the motorized throttle body actuator.

	Name	Connector
2	Throttle body actuator	N75

1. Disconnect the oil vapour recovery pipe.2. Disconnect the condensation oil return pipe from the separator.

Slacken the bolts on the clips securing the air intake ducts to the intake chamber.1. Undo the bolts (1a) and remove the complete intake duct (1b).

1. Disconnect the electrical connection for the timing sensor (light blue).

	Name	Connector
1	Timing sensor	K47

2. Disconnect the electrical connection for the engine rpm and timng sensor (black).

	Name	Connector
2	Rpm sensor	K46

3. Disconnect the electrical connection for the rear detonation sensor (black).

	Name	Connector
3	Detonation sensor - 1	K50

4. Disconnect the electrical connection for the combined sender unit for the coolant temperature gauge and the engine overheating warning light.

	Name	Connector
4	Coolant temperature sender unit	K35

5. Disconnect the electrical connection from the engine coolant temperature sensor.

	Name	Connector
5	Engine temperature sensor	K45

6. Disconnect the earth cable from the left cylinder head tappet cover.

1. Undo the bolts (1a) and remove the left cylinder head ignition coils cover (1b).

1. Disconnect the electrical connection for the air conditioning compressor.

	Name	Connector
1	Air conditioning compressor "on" electromagnet	L20

1. Disconnect the electrical connection for the front detonation sensor.

	Name	Connector
1	Knock sensor - 2	K51

2. Undo the bolts (2a) and remove the electrical wiring securing brackets (2b).3. Disconnect the electrical connections from the injectors.

	Name	Connector
3	Injector	N70

4. Disconnect the electrical connections from the ignition coils.

	Name	Connector
4	Ignition coil	A30

5. Remove the electrical wiring after releasing it from the securing bands.

1. Loosen the engine components drive belt tension by adjusting the belt tensioner.2. Lock the belt tensioner with the belt slack inserting a suitable peg.3. Remove the engine components single drive belt.

1. Undo the bolts (1a) and remove the timing belt guards (1b).

1. Slacken the timing belt tensioner bolts.2. Remove the timing belt from the camshaft pulleys.

1. Undo the bolts (1a) and remove the bracket (1b) securing the timing belt guard.

1. Undo the bolts (1a) and remove the ignition coils (1b) from the cylinder heads.

1. Undo the bolts (1a) and remove the rocker covers (1b) from the cylinder heads.

1. Fit the tool.

	Name	Country
1	Counter-torque	1.820.624.000

2. Undo the nut (2a) and remove the single drive belt drive pulley (2b).3. Remove the timing drive belt.4. Remove the timing belt drive pulley.

Rotate the engine through 180° on the overhauling stand.1. Undo the bolts (1a) and remove the crankcase sump (1b), complete with rpm and timing sensor (1c) and fixed belt tensioner for the engine components single drive belt (1d).

To release the sump, tap it gently with a wooden or resin hammer, then use a screwdriver to lever against the specific projections on the sides of the sump.

1. Undo the bolt fixing the oil pump chain drive to the oil pump.2. Separate the chain drive from the oil pump using the tool.

	Name	Country
2	Extractor	1.860.954.001

1. Undo the bolts (1a) and remove the complete oil pump (1b).

1. Undo the bolt (1a) and remove the fixed single drive belt tensioner (1b).2. Loosen the lower bolt (2a), undo the upper bolts (2b) and move the alternator (2c) away.

1. Remove the crankshaft key using a suitable drift.2. Undo the bolts (2a) and remove the crankcase front cover (2b).3. Remove the gasket.4. Remove the oil pump drive chain.

1. Undo the bolts (1a) and remove the engine flywheel (1b).2. Remove the tool.

	Name	Country
2	Counter-torque	1.820.624.000

1. Fit the tool.

	Name	Country
1	Flange	1.820.618.000

Turn the crankshaft to gain access to the big end bearing cap bolts.2. Undo bolts (2a) and remove big end bearing caps (2b) complete with bearing shells (2c).Remove the tool.

	Name	Country
-	Flange	1.820.618.000

1. Undo the nuts (1a) and remove the front and central main bearing caps (1b) using a suitable tool (1c).2. Remove the half-bearings.

1. Undo the nuts (1a) and remove the rear main bearing cap (1b) using the tools (1c) and (1d).

	Name	Country
1c	Lever	1.821.006.001

	Name	Country
1d	Extractor	1.821.006.002

2. Remove the half-bearing.3. Remove the rubber seals (only for cars up to engine no. 00708).

1. Remove the crankshaft.2. Remove the crankshaft rear oil seal.3. Remove the half-bearings.4. Remove the thrust washers.5. Remove the big end bearing shells.

Refitting ( Removing

) Visually inspect the condition of the main and big end bearing shells and, if necessary, replace them.Check that the thickness of the main journal half-bearings is within the recommended values; if this is not the case, replace them. if this is not the case, replace them.

	Measurement		Value
-	Half-bearing thickness (mm)	Category B	1.839 ÷ 1.845
Category C	1.845 ÷ 1.851
Classe A	1.833 ÷ 1.839

Check that the thickness of the connecting rod half-bearings is within the recommended values; if this is not the case, replace them. if this is not the case, replace them.

	Measurement		Value
-	Connecting rod half bearing thickness (mm)	Category B	1.741 ÷ 1.749
Class A	1.737 ÷ 1.745

Fit the big end bearing shells.Fit the main journal half-bearings in the cylinder block/crankcase.Fit the thrust washers in the cylinder block.

The lubrication ducts in the thrust washers are fitted facing the crankshaft shoulder.

Fit the crankshaft on the cylinder block/crankcase.Thoroughly remove the sealant residues from the rear bearing cap seat, the small holes and the contact surfaces with the oil sump (only for car after engine no. 00709). Thoroughly remove all traces of engine oil using heptane or a similar solvent.Fit the main journal caps complete with half-bearings.

The main journal caps are numbered from 1 to 4 starting from the front of the engine.

Tighten the nuts for the bearing caps to the recommended torque using the special angular tightening tool.

	Fastening	Component	Ø	Value(daNm)
-	Nut	MAIN BEARING CAPS	M12	(Engine crankcase side) 2.5 + 79°

	Name	Country
-	Protractor	1.860.942.000

1. Fit the crankshaft rear oil seal (1a) using the tool (1b).

The oil seal should be fitted in its housing so that it covers the small openings (1c).

	Name	Country
1b	Fitting tool	1.821.150.000

1. Apply the recommended sealant (1a) through holes (1b).

	Type	Component	Name	Qty.
-	Sealant	ENGINE REAR MOUNT GASKETS	LOCTITE 5900	-

Check that the sealant emerges from the whole length of the contact area (1c) between the cap and the engine block and, (only for cars from engine no. 00709, from the holes (1d).

The oil sump should be fitted within 15 minutes of applying the sealant in the openings for the crankshaft rear support. If this is not the case, remove the edges of the sealant.

Fit the tool.

	Name	Country
-	Flange	1.820.618.000

Turn the crankshaft as necessary and fit the big end bearing caps complete with bearing shells and tighten the nuts to torque.

The big end bearing caps have the number of the cylinder to which they belong on one side: when refitting, this number should be on the same side as the one on the small end.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	BIG END BEARING CAPS	M9	1.9 ÷ 2.1 + 48? ÷ 52?

Use the tool for angular tightening of the connecting rod cap bolts.

	Name	Country
-	Protractor	1.860.942.000

Remove the tool.

	Name	Country
-	Flange	1.820.618.000

1. Fit the flywheel (1a) and fix it using the bolts (1b) without tightening them.2. Fit the tool.

	Name	Country
2	Counter-torque	1.820.624.000

Tighten the engine flywheel bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FLYWHEEL	M10	11.6 ÷ 12.9

Remove the tool.

	Name	Country
-	Counter-torque	1.820.624.000

Fit the oil pump drive chain.Fit the engine block front cover complete with gasket and fix it using the bolts.Fit the crankshaft key.Place the alternator back in its housing and secure it using the bolts.Fit the single belt fixed tensioner and fix it using its bolt.Fit the complete oil pump and fix it using the bolts.Tighten the bolt on the oil pump chain drive to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ENGINE OIL PUMP DRIVE CHAIN	M10	4.3 ÷ 5.3

Apply the recommended sealant to the entire perimeter of the crankcase sump.

	Type	Component	Name	Qty.
-	Sealant	OIL SUMP	LOCTITE 5900	-

Fit the crankcase sump.Tighten the oil sump bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	OIL SUMP	M7	1.3 ÷ 1.6

	Fastening	Component	Ø	Value(daNm)
-	Bolt	OIL SUMP	M7	0.9 ÷ 1.2

Rotate the engine through 180° on the overhauling stand.1. Remove the camshaft caps 4 and 7 from the left cylinder head.2. Remove the camshaft caps B and G from the right cylinder head.

1. Fit the tool in place of the removed camshaft caps.

	Name	Country
1	Gauge	1.825.040.000

Slacken the bolts on the camshaft drive pullies using the tool as counter-torque.

	Name	Country
-	Counter-torque	1.822.146.000

Fit the timing belt drive pulley.1. Fit the tool (1a), complete with dial gauge (1b), in the housing of the spark plug for cylinder no. 1.

	Name	Country
1a	Extension	1.825.013.000

Rotate the crankshaft, using small movements (in both directions), until the piston for cylinder no. 1 is at T.D.C. at the power stroke.

Make sure that the last crankshaft rotation is in the direction of operation.

1. Fit the timing belt starting from the drive pulley and continuing in an anti-clockwise direction, making sure that the drive sections are firmly taut.

1. Fit the tool (1a) and secure it with the alternator bolt (1b) and the bolt (1c) to the water pump.

The tool lug (1d) must press against the moving part of the timing belt tensioner.

	Name	Country
1a	Belt tensioner	1.860.950.000

2. Adjust the nut (2a) of the belt tensioner tool until the moving reference on the belt tensioner (2b) is under the fixed reference.

1. Tighten the bolts (1a) for the camshaft pullies to torque using the tool (1b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	TIMING GEAR DRIVEN PULLEYS	M10	6.8 ÷ 8.4

	Name	Country
1b	Counter-torque	1.822.146.000

Remove the tool.

	Name	Country
-	Gauge	1.825.040.000

Fit the camshaft caps in place of the removed tool and tighten the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAMSHAFT CAPS	M8	(Cylinder head side) 1.8 ÷ 2.0

Rotate the crankshaft through two revolutions in its direction of rotation to allow the timing belt to bed in.1. Check that the moving reference on the timing belt tensioner lines up with the fixed reference.2. If the references do not line up, slightly discharge the tensioner acting on the tensioning tool nut and make sure that the references are aligned. 3. Tighten the timing belt tensioner bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	MOBILE TIMING TENSIONER	M8	1.7 ÷ 2.1

Remove the tool.

	Name	Country
-	Belt tensioner	1.860.950.000

1. Fit the tool.

	Name	Country
1	Counter-torque	1.820.624.000

2. Fit the single belt drive pulley (2a) and tighten the nut (2b) to torque.

	Fastening	Component	Ø	Value(daNm)
2b	Nut	CRANKSHAFT PULLEY	M28	20.0 ÷ 24.7

Remove the tool.

	Name	Country
-	Counter-torque	1.820.624.000

Fit the tappet covers and fix them with their bolts.Fit the ignition coils and fix them using the bolts.Fit the bracket securing the timing cover and fix it using the bolts.Fit the timing belt covers and fix them using the bolts.Fit the single drive belt.Push the single belt tensioner with a spanner to remove the belt tensioner retaining pin.Place the electrical wiring back in its housing and fix it to the bands.Connect the electrical connections to the ignition coils.Connect the electrical connections to the injectors.Fit the electrical wiring securing brackets to the rocker covers and fix them using the bolts.Connect the electrical connection for the front knock sensor.Connect the electrical connection for the air conditioning compressor.Fit the left cylinder head ignition coils cover and fix it using the bolts.Connect the earth lead to the left cylinder head tappet cover.Connect the electrical connection to the engine coolant temperature sensor.Connect the electrical connection to the combined sender unit for the coolant temperature gauge and overheating warning light.Connect the electrical connection for the rear knock sensor (black).Connect the electrical connection for the rpm and timing sensor (black).Connect the electrical connection for the timing sensor (light blue).Fit the complete intake chamber and fix it using the bolts.Tighten the bands fixing the air intake ducts to the intake chamber.Connect the condensation oil return pipe to the separator.Connect the oil vapour recovery pipe.Connect the electrical connection to the motorized throttle body actuator.Connect the earth lead on the left cylinder head rocker cover.