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

Record the main bearing half thickness.

	Measurement		Value
-	Crankshaft bearing thickness (mm)	Category B	1.839 - 1.843
Category C	1.842 - 1.846
Classe A	1.836 - 1.840

Record the main bearing half thickness.

	Measurement		Value
-	Thickness (mm)	Category B	1.530 - 1.534
Category C	1.533 - 1.537
Classe A	1.527 - 1.531

Removing ( Refitting ) Position the engine on the overhauling stand  - 1004D40  engine - position on stand and remove . 1. Release the electrical wiring from the band on the timing cover.2. Disconnect the electrical connection for the cam angle sensor.

	Name	Connector
1	Timing sensor	K47

3. Disconnect the electrical connections from the injectors.

	Name	Connector
3	Injector	N70

4. Undo the cable duct fixing bolts. 1. Releasethe electrical wiring from the bands fastening it to the engine coolant supply reservoir coolant return pipe.2. Disconnect the electrical connections from the heater plugs.

	Name	Connector
2	Heater plug	A40

3. Disconnect the electrical connection from the fuel pressure sensor.

	Name	Connector
3	Fuel pressure sensor	K83

Release the electrical wiring from the securing band.Move the engine wiring to the side.1. Loosen the band and disconnect the engine oil vapour recovery pipe from the engine oil filler, then release it from the retaining band. 2. Loosen the band and disconnect the oil vapour recovery pipe from the engine crankcase.3. Loosen the band and disconnect the condensation oil recirculation pipe from the crankcase sump.4. Undo the bolts (4a) and remove the bracket (4b) complete with engine oil vapour separator (4c) and pipes. 1. Undo the bolts (1a) and remove the crankshaft pulley (1b).2. Undo the bolt (2a) and remove the single drive belt fixed tensioner (2b). 1. Undo the bolts (1a) and remove the timing gear covers (1b). 1. Undo the bolts (1a) and remove the bracket on the engine for the reaction rod (1b). 1. Loosen the nut securing the timing belt mobile tensioner.2. Prise off and remove the timing belt. 1. Loosen the band and disconnect the coolant return pipe from the engine coolant reservoir, thermostat side. 1. Loosen the band and disconnect the coolant outlet pipe from the cylinder head, engine coolant return pipe to the coolant reservoir side. 2. Undo the bolts (2a) and remove hose (2b) carrying coolant to the coolant supply reservoir. 1. Disconnect the pipe from the injectors to the fuel return manifold, fuel return manifold side.2. Loosen the band and disconnect the pipe from the pressure pump to the fuel return manifold, fuel return manifold side.3. Undo the bolts (3a) and remove the fuel return manifold (3b). 1. Undo the connectors (1a), (1b) and remove the pipe from the pressure pump to the fuel manifold (1c).

Use a new pipe from the pressure pump to the fuel manifold when refitting.

2. Manually push springs (2a) and disconnect the pipe from the injectors to the fuel recovery manifold (2b), injectors side and remove it.3. Undo the connectors (3a), (3b) and remove the pipes from the fuel manifold to the injectors (3c).

Use new piping from from fuel manifold to injectors upon reassembly.

4. Undo the bolts (4a) and remove the single fuel manifold pipe (4b) complete with fuel pressure sensor (4c). 1. Undo the nuts (1a) and remove the brackets (1b) and injectors (1c).

Start the removal beginning with the injector for cylinder no. 1 and continuing with the injectors for cylinders 2, 3 and 4.

1. Undo the bolts (1a) and remove the camshaft housing assembly (1b).2. Remove the gasket.3. Remove the valve rocker arms.4. Remove the hydraulic tappets. 1. Fit the flywheel lock.

	Name	Country
1	Counter-torque	1.860.846.001

1. Undo the (left hand thread) bolt (1a) and remove the drive pulley (1b). 1. Undo the bolts (1a) and remove the engine flywheel (1b).

The engine flywheel retaining bolts are treated with a compound to prevent them coming undone they should therefore be replaced whenever they are removed.

2. Remove the flywheel lock.

	Name	Country
2	Counter-torque	1.860.846.001

1. Undo the bolts (1a) and remove the engine flywheel protection (1b). Rotate the engine through 180° on the overhauling stand.1. Undo the front and rear bolts (1a) securing the crankcase sump using tool (1b).

	Name	Country
1b	Spanner	1.860.833.001

2. Undo the side bolts (2a) securing the crankcase sump using tool (2b).

	Name	Country
2b	Spanner	1.860.834.001

3. Use the tool to cut the crankcase sump sealant.

	Name	Country
3	Blade	1.870.718.000

4. Remove the crankcase sump. 1. Undo the bolts (1a) and remove the oil cover, flywheel side (1b). 1. Undo the nuts (1a) and remove the timing side rigid engine support (1b). 1. Undo the bolt (1a) and remove the single drive belt tensioner (1b). 1. Undo the bolt (1a) and remove the engine rpm sensor (1b). 1. Undo the bolts (1a) and remove the crankshaft front cover oil seal (1b) with the engine oil pump incorporated.2. Remove the gasket. 1. Fit the tool.

	Name	Country
1	Flange	1.820.618.000

Turn the crankshaft using the tool fitted previously to gain access to the big end bearing cap bolts.2. Undo the bolts (2a) and remove the big end bearing caps (2b).3. Remove the lower big end half-bearings. Remove the tool.

	Name	Country
-	Flange	1.820.618.000

1. Check that the crankshaft end float is within the recommended values using a magnetic base fitted with a dial gauge.

	Measurement		Value
1	End float (mm)		0.049 - 0.211

If the end float of the crankshaft is not within the recommended values, when refitting, reface the seat in the cylinder block/crankcase and use suitable oversize thrust washers. 1. Undo the bolts (1a) and remove the main bearing caps (1b).2. Remove the lower main journal half-bearings.3. Remove the crankshaft.4. Remove the upper main journal half-bearings.5. Remove the thrust washers.Remove the upper connecting rod half-bearings. Refitting ( Removing ) Wash the dismantled components.Lubricate all the components for the mechanical couplings using engine oil.Check the crankshaft bearings, taking into account that no adjustment operations should be carried out to the half-bearings; If there are signs of grooves or seizing, they must be replaced. Record the main bearing half thickness.

	Measurement		Value
-	Half-bearing thickness (mm)	Category B	1.839 ÷ 1.843
Category C	1.842 ÷ 1.846
Classe A	1.836 ÷ 1.840

Record the main bearing half thickness.

	Measurement		Value
-	Connecting rod half bearing thickness (mm)	Category B	1.530 ÷ 1.534
Category C	1.533 ÷ 1.537
Classe A	1.527 ÷ 1.531

Refit the upper big end bearing shells in their seats.Place the thrust washers back in their housings in the third bearing support.Main journal half-bearings have been fitted on crankshafts which have been selected so that the matching clearance is optimum.

The crankshaft is supplied,bythe Parts Dept.,without the appropriate half-bearingsfor 'normal' dimension main journals and crank pins; it is therefore necessary to select the main journal half-bearings to be fitted identifying the grade for each main journal and crank pin for the new crankshaft.

The following is needed for selecting the main journal half-bearings: the code number stamped on the flywheel; the paint mark, if present, next to the main journals. Below is an example of the identification of main journal grades. 1 - Crank pin identification number: the number on the left refers to the first timing side bearing; the final 'N' is a code that does not matter for 4 cylinder engines. 2 - Main journal identification code: the first number on the left refers to the first timing side bearing; the final 'N' is a code that does not matter for 4 cylinder engines. 3 - Set of numbers (if present), in groups of two digits, which indicate the dimensions (thousandth part) of the main journals: the first two numbers on the left refer to the first bearing on the timing side.

Only use the codes in the key, all other codes on the flywheel should not be used.

For the identification of the main journal grade, refer to the numerical code for reference 2 in the key.In the case of the example, the numbers 11111N indicate that all five bearings are Grade A (red colour) as described below.A further method for identifying the grade of the bearings is to read reference 3 in the figure (if present).In the case of the example, the number 94 (first on the left) corresponds to the dimension 52.994 for the first bearing on the timing side which identifies Grade A (red colour); the same method can be used for all the other groups of two digits for the same reference 3 (97 - 95 - 95 - 94). MAIN JOURNAL IDENTIFICATIONGrade A main journal (normal), diameter 52.994 53.000 mm, RED paint mark, code number 1 (94 00)*Grade B main journal (normal), diameter 52.988 52.994 mm, BLUE paint mark, code number 2 (88 94)*Grade C main journal (normal), diameter 52.982 52.988 mm, YELLOW paint mark, code number 3 (82 88)*Grade D main journal (0.127mm undersize) diameter 59.867 59.873 mm, BROWN paint mark, code number 6 (67 73)*Grade E main journal (0.127 mm undersize) diameter 52.861 52.867 mm, GREEN paint mark, code 7 (61 67)*Grade F main journal (0.127 undersize) diameter 52.855 52.861 mm, BLACK paint mark, code number 8 (55 61)* (*) Last two numbers (thousandth part) of the dimensions of the main journals.If a crankshaft is being used where the maximum bearing undersize through regrinding is 0.127 mm, then the grade should be selected by measuring the dimensions of the diameter of the bearing with reference to the above. Having defined the grade and colour for each new or reground crankshaft bearing, it is necessary to select the pair and the size for the bearings which should be the same colour as the corresponding bearing; at the Parts Dept. it is possible to go back to the part no. of the pair of half-bearings required. The above is designed to ensure the optimum operating clearance for all bearings.Lastly, we wish to point out that, usually, the clearance between the main journal and the half-bearing, produced by the selection method described above, should be between the following figures: Minimum: 0.011 mm - Maximum: 0.071 mm; this value can be measured, as a final check, using the Plastic Gauge. Place the upper half-bearings back in their housings in the cylinder block/crankcase.Place the crankshaft back in its housing on the crankcase.1. Place the bearing caps complete with lower half-bearings back in their housings.

The bearing caps have progressive references (from zero to four starting from the front of the engine) which define their fitting position.

1. Tighten the bearing cap bolts (1a) to the recommended torque using the angular tightening tool (1b).

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	MAIN BEARING CAPS	M12	(Engine crankcase side) 2.4 ÷ 2.6 +100?

	Name	Country
1b	Protractor	1.860.942.000

1. Fit the tool.

	Name	Country
1	Flange	1.820.618.000

Refit the lower big end bearing shells in their seats.

To select the connecting rod half-bearings, follow the procedure described previously for the main journal half-bearings.

Place the big end caps complete with half-bearings back in their housings.

The connecting rod caps are fitted so that the number stamped on them is facing the same side as the one stamped on the big end (inlet side).

2. Tighten the bolts (2a) to the recommended torque using angular tightening tool (2b).

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	BIG END BEARING CAPS	M9	2.4 ÷ 2.6 + 60?

	Name	Country
2b	Protractor	1.860.942.000

Remove the tool.

	Name	Country
-	Flange	1.820.618.000

1. Fit the crankshaft front cover (1a), complete with gasket (1b), and fix it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	CRANKSHAFT FRONT COVER	M6	(Engine crankcase side) 0.8 - 1.0

1. Place the seal (1a) in its housing on the crankshaft oil seal front cover using the tool (1b).

	Name	Country
1b	Fitting tool	1.821.247.000

1. Place the rpm sensor (1a) in its seating and secure it tightening the bolt (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	-	-	-	-

1. Place the engine components single drive belt moving tensioner (1a) back in its housing and fix it tightening the bolt (1b).

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FIXED TENSIONER	M8	2.3 ÷ 2.8

1. Refit the timing side rigid engine support (1a)and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	-	-	-	-

1. Refit the flywheel side oil seal (1a) in its seating and tighten the bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FLYWHEEL SIDE COVER	M6	(Engine crankcase side) 0.8 - 1.0

Apply silicon sealant around the edge of the crankcase sump.1. Refit the crankcase sump2. Tighten the side bolts (2a) for the crankcase sump to the recommended torque using the tool (2b).

	Fastening	Component	Ø	Value(daNm)
2a	Side bolts	OIL SUMP	M8

	Name	Country
2b	Spanner	1.860.833.001

3. Tighten the front and rear bolts (3a) for the crankcase sump to the recommended torque using the tool (3b).

	Fastening	Component	Ø	Value(daNm)
3a	Front and rear bolt	OIL SUMP	M6	(Crankcase front/rear covers side) 0.7 ÷ 0.9

	Name	Country
3b	Spanner	1.860.834.001

Place the engine flywheel protection back in its housing and secure it using the bolts.1. Fit the flywheel lock.

	Name	Country
1	Counter-torque	1.860.846.001

2. Refit the engine flywheel (2a) and secure by tightening new sealant-treated bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	FLYWHEEL	M12	(Crankshaft side) 14.4 - 17.6

Use the tool for angular tightening of the engine flywheelbolts.

	Name	Country
-	Protractor	1.860.942.000

1. Place the drive pulley (1a) back in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt with left hand thread	TOOTHED DRIVE PULLEY	M16	32.3 - 35.7

Remove the flywheel lock.

	Name	Country
-	Counter-torque	1.860.846.001

Rotate the engine through 180° on the overhauling stand.Place the hydraulic tappets in their housings.Place the valve rocker arms back in their housings.Place the upper cylinder head gasket back in its housing.1. Remove the plugs (1a) and fit the camshaft timing tools (1b) in the camshaft housing.

Check that the tools, marked with the letter 'A', are correctly inserted in the housings in the camshafts.

	Name	Country
1b	Gauge	1.870.896.900

Remove the inlet side camshaft timing tool and tighten the plug. 1. Place the camshaft housing assembly (1a) back in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	-	-	-	-

Loosen the exhaust side camshaft toothed drive pulley fixing bolt. 1. Undo the bolt for the crankcase front cover shown in the diagram.Temporarily fit the timing drive belt on the drive pulley.2. Fit the tool (2a) and secure it gauged bolts (2b)

To allow the engagement of the locating dowel on the timing drive belt drive pulley in the opening in the tool, rotate the crankshaft using small movements.

	Name	Country
2a	Template	1.860.905.000

	Name	Country
2b	Calibrated screw	1.860.905.010

1. Completely fit the timing belt.2. Use a screwdriver to lever in the hole (2a) until the reference on the tensioner (2b) lines up with the reference hole (2c) and, in this position, tighten the belt tensioner nut (2d) to torque.

	Fastening	Component	Ø	Value(daNm)
2d	Nut	MOBILE TIMING TENSIONER	M10	4.2 ÷ 5.2

Tighten the exhaust side camshaft toothed drive pulley fixing bolt to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	-	-	-

Remove the timing tools.

	Name	Country
-	Gauge	1.870.896.900

Remove the exhaust camshaft template because the inlet side one has already been removed.

	Name	Country
-	Template	1.860.905.000

	Name	Country
-	Calibrated screw	1.860.905.010

Rotate the crankshaft through two revolutions.Check once again that the timing is correct by refitting the timing tools.

Only fit the exhaust camshaft side template because the inlet side one is not accessible.

Check that the tensioning references on the timing belt tensioner are aligned.Tighten the bolt for the crankcase front cover previously removed.Tighten the plug in the camshaft housing for fitting the exhaust side timing tool.1. Refit the injectors (1a) complete with brackets (1b) and secure by tightening nuts (1c) to the specified torque.

Start the refitting beginning with the injector for cylinder no. 4 and continuing with the injectors for cylinders 3, 2 and 1.

	Fastening	Component	Ø	Value(daNm)
1c	-	-	-	-

1. Place the single fuel manifold pipe (1a), complete with fuel pressure sensor (1b), back in its housing and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	-	-	-	-

2. Fit the new pipes from the fuel manifold to the injectors and secure them using the connectors without tightening them.3. Tighten the connectors for the pipes from the fuel manifold to the injectors, injector side, to the recommended torque using a suitable spanner.

	Fastening	Component	Ø	Value(daNm)
3	-	-	-	-

4. Tighten the connectors for the pipes between the fuel manifold and the injectors, fuel manifold side to the recommended torque using a suitable spanner.

	Fastening	Component	Ø	Value(daNm)
4	-	-	-	-

Clean the threaded seats for the above mentioned pipe on the manifold and the injectors using heptane.

5. Place the pipe from the injectors to the fuel recovery manifold (5a) back in its housing and connect it to the injectors pushing it until the clips (5b) can be heard clicking into place. 6. Place the pipe from the pressure pump to the single fuel manifold back in its housing and fix it using the connectors without tightening them.7. Tighten the connector for the pipe from the pressure pump to the single fuel manifold, pump side, to the recommended torque using a suitable spanner.

	Fastening	Component	Ø	Value(daNm)
7	-	-	-	-

8. Tighten the connector for the pipe from the pressure pump to the single fuel manifold, fuel manifold side, to the recommended torque using a suitable spanner.

	Fastening	Component	Ø	Value(daNm)
8	-	-	-	-

Clean the threaded seats for the above mentioned pipe on the manifold and the pressure pump using heptane.

Place the fuel return manifold pipe back in its housing and fix it using the bolts.Connect the pipe from the pressure pump to the fuel return manifold, fuel return manifold side and tighten the band.Connect the pipe from the injectors to the fuel return manifold, fuel return manifold side.Place the coolant return pipe to the engine cooling system reservoir back in its housing and tighten the bolts.Connect the coolant oulet pipe from the cylinder head, engine coolant return pipe to the supply reservoir side and tighten the band. Connect the engine coolant return pipe to the supply reservoir, thermostat side and tighten the band.1. Fit the bracket on the engine for the reaction rod (1a) and fix it tightening the bolts (1b) and (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	-	-	-	-

	Fastening	Component	Ø	Value(daNm)
1c	-	-	-	-

Place the protective timing side covers back in their housings and secure them using the bolts.1. Place the engine components single drive belt fixed tensioner (1a) back in its housing and fix it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	-	-	-	-

Fit the flywheel lock.

	Name	Country
-	Counter-torque	1.860.846.001

2. Place the crankshaft pulley (2a) back in its housing and secure it by tightening bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	-	-	-	-

Remove the flywheel lock.

	Name	Country
-	Counter-torque	1.860.846.001

Connect the condensation oil recirculation pipe to the crankcase sump and tighten the band.Connect the oil vapour recovery pipe to the engine oil filler, tighten the band and secure it using the fastening.Place the engine wiring back in its housing.Secure the electrical wiring to the band.Connect the electrical connection to the fuel pressure sensor.Connect the electrical connections to the heater plugs.Fasten the electrical wiring to the bands on the coolant return pipe to the engine coolant supply reservoir.Tighten the cable duct fixing bolts.Connect the electrical connections to the injectors.Connect the electrical connection to the cam angle sensorFasten the electrical wiring to the band on the timing cover. Remove the engine from the overhaul stand  - 1004D40  engine - position on stand and remove .