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

125000939 - 1024A10 CRANK SHAFT - R + R WITH ENGINE REMOVED - CHECK MAIN AND CONNECTING ROD BEARINGAND REPLACE IF NECESSARY

) Proceed with the removal Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE.1. Open the electrical connection holder case.2. Disconnect the electrical connection for the timing side knock sensor.

	Description	Connector
2	Detonation sensor -1	See K50 DETONATION SENSOR 1 ( CONNECTORS )

1. Loosen the bands securing the intake manifolds to the air chamber.2. Loosen the band securing the engine idle oil vapour recovery pipe, air capacity chamber side.3. Disconnect the electrical connection from the throttle casing with D.V.L.

	Description	Connector
3	Throttle body actuator	See N75 THROTTLE BODY ACTUATOR ( CONNECTORS )

1. Unscrew retaining bolt (1a) and disconnect earth lead (1b) from the air capacity chamber.

	Description	Connector
1b	Earth on engine	See C40 ENGINE EARTH

2. Unscrew the bolt securing the stiffening rod to the reaction link mount on the engine.3. Undo bolts (3a) and remove air capacity chamber (3b).

1. Disconnect the electrical connections from the right cylinder head injectors.

	Description	Connector
1	Injector	See N70 INJECTOR

2. Disconnect the electrical connections from the right cylinder head ignition coils.

	Description	Connector
2	Ignition coil	See A30 IGNITION ''COIL

3. Undo bolts (3a) and move electrical wiring duct (3b) aside.

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

1. Undo the nut (1a) and disconnect the earth lead (1b) from the left cylinder head.

	Description	Connector
1b	Earth on engine	See C40 ENGINE EARTH

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

1. Disconnect the electrical connections from the left cylinder head injectors.

	Description	Connector
1	Injector	See N70 INJECTOR

2. Disconnect the electrical connections from the left cylinder head ignition coils.

	Description	Connector
2	Ignition coil	See A30 IGNITION ''COIL

3. Undo bolts (3a) and move electrical wiring duct (3b) aside.

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

1. Undo the fixing bolts (1a) and remove the upper protective timing cover (1b).

1. Undo the fixing bolts (1a) and remove the lower protective timing cover (1b).

1. Loosen the bolts retaining the timing belt moving tensioner.2. Prise off the timing drive belt from the toothed driven pullies.

1. Undo the bolts (1a) and bolt (1b) remove bracket (1c).

1. Undo the bolts (1a) and remove the left cylinder head cam cover (1b) complete with gasket.

1. Undo the bolts (1a) and remove the right cylinder head cam cover (1b) complete with gasket.

1. Loosen the bolts (1a) for the toothed driven pullies, using the tool (1b) for counter-torque.

	Description	Code
1b	Counter-torque	1.822.146.000

Rotate the engine through 180° on the overhaul stand.1. Undo the bolt (1a) and remove the engine components single belt fixed tensioner (1b).

1. Undo the bolts (1a) and remove the rpm sensor shield (1b).2. Remove the rpm sensor complete with mounting.

1. Undo the bolts fixing the engine oil sump.2. Cut the crankcase sump sealant using the tool.

	Description	Code
2	Blade	1.870.718.000

3. Remove the crankcase sump.

1. Fit the flywheel lock.

	Description	Code
1	Counter-torque	1.860.779.000

1. Undo the nuts (1a) and remove the crankshaft pulley (1b).2. Remove the toothed timing belt.3. Remove the toothed drive pulley

1. Undo the bolt fixing the engine oil pump drive chain to the oil pump.2. Move the engine oil pump drive chain (2a) away from the pump using the tool (2b).

	Description	Code
2b	Extractor	1.860.954.001

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

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

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

The bolts fixing the flywheel have been treated with a special agent; therefore they should be replaced each time they are removed.

2. Remove the flywheel lock.

	Description	Code
2	Counter-torque	1.860.779.000

1. Fit the tool for rotating the crankshaft.

	Description	Code
1	Flange	1.820.618.000

Rotate the crankshaft so that the right bearing cap bolts are accessible.2. Undo the bolts (2a) and remove the bearing caps (2b) on the right side.3. Remove the crankpin half-bearings.

Check that the crankshaft endfloat corresponds to the recommended figures using a magnetic base and dial gauge.

	Measurement		Value
-	End float (mm)		0.080 ÷ 0.265

1. Undo the nuts (1a) and remove the front and centre crankshaft bearings.2. Remove the main journal half-bearings.

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

	Description	Code
1c	Lever	1.821.006.001

	Description	Code
1d	Extractor	1.821.006.002

2. Remove the main journal half-bearing.

1. Remove the crankshaft rear oil seal

1. Remove the crankshaft.2. Remove the main journal half-bearings.3. Remove the thrust washers.Remove the crankpin half-bearings.

Refitting ( Removing

) Wash all the dismantled components thoroughly.Clean any sealant residues from the matching surfaces between the engine oil sump and the engine block.Lubricate all the mechanical components with engine oil.Check that the main journal diameter is within the recommended limits; if not, replace the crankshaft.

	Measurement		Value
-	Main journal diameter (mm)	Category A	59.973 ÷ 59.979
Category B	59.967 ÷ 59.973
Category C	59.961 ÷ 59.967

The nitriding treatment that the crankshaft has undergone means that no regrinding operations can be carried out.

Check that the crank pin diameter is within the recommended limits; if not, replace the crankshaft.

	Measurement		Value
-	Crankpin diameter (mm)	Category A	51.990 ÷ 52.000
Category B	51.980 ÷ 51.990

The nitriding treatment that the crankshaft has undergone means that no regrinding operations can be carried out.

Check that the half-bearings show no signs of grooves or traces of seizing; if this is not the case, they must be replaced.

No adjustment operations whatsoever should be carried out to the half-bearings.

Place the half-bearings in their seats in the engine block.

The half-bearings and the main journals should be matched so that parts of the same grade are used (same distinctive colour).

Great care should be taken over cleanliness when refitting.

1. Place the crankshaft in its housing.2. Fit the calibrated wire (plastigage) for measuring the bearing clearance.

1. Place the bearing cap (1a), complete with half-bearings, back in its housing and secure it tightening the nut (1b) to the recommended torque.

The bearing caps are marked with a progressive number (from one to four starting from the timing side) which defines the fitting position.

The safety references on the cylinder block/crankcase and on the bearing caps should be on the same side.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	BRAKING SYSTEM BRAKES	M8	2.3 - 3.3

2. Use the tool for the angular tightening of the bearing cap bolts.

	Description	Code
2	Torque wrench	1.860.942.000

1. Remove the bearing cap fitted previously and, using a suitable graduated measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).

Measure the clearance for all the bearings taking care to take the measurements one at a time without moving the crankshaft at any time.

	Measurement		Value
1b	Main journal/bearing clearance (mm)	Category A	0.000 ÷ 0.024
Category B	0.000 ÷ 0.024
Category C	0.000 ÷ 0.025

If the figure measured is outside of the tolerance, replace the half-bearings with ones of the correct size and category.

Place the half-bearings in their seats.Place the thrust washers (with the size depending on the crankshaft endfloat measured during the dismantling) in their housings in the rear bearing support.

The thrust washer lubrication ducts should be facing the crankshaft thrust washers.

Place the half-bearings in their seats.Place the crankshaft complete with the tool for rotating it in its housing.1. Place the bearing caps (1a), complete with half-bearing, back in their housings and secure them tightening the nuts (1b) to the recommended torque.

The bearing caps are marked with a progressive number (from one to four starting from the timing side) which defines the fitting position.

The safety references on the cylinder block/crankcase and on the bearing caps should be on the same side.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	MAIN BEARING CAPS	M12	2.4 ÷ 2.6 + 77? ÷ 81?

2. Use the tool for the angular tightening of the bearing cap bolts.

	Description	Code
2	Torque wrench	1.860.942.000

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

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

	Description	Code
1b	Fitting tool	1.821.250.000

1. Apply the recommended sealant (1a) through the openings (1b) and check that it comes out about 5 mm through the openings (1c).

	Type	Component	Description	Qty.
1a	Sealant	ENGINE REAR MOUNT GASKETS	LOCTITE 5900	-

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

Rotate the crankshaft so that the connecting rod pins are accessible.1. Fit the calibrated wire (plastigage) for measuring the bearing clearance.

1. Place the bearing cap (1a) in its seat complete with half-bearings (1b) and secure it by tightening the bolts (1c) to the recommended torque.

The references on the connecting rod cap and the big end should be on the same side.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	Crank pin cap	M9	1.9 ÷ 2.1 + 48? ÷ 52?

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

	Description	Code
-	Torque wrench	1.860.942.000

1. Remove the bearing cap fitted previously and, using a suitable graduated measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).

Carry out the operation of measuring the clearance for all the bearings, taking care to do it, one at a time.

	Measurement		Value
1b	Crank pin/bearing clearance (mm)	Category A	0.020 ÷ 0.060
Category B	0.023 ÷ 0.063

If the figure measured is outside of the tolerance, replace the half-bearings with ones of the correct size and category.

Rotate the crankshaft so that the connecting rod pins are accessible.1. Place the bearing caps (1a) in their seats complete with half-bearings (1b) and secure them by tightening the bolts (1c) to the recommended torque.

The references on the connecting rod cap and the big end should be on the same side.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	Crank pin cap	M9	1.9 ÷ 2.1 + 48? ÷ 52?

Use the tool for the angular tightening of the bearing cap bolts.

	Description	Code
-	Torque wrench	1.860.942.000

Remove the tool for rotating the crankshaft.

	Description	Code
-	Flange	1.820.618.000

1. Position the engine oil pump (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	ENGINE OIL PUMP	M10	(Main bearing caps side) 4.5 - 5.5

1. Position the engine oil pump drive chain in its housing and secure it without tightening the bolt to the recommended torque.2. Place the crankcase front cover (2a), complete with gasket (2b), back in its housing and secure it tightening the bolts (2c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2c	Bolt	FRONT COVER CRANKSHAFT	M6	(Engine crankcase side) 0.8 - 1.0

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

	Description	Code
1b	Fitting tool	1.860.949.000

Place the key in the housing in the crankshaft.Place the toothed drive pulley in its housing.1. Carry out the initial timing of the camshafts. apply a wrench into seat (1a) in the centre of the camshafts and turn to align reference marks (b) on the shafts with the upper cylinder head surface.

The reference marks must face the middle of each cylinder head.

1. Remove caps 4 to 7 from the left cylinder head.2. Remove caps B and G from the right cylinder head.

1. Position the timing templates in place of the camshaft caps removed.

	Description	Code
1	Templates	1.870.849.000

1. Fit the tool (1a) complete with dial gauge (1b) in the seat for the spark plug for cylinder no. 1.

	Description	Code
1a	Fitting tool	1.821.225.000

Rotate the crankshaft through small rotations (in both directions) until the piston for the right head timing side cylinder no. 1 is at T.D.C. in the combustion stroke.

Take care that the last rotation of the crankshaft is in the direction of operation.

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

1. Fit the tool (1a) and secure it using bolt (1b) for the alternator bracket and bolt (1c) for the water pump.

The tooth (1d) for the tool should engage with the moving part of the timing belt tensioner.

	Description	Code
1a	Belt tensioner	1.860.950.000

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

1. Tighten bolts (1a) for the right head toothed driven pullies to the specified torque using the tool (1b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	TIMING DRIVEN PULLIES	M12	(camshaft side) 7.2 - 8.8

	Description	Code
1b	Counter-torque	1.822.146.000

Remove the tools for timing the camshafts.

	Description	Code
-	Templates	1.870.849.000

Place the camshaft caps in their housings to replace the removed tools and secure them tightening the bolts to the recommended 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 toothed timing belt to bed in.1. Check that the moving reference for the timing belt tensioner coincides with the fixed reference.2. If the references are not aligned, gently release the tensioner tension acting on the nut for the tensioning tool until the reference coincide.3. Tighten the nut fixing the moving timing tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	MOBILE TIMING TENSIONER	M8	(Cylinder head side) 1.9 - 2.3

Remove the belt tensioner tool.

	Description	Code
-	Belt tensioner	1.860.950.000

Rotate the engine through 180° on the overhaul stand.1. Place the flywheel in position and secure it without tightening the bolts.

The engine flywheel can only be fitted in one position because the openings for the fixing bolts are not equidistant.

2. Fit the flywheel lock.

	Description	Code
2	Counter-torque	1.860.779.000

3. Tighten the new bolts securing the engine flywheel to the recommended torque.

The bolts fixing the flywheel have been treated with a special agent; therefore they should be replaced each time they are removed.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	FLYWHEEL (MECH.)	M12	(Crankshaft side) 2.9 - 3.2 +48? ÷ 51?

Use the tool for the angular tightening of the flywheel fixing bolts.

	Description	Code
-	Torque wrench	1.860.942.000

1. Fit the engine oil pump drive chain (1a) on the oil pump, then tighten the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	ENGINE OIL PUMP DRIVE CHAIN	M10	(Engine oil pump side) 4.5 - 5.5

2. Position the crankshaft pulley (2a) in its housing and secure it tightening the nuts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Left nut	CRANKSHAFT PULLEY	M28	(Crankshaft side) 22.8 - 25.2

Remove the flywheel lock.

	Description	Code
-	Counter-torque	1.860.779.000

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

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

1. Position the crankcase sump (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	OIL SUMP	M7	(Engine crankcase side) 1.4 - 1.7

Place the rpm sensor complete with mounting in its housing.Place the rpm sensor guard in its housing and secure it using the bolts.1. Position the engine components single belt fixed tensioner (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	SINGLE BELT FIXED TENSIONER VARIOUS	M8	(Crankcase sump side) 2.3 - 2.8

1. - Place the cylinder head cam covers (1a) in their housings with gaskets and secure them tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	TAPPET COVERS	M7	(Cylinder head side) 1.4 - 1.7

Place the bracket in its housing and secure it using the bolts.Fit the lower timing belt covers and secure them using the bolts.Fit the upper timing belt covers and secure them using the bolts.1. Replace the left cylinder head ignition coils (1a) in their housings with gaskets and secure them tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	IGNITION COIL/REEL	M6	(Cam cover side) 0.8 ÷ 1.0

Connect the electrical connection for the rpm sensor.Refit the electrical wiring duct and secure it using the bolts.Connect the electrical connections to the left cylinder head ignition coils.Connect the electrical connections to the left cylinder head injectors.Place the ignition coil cover on the left cylinder head back in its housing and secure it using the bolts.Connect the earth lead to the left cylinder head and secure it using the nut.1. Replace the right cylinder head ignition coils (1a) in their housings with gaskets and secure them tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	IGNITION COIL/REEL	M6	(Cam cover side) 0.8 ÷ 1.0

Refit the electrical wiring duct and secure it using the bolts.Connect the electrical connections to the right cylinder head ignition coils.Connect the electrical connections to the right cylinder head injectors.Fit the air capacity chamber and secure it using the bolts.Tighten the bolt securing the stiffening rod to the reaction link mount on the engine.Connect the earth lead to the air capacity chamber and secure it using the bolt.Connect the electrical connection to the throttle casing with D.V.L.Tighten the band securing the engine idle oil vapour recovery pipe, air capacity chamber side.Tighten the bands securing the intake manifolds to the air chamber.Connect the electrical connection for the timing side knock sensor.Close the electrical connections box.Proceed with the refitting Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE.