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

2400997 - 1024A10 crank shaft - r + r with engine removed - check main and connecting rod bearingand replace if necessary

) Position the engine on the overhauling stand - 1004D40 engine - position on stand and remove . 1. Disconnect the electrical connection from the air conditioning compressor engagement electromagnet.

	Name	Connector
1	Air conditioning compressor engagement electro-magnet	L20

1. Undo the bolts securing the engine oil return pipe from the turbocharger, engine crankcase side.2. Undo connector (1a) and remove engine oil supply pipe to the turbocharger (1b).

1. Undo the bolts (1a) and the nut (1b) and remove the exhaust manifold heat shield (1c) complete with engine lifting bracket (1d).2. Undo the bolt fixing the coolant supply pipe to the engine oil heat exchanger, to the cylinder block/crankcase.3. Undo the bolts (3a), loosen the band (3b) and remove the coolant supply pipe to the engine oil heat exchanger (3c) complete with seal.

1. Undo the nuts (1a) and remove the turbocharger (1b) complete with catalytic converter (1c).

1. Undo the bolts (1a) and remove the timing side rigid engine support (1b) complete with engine lifting bracket (1c).

1. Use a spanner on the moving tensioner (1a) and remove the engine components single drive belt (1b).

1. Undo the bolt (1a) and remove the single drive belt tensioner (1b).2. Completely undo the bolts (2a) loosened previously and remove the crankshaft pulley (2b).3. Undo the nuts (3a) and remove the water pump (3b) complete with gasket.

1. Completely undo the left hand bolt (1a) loosened previously and remove the pulley mounting flange on the crankshaft (1b) - 1004D40 engine - position on stand and remove .

Withdraw the oil level dipstick.Rotate the engine through 180° on the overhauling stand.1. Undo the bolts (1a) and remove the support (1b).2. Undo the nuts (2a) and the bolts (2b) fixing the crankcase sump.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 crankcase oil sump partition (1b).

Rotate the engine through 180° on the overhauling stand.1. Undo the bolt (1a) and disconnect the connector (1b) for the engine oil vapour recovery pipe from the timing cover.

1. Undo the bolts (1a) and remove the timing cover (1b) complete with engine oil suction device (1c) and engine oil pump.Remove the timing cover gasket.2. Recover the brackets.

1. Keep the tool fitted on the exhaust side camshaft - 1004D10 power unit (manual gearbox), removed, remove and re-build .

	Name	Country
1	Template	1.871.000.900

1. Fit the crankshaft timing tool.

	Name	Country
1	Template	1.870.900.300

1. Undo the bolt securing the driven timing pulley.

Mark the position of the timing driven pulley and the toothed drive pulley; If the pulleys are replaced, fit them with the writing turned to the outside.

1. Remove the timing driven driven pulley (1a) together with the chain (1b) and the toothed drive pulley (1c).2. Undo the bolts (2a) and remove the timing chain fixed plate (2b).3. Undo the pin (3a) and remove the timing chain moving plate (3b).

1. Undo the bolts (1a) and remove the air conditioning compressor (1b).

1. Undo the bolts (1a) and remove the air conditioning compressor support (1b).

Rotate the engine through 180° on the overhauling stand.1. Undo the lower crankcase fixing bolts.2. Cut the lower crankcase sealant using the tool.

	Name	Country
2	Blade	1.870.718.000

3. Remove the lower crankcase.Remove the lower main journal half-bearings.

1. Undo the bolts (1a) and remove the connecting rod caps (1b).2. Remove the lower big end half-bearings.

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)		0.055 ÷ 0.265

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. Remove the crankshaft (1a) complete with rear oil seal (1b).2. Remove the upper main journal half-bearings.

The centre half-bearing is joined to the thrust washers; to separate them, press the ends of the half-bearing.

Refitting ( Removing

) Clean the components removed thoroughly and check their condition through a visual inspection.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	1.841 ÷ 1.846
Category C	1.846 ÷ 1.851
Class A	1.836 ÷ 1.841

Record the main bearing half thickness.

	Measurement		Value
-	Connecting rod half bearing thickness (mm)	Category B	1.550 ÷ 1.556
Class A	1.546 ÷ 1.552

Place the upper half-bearings back in their housings, making sure they are perfectly clean.

If the crankshaft has been reground, fit the new and oversize half-bearings to restore the original tolerance conditions. The centre main journal half-bearing incorporates the thrust washers.

The value of the thrust washers is given.

	Measurement		Value
-	Thrust washers (mm)		2.310 ÷ 2.360

The thrust washer undersize is 0.127 mm.

Fit the crankshaft in the housing in the upper cylinder block/crankcase.1. Fit the calibrated wire (Plastigage) to measure the main journal clearance.

1. Place the lower crankcase, complete with lower main journal half-bearings, back in its housing.2. Tighten the centre bolts (2a) fixing the lower crankcase to the recommended torque, following the order illustrated in the diagram and using the angular tightening tool (2b).

	Fastening	Component	Ø	Value(daNm)
2a	Centre bolt	CRANK CASE	M10	(Engine crankcase side) 1.9 ÷ 2.1 + 80? ± 3?

	Name	Country
2b	Protractor	1.860.942.000

3. Tighten the side bolts fixing the lower crankcase to the recommended torque following the order illustrated in the diagram.

	Fastening	Component	Ø	Value(daNm)
3	Centre bolt	CRANK CASE	M8	(Engine crankcase side) 2.9 ÷ 3.2

1. Remove the lower crankcase complete with lower main journal half-bearings and, using a suitable graduated measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).

Check one journal at a time without moving the crankshaft.

	Measurement		Value
1b	Clearance between crankshaft bearings - main journals (mm)		0.028 ÷ 0.048

If the reading is not within the specified range, replace the main bearing halves with new bearing halves of appropriate size and category.

1. After having carried out the check on all the main journals, apply a bead of recommended silicon sealant to the contact surface of the lower crankcase and the upper crankcase as illustrated in the diagram.

No breaks are allowed in the sealant strip. The diameter of the sealant bead should be 2.5 - 3.5 mm.

	Type	Component	Name	Qty.
1	Sealant	CRANK CASE	Loctite type 5900	-

After applying the sealant, clean the crankshaft rear oil seal housing thoroughly.

Proceed with the final fitting of the lower crankcase on the upper crankcase, tightening the fixing bolts following the previous instructions.1. Fit the calibrated wire (Plastigage) to measure the big end bearing clearance.

1. Place the big end caps (1a) complete with half-bearings (1b) back in their housings.

The big end bearing shells can be identified as follows:

upper big end bearing shells, dark coloured three metal connecting rod side;
lower big end bearing shells, light coloured two metal cap side with an opening.

Do not swap the position of the big end bearing shells.

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

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	BIG END BEARING CAPS	M8	1.9 ÷ 2.1 + 40? ± 2?

	Name	Country
2b	Protractor	1.860.942.000

Undo the bolts and remove the connecting rod caps complete with half-bearings fitted previously.1. Using a suitable graduate measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).

Check one journal at a time without moving the crankshaft.

	Measurement		Value
1b	Big end bearings (mm)		0.030 ÷ 0.062

If the reading is not within the specified range, replace the half-bearings with new ones of the appropriate size and grade.

Proceed with the final fitting of the connecting rod caps tightening the fixing bolts following the previous instructions.1. Refit a new front crankshaft rear cover oil seal (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.870.900.200

Rotate the engine through 180° on the overhauling stand.1. Place the air conditioning compressor mounting (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	COMPRESSOR MOUNT (AC)	M8	(Upper and lower engine crankcase side) 2.3 ÷ 2.8

1. Place the air conditioning compressor (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	AIR CONDITIONER ASSEMBLY COMPRESSOR	M8	(Support side) 2.3 ÷ 2.8

1. Fit the crankshaft timing tool.

	Name	Country
1	Template	1.870.900.300

Using suitable equipment, prepare the chain tensioner and keep it in this position using a suitable pin.1. Place the timing chain fixed plate (1a) back in its housing and secure it using the bolts (1b). 2. Fit the exhaust side timing drive pulley (2a) back in its housing together with the chain (2b) and the tooghted drive pulley (2c).

Fit the exhaust side camshaft toothed pulley and the toothed drive pulley in the same position as when they were removed; If the pulleys are replaced, fit them with the writing turned to the outside.

3. Place the timing chain moving plate (3a) in its housing and secure it using the pin (3b).

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

	Fastening	Component	Ø	Value(daNm)
1	Bolt	TIMING DUCT PULLEY	M12	(Exhaust camshaft side) 10.8 ÷ 13.2

Remove the chain tensioner retaining pin and check that the piston is in contact with the moving plate.Place the timing cover gasket in position.1. Fit the tool on the timing cover.

	Name	Country
1	Hose	1.870.900.600

2. Place the timing cover (2a), complete with engine oil suction unit (2b), and engine oil pump in position, then secure it by tightening the bolts (2c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2c	Bolt	CRANKSHAFT FRONT COVER	M6	0.8 ÷ 1.0

Connect the engine oil vapour recirculation pipe connector to the timing cover and tighten the bolts.

Make sure that the O-Ring is correctly positioned.

Rotate the engine through 180° on the overhauling stand.Place the crankcase oil sump partition back in its housing and secure it using the bolts.Apply a bead of recommended silicon sealant to the contact surfaces of the crankcase sump and the lower engine crankcase as illustrated in the diagram below.

No breaks are allowed in the sealant strip. The diameter of the sealant bead should be 3.5 0.5 mm.

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

1. Place the crankcase sump (1a) back in its housing and secure it by tightening the bolts (1b) and the nuts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	OIL SUMP	M6	(Lower engine crankcase side) 0.8 ÷ 1.0

	Fastening	Component	Ø	Value(daNm)
1c	Nut	OIL SUMP	M6	(Timing cover side) 0.8 ÷ 1.0

2. Place the bracket (2a) in position and secure it tightening the bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	GEARBOX/ENGINE COUPLING BRACKET	M8	(Lower engine crankcase side) 2.7 ÷ 3.3

Rotate the engine through 180° on the overhauling stand.Place the engine oil dipstick back in its seating.Remove the tool.

	Name	Country
-	Hose	1.870.900.600

1. Place the crankshaft pulley support flange (1a) in its housing and secure it without tightening the left hand bolt (1b) - 1004D40 engine - position on stand and remove .

1. Place the water pump (1a), complete with gasket, back in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	COOLANT PUMP	M6	(Upper engine crankcase side) 0.8 ÷ 1.0

2. Place the crankshaft pulley (2a) back in its housing and secure it without tightening the bolts (2b).3. Place the engine components single drive belt moving tensioner (3a) back in its housing and fix it tightening the bolt (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	SINGLE SERVICES MOBILE BELT TENSIONER	M10	(Upper engine crankcase side) 4.5 ÷ 5.5

Adjust the moving tensioner and fit the engine components single drive belt using a spanner.1. Place the timing side rigid engine support (1a), complete with engine lifting bracket (1b), in position and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	ENGINE MOUNT TIMING SIDE	M10	(Upper engine crankcase side) 5.7 ÷ 6.3

1. Place the turbocharger (1a), complete with catalytic converter (1b), back in its housing and secure it tightening the nuts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Nut	TURBOCHARGER	M8	(Exhaust manifold side) 2.3 ÷ 2.8

Fit the hose carrying coolant to the engine oil heat exchanger complete with gasket and secure using the band and bolts.

Fold back the gasket tabs

Tighten the bolt fixing the coolant supply pipe to the engine oil heat exchanger to the cylinder block/crankcase.Place the exhaust manifold heat shield, complete with engine lifting bracket, back in its housing and fix it using the nut and the bolts.1. Connect the engine oil supply pipe to the turbocharger (1a) and secure by tightening the connectors (1b) to the recommended torque.

Replace the copper washers for the connectors.

	Fastening	Component	Ø	Value(daNm)
1b	Connector	OIL DELIVERY PIPE TO TURBO	M10	(Turbocharger side/oil filter mounting) 1.1 ÷ 1.3

Place a new gasket between the engine block and the turbocharger engine oil return pipe.2. Tighten the bolt fixing the enigne oil return pipe from the turbocharger, engine crankcase side, to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	OIL RETURN PIPE FROM TURBO	M6	(Turbocharger/engine crankcase side) 0.8 ÷ 1.0

Connect the electrical connection to the air conditioner compressor electromagnet. Remove the engine from the overhaul stand - 1004D40 engine - position on stand and remove .