1024A10 CRANK SHAFT - R + R WITH ENGINE REMOVED - CHECK MAIN AND CONNECTING ROD BEARINGAND REPLACE IF NECESSARY (AUTOMATIC TRANSMISSION) - Alfa - 166 - eLearn

3315359 - 1024A10 crank shaft - r + r with engine removed - check main and connecting rod bearingand replace if necessary (Automatic transmission)

) 1. Remove the 'drip tray' for the power assisted steering fluid reservoir.2. Undo the bolts (2a) and remove the upper protective timing cover (2b).

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

1. Remove the engine oil filler cap.2. Undo the bolts (2a) and remove the left cylinder head spark plugs cover (2b).3. Disconnect the high tension leads (3a) from the left cylinder head spark plugs using the tool (3b).

	Name	Country
3b	Pliers	1.820.636.000

4. Undo the bolt (4a) and remove the engine oil dipstick mounting bracket (4b).

1. Undo the bolts (1a) and remove the left side tappet cover (1b) complete with gasket.

1. Loosen the bands fixing the inlet ducts to the air chamber.2. Disconnect the oil vapour recovery pipe from the right side tappet cover.3. Disconnect the condensation oil return pipe from the right cylinder head.4. Disconnect the high tension leads from the right cylinder head spark plugs.5. Undo the bolts (5a) for the high tension lead mounting bracket (5b) and move the leads aside.6. Disconnect the vacuum intake pipe for the fuel pressure regulator from the air chamber.

1. Undo the bolts (1a) and remove the air chamber (1b), complete with oil vapour separator and pipes.2. Undo the bolts (2a) and remove the inlet ducts (2b).

1. Undo the bolt (1a) and remove the engine mounting bracket (1b) from the right cylinder head.2. Undo the bolts (2a) and remove the right side tappet cover (2b), complete with gasket.3. Remove the spark plug housing gaskets.

1. Rotate the crankshaft so that the references on the camshafts are aligned with those on the bearing caps (cylinder no. 1 at T.D.C.).

1. Undo the bolts (1a) and remove the moving timing belt tensioner (1b).2. Remove the timing belt from the drive pullies.

1. Fit the engine flywheel lock.

	Name	Country
1	Flywheel lock	1.820.228.000

1. Undo the nut (1a) and remove the crankshaft pulley (1b).2. Remove the timing drive belt.3. Remove the camshaft drive pulley (3a) and its spacer (3b).4. Undo the bolt (4a) and remove the single drive belt moving tensioner (4b).

Rotate the engine through 180° on the overhauling stand.1. Release the electrical wiring for the rpm and timing sensor from the fixing on the crankcase sump.2. Undo the bolts (2a) and remove the rpm and timing sensor (2b).3. Undo the bolts fixing the crankcase sump.Heat the area where the crankcase sump matches with the cylinder block and cut the sealant.4. Remove the crankcase sump.

1. Undo the bolts (1a) and remove the alternator mounting bracket (1b).2. Undo the bolts (2a) and remove the crankshaft front cover (2b), complete with oil seal.3. Remove the gasket.

1. Remove the element from the crankshaft.2. Undo the blt fixing the chain drive to the oil pump.

1. Remove the oil pump drive chain (1a) using the tool (1b) to extract it.

	Name	Country
1b	Flange	1.960.954.001

1. Undo the bolts (1a) and remove the engine oil pump (1b).2. Remove the connector complete with O-Rings.

1. Undo and remove the engine oil level sensor.

1. Undo the bolts (1a) and remove the engine flywheel (1b).2. Fit the tool for rotating the crankshaft.

	Name	Country
2	Flange	1.820.618.000

Remove the flywheel lock.

	Name	Country
-	Flywheel lock	1.820.228.000

Turn the crankshaft to gain access to the big end bearing caps.3. Undo the bolts (3a) and remove the big end bearing caps (3b) complete with bearing shells (3c).Release the connecting rods from the crankshaft.

1. Undo the nuts (1a) and remove the front and centre main bearing caps (1b) using the tools (1c) and (1d).

	Name	Country
1c	Connector	1.965.089.001

	Name	Country
1d	Counter weight	1.840.206.001

2. Remove the half-bearings.

1. Undo the nuts (1a) and remove the rear main journal 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.

1. Remove the crankshaft.2. Remove the crankshaft rear oil seal.3. Remove the half-bearings.4. Remove the thrust washers.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
-	Thickness (mm)	Category B	1.839 - 1.845
Category C	1.833 - 1.839
Classe A	1.840 - 1.851

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
-	Thickness (mm)	Classe A	1.737 - 1.745

	Measurement		Value
-	Thickness (mm)	Classe A	1.741 - 1.749

Refit the big end bearing shells in their seats.Place the half-bearings back in their housings in the cylinder block/crankcase.Place the thrust washers back in their housings.

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

Place the crankshaft back in its housing.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.

1. Tighten the nuts (1a) for the bearing caps to the recommended torque using an angular tightening tool (1b).

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

	Name	Country
1b	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 the openings (1b) and check that it comes about 5 mm out of the openings (1c)

	Type	Component	Name	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 the crankshaft rear support.If this is not the case, remove the edge of the sealant.

1. Fit the connecting rod caps (1a), complete with half-bearings (1b), and fix them tightening the bolts (1c) to the recommended torque.

The connecting rod 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)
1c	Bolt	BIG END BEARING CAPS	M9	1.9 ÷ 2.1 + 48? ÷ 52?

Use the tool for angular tightening of the connecting rod cap bolts.2.

	Name	Country
-	Protractor	1.860.942.000

Remove the tool for rotating the crankshaft.

	Name	Country
2	Flange	1.820.618.000

Fit the flywheel lock.

	Name	Country
-	Flywheel lock	1.820.228.000

3. Fit the engine flywheel (3a) and fix it tightening the bolt (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	FLYWHEEL	M12	Crankshaft side 13.7 - 15.1

Fit the engine oil level sensor and tighten it to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	OIL LEVEL DIPSTICK SENSOR	M12	Crankcase sump side 1.7 - 2.1

1. Fit the connector complete with O-Rings.2. Fit the oil pump (2a) and fix it, tightening the bolts (2b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	ENGINE OIL PUMP	M10	Main journal caps side 3.4 - 4.2

Place the oil pump drive chain back in its housing and fix it tightening the bolt to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ENGINE OIL PUMP DRIVE CHAIN	M10	Engine oil pump side 4.3 - 5.3

Place the crankshaft element back in its housing.Remove the flywheel lock.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 0.7 - 0.9

2. Fit the alternator mounting bracket (2a) and fix it using the bolts (2b).

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

	Name	Country
1b	Fitting tool	1.860.949.000

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

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

1. Fitt the crankcase sump (1a) and fix it tightening the bolts (1b) and the bolt (1c) to the recommended torque.

The oil sump should be fitted within 15 minutes of applying the sealant in the openings for the crankshaft rear support otherwise the edge of the sealant must be removed from the rear bearing cap.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	OIL SUMP	M7	Engine crankcase side 1.3 - 1.6

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	OIL SUMP	M7	Engine block side 0.9 - 1.2

2. Fit the timing and rpm sensor (2a) and fix it using the bolts (2b).3. Fix the electrical wiring for the rpm and timing sensor on the crankcase sump.

Fit the timing drive pulley complete with spacer.Remove the spark plug for cylinder no. 1.1. 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.

Fit the timing belt moving tensioner and fix it using the bolts without tightening them.Fit the timing belt and check that the timing references on the camshafts are aligned.1. Fit the tool (1a) and fix it using the bolt (1b) for the alternator (having positioned a spacer previously) and the bolt (1c) to the water pump.

The tool tooth (1d) should press on the moving part of the timing belt tensioner.

	Name	Country
1a	Belt tensioner	1.860.950.000

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

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 is aligned 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 bolts for the timing belt tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	MOBILE TIMING TENSIONER	M8	Cylinder head side 1.7 - 2.1

Check once again that the timing references on the camshafts are aligned.Remove the belt tensioner tool.

	Name	Country
-	Belt tensioner	1.860.950.000

Remove the tool for checking top dead centre.

	Name	Country
-	Extension	1.825.013.000

Fit the timing belt moving tensioner and fix it using the bolt without tightening it.1. Fit the crankshaft lock.

	Name	Country
1	Flywheel lock	1.820.228.000

Fit the crankshaft pulley and fix it tightening the nut to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	CRANKSHAFT PULLEY	M28	Crankshaft side 20.0 - 24.7

Remove the crankshaft lock.1. Fit the spark plug housing gaskets.2. Fit the right side tappet cover (2a), complete with gasket, and fix it tightening the bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	CAM COVERS	M7	Cylinder head side 1.0 - 1.3

3. Fit the engine mounting bracket (3a) on the right cylinder head and fit is using the bolt (3b).

Fit the inlet ducts and fix them using the bolts.Fit the air chamber, complete with oil vapour separator and pipes, and fix it using the bolts.Connect the vacuum intake pipe for the fuel pressure regulator to the air chamber.Place the high tension leads back in their housings and fix them using the brackets.Connect the high tension leads to the right cylinder head spark plugs.Connect the condensation oil return pipe to the right cylinder head.Connect the oil vapour recovery pipe to the tappet cover, right side.Tighten the bands fixing the inlet ducts to the air chamber.1. Fit the left rocker cover (1a), complete with gasket, and fix it tightening the bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CAM COVERS	M7	Cylinder head side 1.0 - 1.3

Fit the engine oil dipstick mounting bracket and fix it using the bolt.Connect the high tension leads to the left cylinder head spark plugs.Fit left cylinder head spark plugs cover and fix it using the bolts.Fit the engine oil filler cap.Fit the lower protective timing covers and fix them using the bolts.Fit the upper protective timing gear cover and fix it using the bolts.Fit the power assisted steering fluid reservoir 'drip tray'.