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. Disconnect the earth cable from the left cylinder head tappet cover.2. Disconnect the electrical connection for the throttle body.

	Name	Connector
2	Integrated 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 cam angle sensor (light blue).

	Name	Connector
1	Cam angle 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 knock sensor (black).

	Name	Connector
3	Detonation sensor	K50

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

	Name	Connector
4	Engine coolant temperature sensor-sender unit	K36

5. 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 from the front knock 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. 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.

	Name	Connector
1b	Ignition coil	A30

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

1. Fit the tool A.

	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 oil sump (1b) complete with engine rpm and timing sensor (1c) and single drive belt tensioner (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. 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. Fit the tool.

	Name	Country
1	Counter-torque	1.820.624.000

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

	Name	Country
-	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 the nuts (2a) and remove the 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 rubber seals.3. 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.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 bearing shells M is within the specified values; if this is not the case, replace them.

	Measurement		Value
-	Thickness (mm)	Category B	1.839 - 1.845
Category C	1.845 - 1.851
Classe A	1.833 - 1.839

if this is not the case, replace them. if this is not the case, replace them.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.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 main bearing caps to torque.

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

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

	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 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.

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 flywheel bolts to torque C.

	Fastening	Component	Ø	Value(daNm)
-	-	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.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)
-	-	ENGINE OIL PUMP DRIVE CHAIN	M14	7.9 - 9.7

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

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

The bolt (1b) should be shimmed with a suitable spacer to recover the thickness of the alternator.

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 tools (1b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
1a	-	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 fix them, tightening the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAMSHAFT CAPS	M8	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 torque C.

	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.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.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 for the rear knock sensor (black).Connect the electrical connection for the engine rpm and timing sensor (black).Connect the electrical connection for the cam angle 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 of the throttle body.Connect the earth lead on the left cylinder head rocker cover.