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

184000842 - 1024A10 CRANK SHAFT - R + R WITH ENGINE REMOVED - CHECK MAIN AND CONNECTING ROD BEARINGAND REPLACE IF NECESSARY

) Place the engine on the overhaul stand. Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE.1. Disconnect the electrical connection from the air conditioning compressor engagement electromagnet.

	Description	Connector
1	Air conditioning compressor engagement electro-magnet	L20

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

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 securing the engine oil heat exchanger coolant supply pipe to the engine block.3. Undo the bolts (3a), loosen the band (3b) and remove the engine oil heat exchanger coolant supply pipe (3c) complete with gasket.

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 in an anti-clockwise direction on the moving tensioner (1a) and remove the engine components single drive belt (1b).

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

1. Completely undo the left bolt (1a) loosened previously and remove the pulley mounting flange on the crankshaft (1b). Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE.

Release the engine oil dipstick.Rotate the engine through 180° on the overhaul stand.1. Undo the bolts (1a) and remove the support (1b).2. Undo the nuts (2a) and the bolts (2b) securing the crankcase sump.3. Cut the crankcase sump sealant using the tool.

	Description	Code
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 overhaul 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. Keep the brackets.

1. Keep the tool fitted on the exhaust side camshaft Op. 1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, REMOVE AND RE-BUILD.

	Description	Code
1	Template	1.871.000.900

1. Fit the camshaft timing adjustment tool.

	Description	Code
1	Template	1.870.900.300

1. Undo the timing driven pulley fixing bolt.

Mark the position of the timing driven pulley and the timing drive pulley; if the pullies are replaced, fit them with the writing facing outwards.

1. Remove the timing driven pulley (1a) together with the chain (1b) and the timing 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 fixed plate (3b).

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

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

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

	Description	Code
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 connecting rod half-bearings.

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

	Measurement		Value
1	End float (mm)		0.055 ÷ 0.265

If the value for the crankshaft endfloat does not correspond with the recommended figures, when refitting, regrind the crankcase seat 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 central main bearing half is joined to the thrust half-rings. Press the ends of the half-bearing to separate.

Refitting ( Removing

) Clean the parts removed thoroughly and check their condition visually.Lubricate all the mechanical components with engine oil.Check the main bearings and connecting rod bearings, noting that the half-bearings should not be adapted. Replace them if scoring or signs of binding are noted.The size of the main journal half-bearings is given.

	Measurement		Value
-	Main bearing half thickness (mm)	Category A	1.836 ÷ 1.841
Category B	1.841 ÷ 1.846
Category C	1.846 ÷ 1.851

The size of the connecting rod half-bearings is given.

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

Place the upper main bearing halves in their seats taking great care over cleanliness.

If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions. The thrust half-rings are built into the central main bearing half.

The thrust half-ring thickness is given.

	Measurement		Value
-	Thrust half-washer thickness (mm)		2.310 ÷ 2.360

The thrust half-washer undersize is 0.127 mm.

Fit the crankshaft in its seat on the crankcase.1. Fit the calibrated wire (plastigage) for measuring the bearing clearance.

1. Refit the lower crankase with lower main bearing halves in its seat.2. Tighten the central bolts (2a) securing the lower crankcase to the specified torque, following the order shown in the figure. Use tool (2b) for angular tightening.

	Fastening	Component	Ø	Value(daNm)
2a	Central bolt	ENGINE CRANKCASE	M10	(Engine crankcase side) 1.9 - 2.1 + 80 ± 3?

	Description	Code
2b	Torque wrench	1.860.942.000

3. Tighten the lower crankcase side bolts to the specified torque, following the order shown in the figure.

	Fastening	Component	Ø	Value(daNm)
3	Central bolt	ENGINE CRANKCASE	M8	(Engine crankcase side) 2.9 - 3.2

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

Check one journal at a time, without rotating the crankshaft.

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

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

1. After checking all the main journals, apply a strip of specified silicon sealant to the contact surfaces between the lower crankcase and the upper crankcase as shown in the diagram in the figure.

The sealant strip must be unbroken. The sealant strip diameter must be 2.5 3.5 mm

	Type	Component	Description	Qty.
1	Sealant	ENGINE CRANKCASE	Loctite 5900	-

After applying the sealant clean the crankshaft lower oil seal seat.

Fit the lower crankcase to the upper crankcase permanently by tightening the bolts as shown previously.1. Fit the calibrated wire (plastigage) for measuring the bearing clearance.

1. Refit the connecting rod cap assemblies (1a) in their seats with upper connecting rod bearing halves using tool (1b).

The connecting rod bearing halves may be identified as follows:upper connecting rod bearing half, connecting rod side, trimetallic and dark in colour;lower connecting rod bearing half, cap side bimetallic, light coloured with a hole.Never reverse the positioning of the connecting rod bearing halves under any circumstances.

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

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	CONNECTING ROD CAPS	M8	1.9 ÷ 2.1 + 40? ± 2?

	Description	Code
2b	Torque wrench	1.860.942.000

Undo the bolts and remove the connecting rod caps with the half-bearings fitted previously.1. Use an appropriate graduated measuring tool (1a) to measure the clearance indicated by the plastigage (1b).

Check one journal at a time, without rotating the crankshaft.

	Measurement		Value
1b	Crankshaft crankpins (mm)		0.030 ÷ 0.062

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

Fit the connecting rod caps permanently by tightening the bolts as shown previously.1. Fit the crankshaft rear oil seal (1a) using the tool (1b).

	Description	Code
1b	Fitting tool	1.870.900.200

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

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

1. Fit the camshaft timing adjustment tool.

	Description	Code
1	Template	1.870.900.300

Use a suitable tool (e.g. vice) to set the chain tensioner and hold it fully back with a retaining pin.1. Place the timing chain fixed pad (1a) back in its housing and secure it using the bolts (1b).2. Refit the exhaust side camshaft toothed drive pulley (2a) together with chain (2b) and toothed drive pulley (2c).

Fit the exhaust side camshaft toothed drive pulley and the toothed drive pulley according to the position marked on disassembly. If the pulleys are replaced, fit with the wording facing outwards.

3. Place the timing chain mobile pad (3a) back in its housing and secure it using the pin (3b).

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

	Fastening	Component	Ø	Value(daNm)
1	Bolt	TIMING DRIVEN 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 mobile pad.Place the camshaft cover gasket back in its housing.1. Fit the tool to the camshaft cover.

	Description	Code
1	Hose	1.870.900.600

2. Refit the timing cover (2a) complete with engine oil suction device (2b) and engine oil pump. 1. Tighten bolts (1a) and nuts (1b) securing the timing cover to the specified torque.

Follow the order shown in the figure for each tightening sequence. The tightening to 0.8 - 1.0 daNm is performed in two stages: a pretightening to 0.4 daNm followed by an additional tightening of 0.8 - 1.0 daNm.

	Fastening	Component	Ø	Value (daNm)
1a	Bolt	FRONT COVER CRANKSHAFT	M6	0.8 - 1.0 daNm

	Fastening	Component	Ø	Value (daNm)
1b	Nut	FRONT COVER CRANKSHAFT	M6	0.8 - 1.0 daNm

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

Ensure the o-ring is present and correctly positioned.

Rotate the engine through 180° on the overhaul stand.Place the crankcase oil sump partition back in its housing and secure it using the bolts.Apply a strip of recommended silicon sealant to the contact surfaces between the crankcase sump and lower crankcase as shown in the diagram in the figure.

The sealant strip must be unbroken. The sealant strip diameter must be 3.5 0.5 mm

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

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

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

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

2. Place the bracket (2a) in its housing and secure it by 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 overhaul stand.Place the engine oil dipstick back in its housing.Remove the tool.

	Description	Code
-	Hose	1.870.900.600

1. Position the crankcase pulley support flange (1a) in its housing and secure it with the left-threaded bolt (1b) without tightening it. Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE.

1. Place the water pump (1a), complete with gasket in position, then tighten the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	COOLANT PUMP	M6	(Engine upper crankcase side) 0.8 - 1.0

2. Position the crankshaft pulley (2a) in its housing and secure it tightening the nuts (2b) to the recommended torque.3. Position the auxiliary drivebelt mobile tensioner (3a) in its housing and secure it tightening the bolt (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	SINGLE BELT MOVING TENSIONER VARIOUS	M10	(Engine upper crankcase side) 4.5 - 5.5

Adjust the mobile tensioner with a wrench and fit the auxiliary drivebelt.1. Place the timing side rigid engine support (1a) in its housing with the engine lift bracket (1b) and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	RIGID ENGINE MOUNT, TIMING SIDE	M10	(Engine upper crankcase side) 5.7 - 6.3

1. Place the turbocharger (1a) in its housing complete with catalytic converter (1b) and fasten it tightening the bolts (1c) to the recommended torque.

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

Replace the pipe carrying coolant to the engine oil heat exchanger complete with gasket, then tighten the collar and bolts.

Fold over the gasket safety tabs.

Tighten the bolt securing the pipe carrying coolant to the engine oil heat exchanger to the crankcase.Refit the exhaust manifold heat shield with the engine lift bracket and secure with the nut and bolts.1. Position the pipe carrying engine oil to the turbocharger (1a) in its housing and secure it tightening connectors (1b) to the recommended torque.

Replace the copper washers on the connectors.

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

Position a new gasket between the crankcase and the engine oil return pipe to the turbocharger.2. Tighten the bolts securing the engine oil return pipe from the turbocharger, crankcase side, to the specified torque.

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

Connect the electrical connection to the air conditioning compressor engagement electromagnet.Remove the engine from the overhaul stand Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE.