2892344 - 1024A10 crank shaft - r + r with engine removed - check main and connecting rod bearingand replace if necessary
Removing
(
Refitting
)
- 1004D10 power unit (manual gearbox), removed, remove and
re-build - 1004E10 engine, removed - remove cylinder head and oil sump
for inspection - includes positioning on stand and removal1. Using the tool (1a), lock the gear, undo the fixing bolt (1b)
and remove the gear (1c).2. Remove the crankshaft gear from the housing on the shaft.
| Name | Country |
|---|
| 1a | Counter-torque | 1.860.765.000 |
1. Undo the bolts and nut.2. Remove the timing belt lower rear shield.
1. Unscrew the retaining bolts2. Remove the crankshaft front cover.
1. Position the flywheel retainer.2. Undo the fixing bolts (2a) and remove the clutch plate (2b).
| Name | Country |
|---|
| 1 | Counter-torque | 1.860.846.000 |
1. Unscrew the retaining bolts2. Remove the flywheel together with the flywheel lock positioned
previously.
1. Undo the fixing bolts (1a) and remove the crankshaft rear cover
(1b).
1. Unscrew the retaining bolts2. Remove the engine oil pump (2a) complete with draught element
(2b).Recover the oil pump gasket.3. Undo the fixing bolt (3a) and remove the section inside the cylinder
block/crankcase (3b) for the oil dipstick.
1. Using the service bolts (1a), fit the tool (1b) for rotating
the crankshaft.
| Name | Country |
|---|
| 1b | Flange | 1.860.815.000 |
1. Undo the fixing bolts (1a) and remove the connecting rod cap
(1b).2. Remove the bottom big end bearing shell.3. Remove the connecting rod - piston assembly.4. Remove the upper connecting rod half-bearing.Proceed in the same way with the removal
of the pistons and connecting rods for the remaining cylinders.5. Undo the fixing bolts (5a) and remove the bearing caps (5b).6. Remove the lower bearings.7. Remove the crankshaft.8. Remove the upper bearings.9. Remove the thrust rings.
Refitting
(
Removing
)
Clean the oil ports in the crankcase using
a compressed air gun.Measure the diameter of the main journals
and the diameter of the crank pins.
| Measurement | | Value |
|---|
| - | Main bearing journal diameter (mm) | Category B | 50.780 - 50.790 |
| Classe A | 50.790 - 50.800 |
| Measurement | | Value |
|---|
| - | Crankpin diameter (mm) | Category B | 45.503 - 45.513 |
| Classe A | 45.513 - 45.523 |
If the diameter of the main journals is
not within the recommended values, regrind them in accordance with the
recommended undersize.
| Measurement | | Value |
|---|
| - | Main bearing journal undersize (mm) | | 0.254 - 0.508 |
If the diameter of the crankpins is not
within the recommended values, regrind them in accordance with the
recommended undersize.
| Measurement | | Value |
|---|
| - | Crankpin undersize (mm) | | 0.254 - 0.508 |
 | The shaft has undergone a nitriding
treatment; therefore if it is reground it must undergone the same
procedure again and the dimensions must then be checked. |
Check the crankshaft bearings, taking into
account that no adjustment operations should be carried out to the
half-bearings. If there are grooves or signs of seizing then they
must be replaced.Fit the half-bearings, making sure that
they are scrupulously clean and taking care to position the half-bearing
without splining on the centre bearing support.If the crankshaft has been reground, fit
new, oversize half-bearings to restore the original tolerance conditions.1. Fit the crankshaft in the special housing in the cylinder block/crankcase.2. Fit the calibrated wire (Plastigage) to measure the main journal
cleaarance.3. Fit the bearing caps.4. Tighten the cap bolts to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 4 | Bolt | MAIN BEARING CAPS | M10 | 8 |
| The bearing caps have progressive
references from zero to four starting from the front of the engine
which define their fitting position. |
1. Remove the bearing caps fitted previously and, using a suitable
graduated mesuring instrument (1a), measure the clearance shown
by the calibrated wire (1b).
| Measurement | | Value |
|---|
| 1b | Clearance between crankshaft bearings - main
journals (mm) | | 0.019 - 0.508 |
Measure the clearance at all the bearings,
taking care to do it one bearing at a time without ever moving the crankshaft.Check that the thickness of the thrust
washers is within the recommended value.
| Measurement | | Value |
|---|
| - | Thickness of thrust washers (mm) | | 2.310 - 2.360 |
Fit the thrust washers on the flywheel
side first support.Fit the bearing caps.Tighten the cap bolts to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | MAIN BEARING CAPS | M10 | 8 |
| The bearing caps have progressive
references from zero to four starting from the front of the engine
which define their fitting position. |
Position the tool for rotating the crankshaft.
| Name | Country |
|---|
| - | Flange | 1.860.815.000 |
Rotate the crankshaft using the tool fitted
previously.1. The connecting rod-piston assemblies are fitted with the engine
rotation arrow (1a) stamped on the piston crown facing the inlet
side.2. Check that the stamps for the cylinder liner/bore to which the
connecting rod belongs are on the exhaust side.
1. Fit the connecting rod-piston assembly (1a), complete with half-bearing,
using the tool (1b) for compressing the piston rings and the subsequent
fitting of the piston in the liner/bore.
| Name | Country |
|---|
| - | Fitting tool | 1.860.700.000 |
1. Check the clearance of the connecting rod bearings, using the
calibrated wire (Plastigage) to measure the fitting clearance.
Fit the connecting rod cap.Tighten the nuts fixing the connecting
rod caps to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Nut | CONNECTING ROD CAP FASTENERS | M9 | 5.1 |
Undo the nuts and remove the connecting
rod cap fitted previously.1. Using a suitable graduated measuring instrument (1a), measure
the clearance on the calibrated wire (1b).
| Measurement | | Value |
|---|
| 1b | Thickness of thrust washers (mm) | | 2.310 - 2.360 |
If the figure measured is not within the
recommended values, replace the connecting rod bearings.Carry out this check on all the bearings,
one at a time, without ever rotating the crankshaft.Fit the connecting rod cap.Tighten the nuts fixing the connecting
rod caps to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Nut | CONNECTING ROD CAP FASTENERS | M9 | 5.1 |
Fit the section of the engine oil dipstick
inside the cylinder block/crankcase.Position a new gasket on the oil pump.Fit the oil pump tightening the fixing
bolts to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | ENGINE OIL PUMP | M6 | 2.5 |
Fit the crankshaft rear cover.Fit the engine flywheel, securing the fixing
bolts.Fit the engine flywheel lock.
| Name | Country |
|---|
| - | Counter-torque | 1.860.846.000 |
Tighten the flywheel fixing bolts to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | FLYWHEEL | M10 | 8.3 |
Align the driven disc for fitting the clutch
assembly using the centring pin.Tighten the bolts fixing the clutch to
the engine flywheel.
| Name | Country |
|---|
| - | Clutch centering | 1.870.447.000 |
Fit the new gasket for the cylinder block/crankcase cover.1. Remove the gasket (1a) from the front cover, using a drift in
the slot (1b).
Fit the front cover to the engine block.Tighten the fixing bolts to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | CRANKSHAFT FRONT COVER | M6 | 0.7 |
1. Using the tool, fit the new oil seal in the housing.
| Name | Country |
|---|
| 1 | Fitting tool | 1.860.878.000 |
Fit the timing belt lower rear shield.Clean the crankcase and oil sump contact
surfaces to remove traces of silicone sealant.Apply silicone sealant around the edge
of the crankcase sump.Fit the oil sump to the crankcase.Tighten the oil sump fixing bolts to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | OIL SUMP | M6 | 0.9 |
Clean the cylinder head and crankcase contact
surfaces.Position the cylinder head gasket with
the wording 'ALTO' [TOP] facing you. | ASTADUR type cylinder head gaskets
are fitted. These gaskets are made from a special material designed
to undergo polymerization during the use of the engine. This means
that they harden considerably during use. |
In order for the polymerization process
to take place it is necessary:
- to keep the gasket in its sealed plastic container
- not to take out of its container until ready to fit;
- not to lubricate the gasket or contaminate with oil,
and to ensure the crankcase and cylinder head surfaces are clean.
Before fitting the cylinder head, rotate
the crankshaft so that the piston for cylinder no. 1 is approximately
at T.D.C.Position the cylinder head on the crankcase.1. Tighten the cylinder head bolts, following the order shown in
the figure below.2. Using the tool (2a), tighten the head fixing bolts (2b) to torque
following the order illustrated previously.
| Name | Country |
|---|
| 2a | Protractor | 1.895.897.000 |
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | CYLINDER HEAD | M10 x 1.25 | 4 + 90° + 90° |
Connect the water pump coolant pipe.Fit the exhaust manifold to the cylinder
head.Fit the power assisted steering pump mounting
bracket on the exhaust manifold.Tighten the nuts fixing the exhaust manifold
to the cylinder head.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | EXHAUST MANIFOLD/S | M6 | 3 |
Fit the exhaust manifold heat shield.Tighten the nuts fixing the bulkhead.Fit a new cylinder head extension gasket.Fit the camshaft housing, taking care not
to let the hydraulic tappets drop.Tighten the cylinder head extension bolts
to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | CYLINDER HEAD EXTENSION GASKET | M6 | (exhaust side) 1,5 |
Position the new gasket for the inlet side
camshaft housing.Fit the camshaft housing, taking care not
to let the hydraulic tappets drop.Tighten the cylinder head extension bolts
to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | CYLINDER HEAD EXTENSION GASKET | M6 | 1.5 |
Fit the rear protection for the timing
belt.Fit the fixed tensioner for the timing
belt tightening the fixing bolt to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | FIXED TENSIONER | M12 x 1.25 | 8.7 |
Fit the camshaft pullies without tightening
the fixing bolts.Remove the camshaft rear covers from the
camshaft housings.With the piston set to the newly-obtained
TDC position, adjust camshaft timing.1. Position camshaft timing adjustment tools.2. When fitting the tools, align shaft seat (2a) with key (2b) on
the tools.3. Tighten the tool retaining nuts.
| Name | Country |
|---|
| 1 | Template | 1.860.874.000 |
| The tools are stamped with the
letters 'A' (intake) and 'S' (exhaust) to facilitate correct positioning
on the shafts. The tools are not interchangeable. |
Remove the spark plugs from their sockets
on the cylinder head.1. Dial gauge (1a) supported by probe (1b) into the socket of the
cylinder no. 1 spark plug. Turn the crankshaft with small, even
movements until the dial gauge shows the cylinder no. 1 piston is
at TDC.
| Name | Country |
|---|
| 1b | Probe mount | 1.860.895.000 |
1. Refit the timing drive belt, fitting it initially on the crankshaft
gear (1a), the oil pump gear (1b), the fixed pulley (1c), the inlet
timing pulley (1d), the exhaust timing pulley (1) and, lastly, on
the automatic tensioning device (1f).
1. Withdraw the retaining bolt.2. Position the toothed belt tensioning tool.
| Name | Country |
|---|
| 2 | Belt tensioner | 1.860.876.000 |
1. Adjust the tool until the belt is as taut as possible, i.e. when
the moving belt tensioner pointer is at the end of its travel.2. Tighten the tensioner retaining nut.
Use the pulley tightening tool to tighten
the camshaft pulley retaining bolts to the specified torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | TIMING GEAR DRIVEN PULLEYS | M12 | 12 |
| Name | Country |
|---|
| - | Support for counter-torque | 1.860.831.000 |
| Name | Country |
|---|
| - | Adaptor | 1.860.885.000 |
Remove the camshaft timing tools.
| Name | Country |
|---|
| - | Template | 1.860.874.000 |
Remove the dial gauge together with the
probe.
| Name | Country |
|---|
| - | Probe mount | 1.860.895.000 |
Rotate the crankshaft through two revolutions
in its normal direction of rotation.1. Loosen the belt tensioner retaining nut and use tool (1a) to
slightly release belt tension until moving reference (1b) is aligned
with fixed reference (1c) on the tensioning device.2. Tighten the tensioning device retaining nut to the specified
torque.
| Name | Country |
|---|
| 1a | Belt tensioner | 1.860.876.000 |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2 | Bolt | MOBILE TIMING TENSIONER | M6 | 2.5 |
Remove the tool and tighten the retaining
bolt removed previously to the specified torque in order to fit
the tensioning tool. | It is good practice to check timing
again by refitting the tools to the camshafts and adjusting the engine
until cylinder no. 1 is set to TDC, measured using the dial gauge
and probe.If the engine timing is not correctly adjusted
or the timing belt is found to be faulty, the removal-refitting
and engine timing adjustment operation must be repeated. |
Fit the rear covers for the camshafts.Fit the support for the ignition coils,
tightening the nuts fixing the support and the covers to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Nut | INTAKE AND EXHAUST CAMSHAFT REAR COVER | M6 | 0.9 |
Position the flywheel retainer.
| Name | Country |
|---|
| - | Counter-torque | 1.860.846.000 |
Fit the crankshaft pulley with its phonic
wheel.Tighten the nut to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Nut | CRANKSHAFT PULLEY | M20 | 19 |
Remove the flywheel lock.Fit the single timing belt shield.Fit the oil dipstick at the same time as
the inlet manifold.Fit the wiring duct on the inlet manifold.Tighten the lower bolt fixing the oil dipstick
and the nuts fixing the inlet manifold.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Nut | INLET MANIFOLD | M8 | 2.5 |
Fit the air intake casing.Tighten the bolts and nuts securing the
casing to the cylinder head extension.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | INLET AIR DUCT | M7 | 1.5 |
Tighten the bolts and nuts to the intake
manifold.Fit the shield and fix it using the nuts.Connect the coolant pipe.Fit the engine oil filler pipe.Tighten the fixing bolts and connect the
oil vapour inlet pipe.Fit the ignition coils on the special mounting
bracket, tightening the bolts to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | IGNITION COIL/REEL | M6 | 0.9 |
Connect the supply connections for the
coils to the spark plugs.Position the power assisted steering pump
complete with supports.1. Fit the timing belt on the water pump and power assisted steering
pump pullies.2. Working on the bolt and the adjustment nut, tension the power
assisted steering pump drive belt.3. Using a torque wrench, check that the belt tension is correct.4. Tighten the bolts fixing the power assisted steering pump brackets
to torque.Fit the plastic shield for the pump.
| Name | Country |
|---|
| 3 | Torque wrench | 1.895.762.000 |
| Measurement | | Value |
|---|
| - | Power steering pump new belt tension (daN) | | 32 - 45 |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 4 | Nut | POWER STEERING PUMP SUPPORT/BRACKET | M10 | 5 |
Position the electrical wiring and connect
the electrical connections.
| Name | Connector |
|---|
| - | Detonation sensor | K50 |
| Name | Connector |
|---|
| - | RPM sensor | K46 |
| Name | Connector |
|---|
| - | Brake fluid level sensor (switch) | K30 |
| Name | Connector |
|---|
| - | Alternator | A10 |
| Name | Connector |
|---|
| - | Injector | N70 |
| Name | Connector |
|---|
| - | Ignition coil | A30 |
| Name | Connector |
|---|
| - | Engine coolant temperature sensor | K45 |
| Name | Connector |
|---|
| - | Throttle position sensor | K56 |
| Name | Connector |
|---|
| - | Idle actuator | N74 |
| Name | Connector |
|---|
| - | Integrated air temperature sensor | K43 |
Position the part of the wiring concerned
in the special duct. - 1004D10 power unit (manual gearbox), removed, remove and
re-build
