3363560 - 1024A10 crank shaft - r + r with engine removed - check main and connecting rod bearingand replace if necessary

Removing ( Refitting )  - 1004D40  engine - position on stand and remove - 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).

NameCountry
1aCounter-torque1.860.765.000
2. Remove the crankshaft gear from the housing on the shaft.
1. Undo the bolts and the nut.2. Remove the timing belt lower rear shield.
1. Undo the retaining bolts.2. Remove the crankshaft front cover.
Position the flywheel retainer.

NameCountry
-Counter-torque1.860.846.000
1. Undo the retaining bolts.2. Remove the engine flywheel together with the flywheel lock positioned previously.
1. Undo the fixing bolts (1a) and remove the crankshaft rear cover (1b).
1. Undo the retaining bolts.2. 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 of the engine oil dipstick inside the cylinder block/crankcase (3b).
1. Using the service bolts (1a), fit the tool (1b) for rotating the crankshaft.

NameCountry
1bFlange1.860.815.000
1. Undo the fixing bolts (1a) and remove the connecting rod cap (1b).2. Remove the lower big end bearing shell.3. Remove the connecting rod - piston assembly.4. Remove the upper big end bearing shell.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 crankshaft bearings.7. Remove the crankshaft.8. Remove the upper crankshaft bearings.9. Remove the thrust rings.
Refitting ( Removing ) Using compressed air gun, clean the oil ports in the crankshaft.Measure the diameter of the main journals and the crank pins.

MeasurementValue
-Main bearing journal diameter (mm)Category B50.780 - 50.790
Classe A50.790 - 50.800

MeasurementValue
-Crankpin diameter (mm)Category B45.503 - 45.513
Classe A45.513 - 45.523
If the diameter of the main journals is not within the recommended values, regrind them in accordance with the recommended undersize.

MeasurementValue
-Main bearing journal undersize (mm)0.127
If the diameter of the crankpins is not within the recommended values, regrind them in accordance with the recommended undersize.

MeasurementValue
-Crankpin undersize (mm)0.127
The shaft has undergone a nitriding treatment; therefore if it needs regrinding it should undergo the nitriding treatment again and the dimensions should then be checked.
Check the crankshaft bearings, taking into account that no adjustment operations should be carried out on half-bearings. If there are signs of grooves or seizing, they must be replaced.Fit the half-bearings, ensuring that they are scrupulously clean and take care to position the half-bearing without splining on the centre bearing support.If the crankshaft has been reground, fit the new and 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 clearance.3. Fit the bearing caps.4. Tighten the bearing cap bolts to torque.

FasteningComponentØValue(daNm)
4BoltMAIN BEARING CAPSM107.2 - 8.8
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 measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).

MeasurementValue
1bClearance between crankshaft bearings - main journals (mm)0.019 - 0.050
Measure the clearance at all the bearings, taking care to carry out this operation, one bearing at a time, without ever moving the crankshaft.Check that the thickness of the thrust washers is within the recommended figures.

MeasurementValue
-Thickness of thrust washers (mm)2.310 - 2.360
Fit the thrust washers on the first flywheel side support.Fit the bearing caps.Tighten the bearing cap bolts to torque.

FasteningComponentØValue(daNm)
-BoltMAIN BEARING CAPSM107.2 - 8.8
The bearing caps have progressive references from zero to four starting from the front of the engine which define their fitting position.
Positin the tool for rotating the crankshaft.

NameCountry
-Flange1.860.815.000
Rotate the crankshaft using the tool fitted previously.1. The connecting rod-piston assemblies are fitted with the engine rotation arrow stamped on the piston crown facing the inlet side.2. Check that the stamps for the cylinder bore/liner 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 introduction of the piston in the liner/bore.
1. Check the clearance of the connecting rod bearings, using the calibrated wire (Plastigage).
Fit the connecting rod bearing.Tighten the nuts fixing the connecting rod caps to torque.

FasteningComponentØValue(daNm)
-NutBIG END BEARING CAPSM94.8 - 5.4
Undo the nuts and remove the connecting rod cap fitted previously.1. Using a suitable graduate measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).

MeasurementValue
1bBig end bearing - crankpin play (mm)0.025 - 0.063
If the value measured does not correspond to the recommended figures, replace the connecting rod bearings.Carry out this check on all the connecting rod bearings, one at a time, without rotating the crankshaft.Fit the connecting rod bearing.Tighten the nuts fixing the connecting rod caps to torque.

FasteningComponentØValue(daNm)
-NutBIG END BEARING CAPSM94.8 - 5.4
Fit the section of the engine oil dipstick inside the cylinder block/crankcase.Position a new oil pump gasket.Fit the oil pump tightening the fixing bolts to torque.

FasteningComponentØValue(daNm)
-BoltENGINE OIL PUMPM82.3 ÷ 2.8
Fit the crankshaft rear cover.Fit the engine flywheel, securing the fixing bolts.Fit the engine flywheel lock.

NameCountry
-Counter-torque1.860.846.000
Tighten the bolts fixing the flywheel to torque.

FasteningComponentØValue(daNm)
-BoltFLYWHEELM107.5 - 9.1
1. Remove the gasket (1a) from the front cover using a drift in the slit (1b).
Fit the front cover to the engine block.Tighten the fixing bolts to torque.

FasteningComponentØValue(daNm)
-BoltCRANKSHAFT FRONT COVERM60.8 - 1.0
1. Using the tool, fit the new oil seal in the housing.

NameCountry
1Fitting tool1.860.878.000
Fit the timing belt lower rear shield.Clean the crankcase and oil sump contact surfaces to remove traces of silicone sealant.Apply silicon sealant around the edge of the crankcase sump.Fit the oil sump to the crankcase.Tighten the oil sump fixing bolts to torque.

FasteningComponentØValue(daNm)
-BoltOIL SUMPM60.8 - 1.0
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 nylon container; - to only take it out of its container shortly before fitting; - not to lubricate the gasket or contaminate it with oil and to ensure that the crankcase and cylinder head surfaces are clean.
Before fitting the cylinder head, rotate the crankshft until the piston for cylinder no. 1 is approximately at T.D.C.Position the cylinder head on the crankcase.Tighten the cylinder head bolts, following the order shown in the figure below.1. Using the tool (1a) tighten the cylinder head fixing bolts (1b) to torque, following the order illustrated previously.

NameCountry
1aProtractor1.860.942.000

FasteningComponentØValue(daNm)
1bBoltCYLINDER HEADM104 + 90° + 90°
Connect the water pump engine 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 .

FasteningComponentØValue(daNm)
-NutEXHAUST MANIFOLD/SM82.3 ÷ 2.8
Fit the exhaust manifold heat shield.Tighten the nuts fixing the bulkhead.Fit a new cylinder head gasket.Fit the camshaft housing, taking care not to let the hydraulic tappets drop.Tighten the cylinder head fixing bolts to torque.

FasteningComponentØValue(daNm)
-BoltRIGHT CYLINDER HEAD EXTENSIONM8(Cylinder head side) 1.4 ÷ 1.7
Position the new inlet side camshaft housing gasket.Fit the camshaft housing, taking care not to let the hydraulic tappets drop.Tighten the cylinder head fixing bolts to torque.

FasteningComponentØValue(daNm)
-BoltUPPER CYLINDER HEADSM8(Cylinder head side) 1.4 ÷ 1.7
Fit the timing belt rear protection.Fit the timing belt fixed tensioner, tightening the fixing bolt to torque.

FasteningComponentØValue(daNm)
-BoltFIXED TENSIONERM127.8 - 9.6
Fit the camshaft pullies, without tightening the fixing bolts.Remove the camshaft rear covers from the camshaft housing.Check that the piston for cylinder no.1 is approximately at T.D.C., then time the camshafts.1. Position camshaft timing adjustment tools.

NameCountry
1Template1.860.874.000
2. When fitting the tools, align shaft seat (2a) with key (2b) on the tools.3. Tighten the tool retaining nuts.
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. Position a dial gauge (1a), supported by a pointer (1b) in the housing for the spark plug for cylinder no. 1. Turn the crankshaft with small, even movements until the dial gauge shows the cylinder no. 1 piston is at TDC.

NameCountry
1bProbe mount1.860.895.000
1. Proceed with fitting timing drive belt (1a), fitting it initially on crankshaft gear (1b) then oil pump gear (1c), fixed guide pulley (1d), inlet camshaft pulley (1e), exhaust camshaft pulley (1e) and lastly on automatic tensioner (1g).
1. Undo retaining bolts2. Position the toothed belt tensioning tool.

NameCountry
2Belt tensioner1.860.876.000
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 to the specified torque

FasteningComponentØValue(daNm)
2NutMOBILE TIMING TENSIONERM82.3 ÷ 2.8
Use the pulley tightening tool to tighten the camshaft pulley retaining bolts to the specified torque.

NameCountry
-Counter-torque1.860.831.001

NameCountry
-Adaptor1.860.885.000

FasteningComponentØValue(daNm)
-BoltTIMING GEAR DRIVEN PULLEYSM1210.8 - 13.2
Remove the camshaft timing tools.

NameCountry
-Template1.860.874.000
Remove the dial gauge together with the probe.

NameCountry
-Probe mount1.860.895.000
Rotate the crankshaft through two revolutions in its normal direction of rotation.1. Loosen the moving tensioner nut.2. Use tool (2a) to slacken toothed timing belt tension gradually until mobile pointer (2b) is aligned with fixed reference (2c).

NameCountry
2aBelt tensioner1.860.876.000
Tighten the nut for the moving tensioner to the recommended torque.

FasteningComponentØValue(daNm)
-NutMOBILE TIMING TENSIONERM82.3 ÷ 2.8
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 engine timing adjustment operation must be repeated.
Fit the camshaft rear covers.Fit the support for the ignition coils, tightening the nuts fixing the support and the covers to torque.

FasteningComponentØValue(daNm)
-NutINTAKE AND EXHAUST CAMSHAFT REAR COVERM60.8 - 1.0
Position the flywheel retainer.

NameCountry
-Counter-torque1.860.846.000
Fit the crankshaft pulley with its phonic wheel.Tighten the pulley retaining nut to torque.

FasteningComponentØValue(daNm)
-NutCRANKSHAFT PULLEYM2018.0 - 20.0
Remove the flywheel lock.

NameCountry
-Counter-torque1.860.846.000
Fit the timing belt single 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 to the specified torque

FasteningComponentØValue(daNm)
-NutINLET MANIFOLDM82.3 ÷ 2.8
Fit the air intake casing.Tighten the bolts and nuts securing the casing to the cylinder head extension.

FasteningComponentØValue(daNm)
-BoltINLET AIR DUCTM71.4 ÷ 1.7
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 mounting bracket, tightening the bolts to torque.

FasteningComponentØValue(daNm)
-BoltIGNITION COIL/REELM60.8 - 1.0
Connect the supply connections for the coils to the spark plugs.Position the power assisted steering pump complete with supports.1. Fit the drive belt on the water pump and power assisted steering pump pullies.2. Acting on the adjustment nut and bolt, tension the power assisted steering pump drive belt.3. Using a dynamometer, check that the belt tension is correct.

NameCountry
3Torque wrench1.895.762.000

MeasurementValue
3Power steering pump new belt tension (daN)32 - 45
4. Tighten the bolts fixing the power assisted steering pump brackets to torque.

FasteningComponentØValue(daNm)
4NutPOWER STEERING PUMP SUPPORT/BRACKETM104.5 ÷ 5.5
Fit the pump plastic shield.
Position the electrical wiring.Connect the electrical connection for the detonation sensor.Connect the electrical connection for the rpm sensor.Connect the electrical connection to the brake fluid level sensor.Connect the electrical connection to the alternator.Connect the electrical connections to the injectors.Connect the electrical connections to the ignition coils.Connect the electrical connection to the engine coolant temperature sensor.Connect the electrical connection to the butterfly position sensor.Connect the electrical connection to the idle actuator.Connect the electrical connection to the intake air temperature sensor.Position the part of the wiring concerned in the duct. - 1004D40  engine - position on stand and remove