2585290 - 1024A10 CRANKSHAFT - R.R WITH ENGINE REMOVED - CHECK AND, IF NECESSARY, REPLACE MAIN JOURNALS AND CRANKPINS

Removing ( Refitting )     Op. 1004d10 POWER UNIT (MANUAL GEARBOX), REMOVED, REMOVE AND RE-BUILDRefit the lower and upper guards for the timing control beltFit the auxiliary drivebelt pulley to the crankshaft and tighten the bolts to the recommended torque.

FasteningComponentØValue(daNm)
-BoltCRANKSHAFT PULLEYM8 x 1.252.2
1. 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.
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.
1. Position the flywheel retainer.2. Undo the fixing bolts (2a) and remove the clutch plate (2b).
1. Undo the retaining bolts.
1. Undo the fixing bolts (1a) and remove the crankshaft rear cover (1b).
1. Undo the retaining bolts.
1. Using the service bolts (1a), fit the tool (1b) for rotating the crankshaft.
Refitting ( Removing ) 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.
Using compressed air gun, clean the oil ports in the crankshaft.

MeasurementValue
-Main bearing journal diameter (mm)Category B50.780 - 50.790
Classe A50.790 - 50.800
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 - 0.508
Measure the clearance at all the bearings, taking care to carry out this operation, one bearing at a time, without ever moving the crankshaft.

MeasurementValue
-Thickness of thrust washers (mm)2.310 - 2.360
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.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).

FasteningComponentØValue(daNm)
-NutCONNECTING ROD CAP FASTENERSM95.1

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.

FasteningComponentØValue(daNm)
-NutCONNECTING ROD CAP FASTENERSM95.1
Fit the connecting rod bearing.

FasteningComponentØValue(daNm)
-BoltENGINE OIL PUMPM62.5
Fit the front cover to the engine block.Tighten the fixing bolts to torque.1. Using the tool, fit the new oil seal in the housing.

FasteningComponentØValue(daNm)
-BoltCRANKSHAFT FRONT COVERM60.7

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.

FasteningComponentØValue(daNm)
-BoltOIL SUMPM60.9
Tighten the oil sump fixing bolts to torque.Clean the cylinder head and crankcase contact surfaces.Position the cylinder head gasket with the word ''ALTO'' [TOP] visible to the fitter.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.

NameCountry
2aProtractor1.860.942.000
1. Tighten the cylinder head bolts, following the order shown in the figure below.2. Using the tool (2a), tighten the bolts (2b) fixing the head to torque, following the order illustrated previously.

FasteningComponentØValue(daNm)
-BoltCYLINDER HEADM10 x 1.254 + 90° + 90°
ASTADUR type cylinder head gaskets are fitted. These gaskets are made out of special material designed to undergo polymerization during engine service. This means that they harden considerably during use.

In order for the polymerization process to take place it is necessary:

    Connect the water pump engine coolant pipe.Fit the exhaust manifold to the cylinder head.

    		FasteningComponentØValue(daNm)
    -BoltEXHAUST MANIFOLD/SM63
    Remove the spark plugs from their sockets on the cylinder head.
    1. Proceed with fitting the timing drive belt, fitting it initially on the crankshaft gear (1a), the oil pump gear (1b), the fixed pulley (1c), the inlet camshaft pulley (1d), the exhaust camshaft pulley (1e) and, lastly, on the automatic tensioner (1f).
    1. Undo retaining bolts2. Position the toothed belt tensioning tool.
    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.Remove the camshaft timing tools.Remove the dial gauge together with the probe.

    		FasteningComponentØValue(daNm)
    -BoltTIMING GEAR DRIVEN PULLEYSM1212
    Rotate the crankshaft through two revolutions in its normal direction of rotation.

    		NameCountry
    -Support for counter-torque1.860.831.000
    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.

    		NameCountry
    -Adaptor1.860.885.000

    		NameCountry
    -Template1.860.874.000

    		NameCountry
    -Probe mount1.860.895.000

    		NameCountry
    1aBelt tensioner1.860.876.000

    		FasteningComponentØValue(daNm)
    2BoltMOBILE TIMING TENSIONERM62.5
    Remove the tool and tighten the retaining bolt removed previously to the specified torque in order to fit the tensioning tool.

    		FasteningComponentØValue(daNm)
    -NutINTAKE AND EXHAUST CAMSHAFT REAR COVERM60.9

    		NameCountry
    -Counter-torque1.860.846.000

    		FasteningComponentØValue(daNm)
    -NutCRANKSHAFT PULLEYM2019
    FasteningComponentØValue(daNm)
    -NutINLET MANIFOLDM82.5

    		FasteningComponentØValue(daNm)
    -BoltINLET AIR DUCTM71.5
    FasteningComponentØValue(daNm)
    -BoltIGNITION COIL/REELM60.9
    NameCountry
    3Torque wrench1.895.762.000

    		MeasurementValue
    -Power steering pump new belt tension (daN)32 - 45

    		FasteningComponentØValue(daNm)
    4NutPOWER STEERING PUMP SUPPORT/BRACKETM105
    Fit the camshaft rear covers.