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

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

) Position the electrical wiring and connect the electrical connections. Op. 1004d10 POWER UNIT (MANUAL GEARBOX), REMOVED, REMOVE AND RE-BUILDPosition the part of the wiring concerned in the duct.

	Name	Connector
-	Detonation sensor	See K50 DETONATION SENSOR ( ENGINE )

Position the engine on the overhauling stand.

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

1. Undo the bolts (1a) and the nut (1b) and remove the exhaust manifold heat shield (1c) complete with engine lifting bracket (1d).

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 on the moving tensioner (1a) and remove the engine components single drive belt (1b).

1. Undo the bolt (1a) and remove the single drive belt tensioner (1b).2. Completely undo the bolts (2a) loosened previously and remove the crankshaft pulley (2b).

1. Completely undo the left hand bolt (1a) loosened previously and remove the pulley mounting flange on the crankshaft (1b).

Withdraw the oil level dipstick.

1. Undo the bolts (1a) and remove the crankcase oil sump partition (1b).

Rotate the engine through 180° on the overhauling 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.

1. Keep the tool fitted on the exhaust side camshaft

	Name	Country
1	Template	1.871.000.900

1. Fit the crankshaft timing tool.

1. Undo the bolt securing the driven timing pulley.

1. Remove the timing driven driven pulley (1a) together with the chain (1b) and the toothed drive pulley (1c).

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

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

Rotate the engine through 180° on the overhauling stand.1. Undo the lower crankcase fixing bolts.

1. Undo the bolts (1a) and remove the connecting rod caps (1b).2. Remove the lower big end half-bearings.

1. Check that the crankshaft end float is within the recommended values using a magnetic base fitted with a dial gauge.If the end float of the crankshaft is not within the recommended values, when refitting, reface the seat in the cylinder block/crankcase and use suitable oversize thrust washers.

Refitting ( Removing

) 1. Remove the crankshaft (1a) complete with rear oil seal (1b).2. Remove the upper main journal half-bearings

The centre half-bearing is joined to the thrust washers; to separate them, press the ends of the half-bearing.

Clean the components removed thoroughly and check their condition through a visual inspection.Lubricate all the components for the mechanical couplings using engine oil.

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

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

Check the crankshaft bearings, taking into account that no adjustment operations should be carried out to the half-bearings; If there are signs of grooves or seizing, they must be replaced.

	Measurement		Value
-	Thrust washers (mm)		2.310 ÷ 2.360

1. Place the lower crankcase, complete with lower main journal half-bearings, back in its housing.

	Fastening	Component	Ø	Value(daNm)
2a	Centre bolt	CRANK CASE	M10	(Engine crankcase side) 1.9 ÷ 2.1 + 80? ± 3?

1. Remove the lower crankcase complete with lower main journal half-bearings and, using a suitable graduated measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).

Check one journal at a time without moving the crankshaft.

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

1. After having carried out the check on all the main journals, apply a bead of recommended silicone sealant to the contact surface of the lower crankcase and the upper crankcase as illustrated in the diagram.After applying the sealant, clean the crankshaft rear oil seal housing thoroughly.

Proceed with the final fitting of the lower crankcase on the upper crankcase, tightening the fixing bolts following the previous instructions.1. Fit the calibrated wire (Plastigage) to measure the big end bearing clearance.

1. Place the big end caps (1a) complete with half-bearings (1b) back in their housings.2. Tighten the bolts (2a) fixing the connecting rod caps to the recommended torque using the angular tightening tool (2b).

The big end bearing shells can be identified as follows:upper big end bearing shells, dark coloured three metal connecting rod side;lower big end bearing shells, light coloured two metal cap side with an opening.Do not swap the position of the big end bearing shells.

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	BIG END BEARING CAPS	M8	1.9 ÷ 2.1 + 40? ± 2?

Undo the bolts and remove the connecting rod caps complete with half-bearings fitted previously.1. Using a suitable graduated measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).

	Measurement		Value
1b	Big end bearings (mm)		0.030 ÷ 0.062

Proceed with the final fitting of the connecting rod caps tightening the fixing bolts following the previous instructions.1. Refit a new front crankshaft rear cover oil seal (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.870.900.200

Rotate the engine through 180° on the overhauling stand.

	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 conditioning compressor (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

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

1. Fit the crankshaft timing tool.

Using suitable equipment, prepare the chain tensioner and keep it in this position using a suitable pin.

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

	Fastening	Component	Ø	Value(daNm)
1	Bolt	TIMING DUCT 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 moving plate.Place the timing cover gasket in position.1. Fit the tool on the timing cover.2. Place the timing cover (2a), complete with engine oil suction unit (2b), and engine oil pump in position, then secure it by tightening the bolts (2c) to the recommended torque.

	Name	Country
1	Hose	1.870.900.600

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

	Type	Component	Name	Qty.
-	Sealant	OIL SUMP	LOCTITE 5900	-

Rotate the engine through 180° on the overhauling stand.

1. Place the crankcase sump (1a) back in its housing and secure it by tightening the bolts (1b) and the nuts (1c) to the recommended torque.2. Place the bracket (2a) in position and secure it tightening the bolts (2b) to the recommended torque.

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

Rotate the engine through 180° on the overhauling stand.

	Name	Country
-	Hose	1.870.900.600

Place the engine oil dipstick back in its seating.Remove the tool.

1. Place the water pump (1a), complete with gasket, back in its housing and secure it tightening the bolts (1b) to the recommended torque.2. Place the crankshaft pulley (2a) back in its housing and secure it without tightening the bolts (2b).

	Fastening	Component	Ø	Value(daNm)
1b	Nut	COOLANT PUMP	M6	(Upper engine crankcase side) 0.8 ÷ 1.0

Adjust the moving tensioner and fit the engine components single drive belt using a spanner.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	ENGINE MOUNT TIMING SIDE	M10	(Upper engine crankcase side) 5.7 ÷ 6.3

1. Place the turbocharger (1a), complete with catalytic converter (1b), back in its housing and secure it tightening the nuts (1c) to the recommended torque.

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

Fit the hose carrying coolant to the engine oil heat exchanger complete with gasket and secure using the band and bolts.Tighten the bolt fixing the coolant supply pipe to the engine oil heat exchanger to the cylinder block/crankcase.Place the exhaust manifold heat shield, complete with engine lifting bracket, back in its housing and fix it using the nut and the bolts.