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

) Op. 1004d10 POWER UNIT (MANUAL GEARBOX), REMOVED, REMOVE AND RE-BUILD Op. 1004E10 ENGINE, REMOVED - REMOVE CYLINDER HEAD AND OIL SUMP FOR INSPECTION - INCLUDES POSITIONING ON STAND AND REMOVAL1. Position the flywheel retainer.

	Name	Country
1	Counter-torque	1.860.846.000

2. Undo the fixing bolts (2a) and remove the clutch plate (2b).

1. Fit the crankshaft gear lock (1a) as shown.

	Name	Country
1a	Counter-torque	1.870.744.000

Work with flywheel retainer 1860846000 fitted.

2. Unscrew the bolt securing the crankshaft gear and remove.

1. Unscrew the bolts securing the flywheel .2. Remove the engine flywheel together with plate (2a) and flywheel lock positioned previously.

1. Undo the fixing bolts (1a) and remove the crankshaft rear cover (1b).

1. Undo the bolts (1a) and the nut (1b) and remove the water pump (1c).

1. Undo bolts (1a) and remove crankcase front cover (1b) with built in oil pump, complete with crankshaft front oil seal (1c) suction pump (1d) and oil filter.2. Remove engine block lower seal

1. Using service bolts to fit tool (1a) for rotating the crankshaft.

	Name	Country
1a	Flange	1.860.815.000

Rotate the crankshaft using the tool fitted previously until cylinders no. 1 and no. 4 are at T.D.C1. Undo the bolts (1a) and remove the connecting rod caps (1b) for cylinders 1 and 4.2. Remove lower connecting rod bearing halves for cylinders no. 1 and no. 4.3. Remove the connecting rod-piston assemblies for cylinders no. 1 and 4.4. Remove upper connecting rod bearing halves for cylinders no. 1 and no. 4.

	Name	Country
-	Flange	1.860.815.000

1. Check using a dial guage with a suitable magnetic base that the crankshaft end float is within the recommended values

	Measurement		Value
1	End float (mm)		0.055 ÷ 0.265

If the end float of the crankshaft is not within the recommended value, when refitting, reface the seats in the crankcase and use suitable 0.127 mm oversize thrust washers (secured to the central main bearing halves)1. Undo the bolts (1a) and remove the main bearing caps (1b).2. Remove the lower main journal half-bearings.3. Remove the crankshaft.4. Remove the upper main bearing shells.

The main bearing half incorporates the thrust half rings of the crankshaft.

Refitting ( Removing

) Clean the oil ports in the crankcase using a compressed air gun.Check the static balance of the crankshaft resting the main journals on suitable parallels.

	Measurement		Value
-	Main bearing journal diameter (mm)	Category B	47.988 - 47.994
Category C	47.982 - 47.988
Classe A	47.994 - 48.000

Check that the diameter of the main journals is within the recommended values.

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.

	Measurement		Value
-	Main bearing journal undersize (mm)		0.254 - 0.508

If the diameter of the main journals is not within the recommended values, regrind them in accordance with the recommended undersize.

	Measurement		Value
-	Crankpin diameter (mm)	Category B	41.995 - 42.001
Category C	41.988 - 41.995
Classe A	42.001 - 42.008

Check that the diameter of the crankpins is within the recommended values.

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.

	Measurement		Value
-	Crankpin 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.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 main half-bearings in the crankcase housing so that the lubrification holes align. Ensure this is carried out in completely clean conditions. The central main bearing half has built-in thrust half rings as its function is as thrust block 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.

1. Fit the connecting rod caps (1a), complete with half-bearings (1b), and fix them tightening the bolts (1c) to the recommended torque using tool (1d) for angle tightening.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	MAIN BEARING CAPS	M10 x 1.25	2 + 90°

	Name	Country
1d	Protractor	1.860.942.000

1. Remove the main bearing caps and check journal backlash using a graduated measuring device to measure the width of the guaged wire.

Check one pin at a time without turning the crankshaft.

	Measurement		Value
-	Clearance between crankshaft bearings - big end bearings (mm)		0.025 - 0.049

After checking all the main journals, refit the main bearing caps complete with bearing shells and tighten the bolts to the specified torque.Positin the tool for rotating the crankshaft.

	Name	Country
-	Flange	1.860.815.000

Rotate the crankshaft using the tool fitted previously.The piston- connecting rod assemblies are fitted by rotating them according to the following references.1. Class of connecting rod and arrow indicating the distribution side.2. Stamp area for the cylinder bore/liner number to which the connecting rod belongs .3. Connecting rod pin offset.

1. Fit the connecting rod-piston assembly (1a), complete with half-bearing, using the tool (1b) for compressing the piston rings and later introducing the piston in the liner/bore.

	Name	Country
1b	Fitting tool	1.860.700.000

Rotate the engine on the overhauling stand.1. Apply calibrated wire (plastigage) to measure crankpin backlash.

1. Fit the connecting rod caps (1a), complete with half-bearings (1b), and fix them tightening the bolts (1c) to the recommended torque.

The connecting rod caps are fitted so that the number stamped on them is facing the same side as the one stamped on the big end (inlet side).

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	CONNECTING ROD CAP FASTENERS	M8 x 1	4.1

1. Remove the connecting rod caps and check journal backlash, measuring the width of the calibrated wire using a graduated measuring device.

Check the one connecting rod pin at a time without rotating the crankshaft.

	Measurement		Value
-	Clearance between big end bearings-Crankpins (mm)		0.024 - 0.062

If the figure measured is not within the recommended values, replace the connecting rod bearings.Fit the connecting rod caps complete with half bearings and tighten the bolts to the specified torque.Remove the tool for rotating the crankshaft.

	Name	Country
-	Flange	1.860.815.000

1. Position a new gasket on the oil pump.2. Fit the crankcase front cover (2a) with built-in oil pump, complete with suction pump and oil filter and tighten the bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	ENGINE OIL PUMP	M6	1

1. Fit a new crankshaft front cover oil seal (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.860.903.000

1. Fit the crankcase rear cover (1b) and secure it using bolts (1a) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	FLYWHEEL SIDE COVER	M6	1

1. Fit the crankshaft rear oil seal (1a) using tools(1b) and (1c).

	Name	Country
1b	Grip	1.860.879.000

	Name	Country
1c	Fitting tool	1.860.881.000

1. Fit the flywheel lock.2. Fit engine flywheel (2a) with safety plate (2b) and secure it using bolts (2c) to the specified torque.

	Name	Country
1	Counter-torque	1.860.846.000

	Fastening	Component	Ø	Value(daNm)
2c	Bolt	FLYWHEEL	M8 x 1.25	4.4

1. Fit the gear on the crankshaft.

	Name	Country
2	Counter-torque	1.870.744.000

2. Fit the crankshaft locking tool.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	TOOTHED DRIVE PULLEY	M11	2 + 90°

Apply the recommended sealent to the outside edge of the water pump in one continuous line.

	Type	Component	Name	Qty.
-	Silicon sealant	COOLANT PUMP	-	-

1. Fit link (1a) and fix it tightening the bolts (1b) and nut(1c) to the recommended torque.

1. Line up the driven plate for fitting the clutch assembly (1a), using the centring pin (1b).2. Tighten the bolts fixing the clutch to the engine flywheel.

	Name	Country
1b	Clutch centering	1.870.418.000

Remove the engine flywheel lock

Rotate the engine on the overhauling stand.Clean the crankcase and oil sump contact surfaces to remove traces of silicone sealant.1. Apply the the recommended sealant around the outside of the crankcase sump as shown.

Ensure there is a good join between both ends.

2. Fit the crankcase sump (2a) andsecure it using bolts (2b) and nuts (2c) to the recommended torque.

When fitting the crankcase sump, avoid major sideways movements which may remove the sealant.

	Type	Component	Name	Qty.
1	Silicon sealant	OIL SUMP	Arexon RHODORSIL 5552	-

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	OIL SUMP	M6	1

Rotate the engine on the overhauling stand.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	CYLINDER HEAD	M9 x 1.25	3 + 90° + 90°

Fit the centering pins on the crankcaseFit the seal on the crankcase with the the word ''ALTO'' [top] facing the operator, taking care not to dirty or lubricate the seal and the surface of the crankcase.Position the cylinder head on the crankcase.1. Tighten the cylinder head bolts (1a) to the recommended torque using the angular tightening tool (1b).

Fit the tappet cover, complete with seal, and fix it tightening the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAM COVER	M6	1

Then adjust the engine as follows:1. Turn the timing control toothed pulley so that the timing notches are aligned.

1. Fit tool (1a) and (1b) on timing belt mobile tensionerSettle the timing control belt by rotating the crankshaft through two revolutions in its normal direction of rotation.

	Name	Country
1a	Belt tensioner	1.860.745.300

2. Tighten the nut for the timing control belt mobile tensioner to the recommended torque.

	Name	Country
1b	Belt tensioner	1.860.745.100

	Fastening	Component	Ø	Value(daNm)
2	Nut	MOBILE TIMING TENSIONER	M8 x 1.25	2.8