1024A10 CRANK SHAFT - R + R WITH ENGINE REMOVED - CHECK MAIN AND CONNECTING ROD BEARINGAND REPLACE IF NECESSARY - Fiat - DUCATO - eLearn

244000675 - 1024A10 CRANK SHAFT - R + R WITH ENGINE REMOVED - CHECK MAIN AND CONNECTING ROD BEARINGAND REPLACE IF NECESSARY

) 1. Fit the tool.

	Description	Code	Function
1	Counter-torque	1.860.741.000	Tool for preventing crankshaft rotation

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

1. Undo the flywheel fixing bolts.2. Remove the tool.

	Description	Code	Function
2	Counter-torque	1.860.741.000	Tool for preventing crankshaft rotation

3. Remove the flywheel.

1. Remove the protective cover.2. Undo the bolts (2a) and remove the crankcase rear cover (2b) with the oil seal incorporated.

See in Op. 1020D131. Undo the bolts fixing the crankcase sump.2. Cut the sealant using the tool

	Description	Code	Function
2	Blade	1.870.718.000	Detatch sump from crankcase

3. Remove the crankcase sump.

1. Undo the bolts (1a) and remove the engine oil intake duct (1b) releasing it from its housing.

1. Fit the tool.

	Description	Code	Function
1	Flange	1.860.815.000	Crankshaft rotation

It is advisable to rotate the crankshaft through 180 ° at a time, always in the same direction. Every time the crankshaft is rotated, the camshaft must be rotated in the same direction through half the distance to prevent contact between the pistons and the valves with the damage that would cause.

- Rotate the crankshaft using the tool fitted previously until the cylinder concerned is at B.D.C.2. Undo the bolts (2a) and remove the connecting rod cap (2b).3. Remove the lower connecting rod half-bearing.4. Remove the upper connecting rod half-bearing.- Carry out the same operations to remove the connecting rod half-bearings for the remaining cylinders.- Remove the tool.

	Description	Code	Function
.	Flange	1.860.815.000	Crankshaft rotation

1. Undo the bolts (1a) and remove the lower crankcase (1b) and the gasket (1c).2. Remove the lower main journal half-bearings.3. Remove the crankshaft.4. Remove the upper main journal half-bearings.

Refitting ( Removing

) 1. Extract the gearbox input shaft centering ring using the tool.

	Description	Code	Function
1	Mallet	1.840.206.001	Gearbox drive input shaft locating ring

	Description	Code	Function
1	Extractor	1.840.207.814	Gearbox drive input shaft locating ring

1. Make two millings in the timing gear (1a), then extract it using a special extractor (1b).

- Check that there are no deposits or blockages in the crankshaft lubrication ducts.- Check the static balance of the crankshaft resting the main journals on suitable parallels.- Check that the diameter of the main journals corresponds to the recommended figures.

	Subject	Value
.	Crankshaft	mm
-	Main journal diameter	80,182 - 80,208
-	Main journal diameter	86,182- 86,208 (*)

- (*) main journal n°5- If the diameter of the main journals is not correct, they should be reground to the recommended undersize.

	Subject	Value
.	Crankshaft	mm
-	Main journal undersize	0,254 - 0,508

The main journals should all be reground to the same undersize.The undersize should be marked by a special stamp on the side of the no. 1 crank arm.For undersize main journals: the letter M.For undersize main journals and crankpins: the letters MB.

- Check that the diameter of the crankpins corresponds to the recommended figures.

	Subject	Value
.	Crankshaft	mm
-	Crankpin diameter	56,515 - 56,538

- If the diameter of the crankpins is not correct, they should be reground to the recommended undersize.

The crankpins should all be reground to the same undersize.The undersize should be marked by a special stamp on the side of the no. 1 crank arm.For undersize crankpins: the letter B.For undersize main journals and crankpins: the letters MB.

	Subject	Value
.	Crankshaft	mm
-	Crankpin undersize	0,254 - 0,508

	Subject	Value
.	Crankshaft	mm
-	Ovality	0,005
-	Taper	0,005

	Subject	Value
.	Crankshaft	mm
-	Main journal misalignment	0,05
-	Crankpin misalignment	0,125

1. Regrind the shaft following the recommended figures.

Since the rolled section of the grooves may be damaged during the undersize of 0.508 mm for crankpins and 0.254 and 0.508 mm for main journals, the grooves must be rolled after the regrinding following the instructions given below

- Visually inspect the condition of the main journal and crankpin half-bearings and replace them if necessary.- Check that the thickness of the half-bearings corresponds to the recommended figures; if not, replace them.

	Subject	Value
.	Main bearing half thickness	mm
-	Category A	2,165 - 2,174
-	Category B	2,319 - 2,428
-	Category C	2,573 - 2,682

- Check that the thickness of the half-bearings corresponds to the recommended figures; if not, replace them.

	Subject	Value
.	Connecting rod bearing half thickness	mm
-	Category A	1,875 - 1,884
-	Category B	2,129 - 2,138
-	Category C	2,483 - 2,492

- Fit the upper main journal half-bearings in the cylinder block/crankcase.- Fit the crankshaft in the crankcase.1. Fit the calibrated wire (plastigate) for measuring the bearing clearance.

Do not move the crankshaft during the checking operations.

- Position the gaskets and the lower main journal half-bearings on the lower crankcase.- Fit the lower crankcase.1. Tighten the bolts fixing the lower crankcase to the recommended torque in the order given.

	Value - daNm	Fastening	Component	Ø
1	(engine crankcase side) 4.5 -5.5	Bolt	LOWER CRANKCASE	M14

1. Remove the lower crankcase and the half-bearings and measure the bearing clearance using the special gauge.

	Subject	Value
.	Crankshaft bearings	mm
-	Radial clearance	0,032 - 0,102

If the figure measured is outside of the tolerance, replace the half-bearings with ones of the correct size and category.

1. Check that the crankshaft endfloat corresponds to the recommended figures using a magnetic base and dial gauge.

	Subject	Value
.	Crankshaft	mm
-	End float	0,049 - 0,211

- If the crankshaft endfloat does not correspond to the recommended figure, the crankshaft must be reground and the crankshaft half-bearings replaced as a result.

The flywheel side crankshaft bearing has thrust washers incorporated. It is only available as spares with normal size thrust washers.

- Fit the lower crankcase complete with half-bearings.1. Tighten the bolts fixing the lower crankcase to the recommended torque in the order given.

	Value - daNm	Fastening	Component	Ø
.	(engine crankcase side) 4.5 -5.5	Bolt	LOWER CRANKCASE	M14

- Fit the upper connecting rod half-bearings on the big end.1. Fit the calibrated wire (plastigate) for measuring the bearing clearance.

Check the bearings, one at a time, without rotating the crankshaft.

- Fit the connecting rod caps complete with half-bearings.

Fit the connecting rods so that the number stamped on each rod faces towardt he same side as the number stamped on the big end (pressure pump side).

1. Tighten the bolts (1a) to torque, using the angular tightening tool (1b).

	Value - daNm	Fastening	Component	Ø
1a	4,5 - 5,5 + 63°	Bolt	CONNECTING ROD CAPS	M12

	Description	Code	Function
1b	Torque wrench	1.860.942.000	Connecting rod cap bolt tightening

1. Remove the connecting rod cap and the half-bearing and measure the bearing clearance using the special gauge.

	Subject	Value
1	Engine connecting rod bearings	mm
-	Radial clearance	0,35 - 0,83

If the figure measured is outside of the tolerance, replace the connecting rod half-bearings with ones of the correct size and category.

1. Fit the gearbox input shaft centering ring using the tool.

	Description	Code	Function
1	Drift	1.860.479.002	Gearbox drive input shaft locating ring

- Heat the timing gear in the oven letting it reach a temperature 20°C higher than the crankshaft.

do not exceed 350 °C.

1. fit the timing gear (1a) ensuring that the groove coincides with the key (1b).

- Fit the upper connecting rod half-bearings on the big end.- Rotate the crankshaft until cylinders no.1 and 4 are at B.D.C.- Fit the connecting rod caps complete with the half-bearings for cylinders no. 1 and 4 and secure them without tightening the bolts.

Fit the connecting rods so that the number stamped on each rod faces towardt he same side as the number stamped on the big end (pressure pump side).

- Proceed in the same way to fit the 2nd and 3rd cylinder connecting rod caps.1. Tighten the bolts (1a) to the recommended torque, using the angular tightening tool (1b).

	Value - daNm	Fastening	Component	Ø
1a	4,5 - 5,5 + 63°	Bolt	CONNECTING ROD CAPS	M12

	Description	Code	Function
1b	Torque wrench	1.860.942.000	Connecting rod cap bolt tightening

- Remove the tool.

	Description	Code	Function
.	Flange	1.860.815.000	Crankshaft rotation

- Fit the engine oil intake and tighten the fixing bolts.- Apply silicon sealant to the entire perimeter of the crankcase sump.

	Description	Qty.	Component	Type	Classification
.	Dow Corning 7091	-	OIL SUMP	Silicone sealant	-

- Fit the crankcase sump.- Tighten the bolts fixing the crankcase sump to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	1,8	Bolt	OIL SUMP	M8

See in Op. 1020D13- Fit the protective cover.- Fit the crankcase rear cover with the oil seal incorporated and tighten the fixing bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	(engine crankcase side) 2.5	Bolt	REAR COVER CRANKSHAFT	M8

1. Fit the tool.

	Description	Code	Function
1	Counter-torque	1.860.741.000	Tool for preventing crankshaft rotation

2. Fit the flywheel (2a), apply thread-locking agent to the bolts (2b) and tighten them to the recommended torque using the angular tightening tool (2c).

	Description	Qty.	Component	Type	Classification
2b	LOCTITE 573		FLYWHEEL (MECH.)	Thread locking agent

	Value - daNm	Fastening	Component	Ø
2b	(engine crankshaft side) 2.7 -3.3 + 90°		FLYWHEEL (MECH.)	M12

	Description	Code	Function
2c	Torque wrench	1.860.942.000	Flwheel retaining bolt tightening

1. Fit the clutch (1a) using the tool (1b)

	Description	Code	Function
1b	Clutch locating tool	1.870.402.000	Clutch installation

2. - Tighten the fixing bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2	(Engine crankshaft side) 13.6 -16.8	Bolt	CLUTCH ASSEMBLY	M12

3. Remove the tool.

	Description	Code	Function
3	Counter-torque	1.860.741.000	Tool for preventing crankshaft rotation

- Proceed with positioning the engine on the rotary overhaul stand.- Proceed with the removal of all the components connected to the lower crankcase and to the cylinder head.- Remove the lower crankcase and the crankshaft.- These operations are described in the following procedures: See in Op. 1004D40 See in Op. 1004E10 See in Op. 1004E20