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

Removing ( Refitting ) 1. Fit the tool.
DescriptionCodeFunction
1Counter-torque1.860.741.000Tool for preventing crankshaft rotation
2. Undo the bolts (2a) and remove the clutch (2b).
1. Undo the flywheel fixing bolts.2. Remove the tool.
DescriptionCodeFunction
2Counter-torque1.860.741.000Tool 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
DescriptionCodeFunction
2Blade1.870.718.000Detatch 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.
DescriptionCodeFunction
1Flange1.860.815.000Crankshaft 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.
DescriptionCodeFunction
.Flange1.860.815.000Crankshaft 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.
DescriptionCodeFunction
1Mallet1.840.206.001Gearbox drive input shaft locating ring
DescriptionCodeFunction
1Extractor1.840.207.814Gearbox 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.
SubjectValue
.Crankshaftmm
-Main journal diameter80,182 - 80,208
-Main journal diameter86,182- 86,208 (*)
- (*) main journal n°5- If the diameter of the main journals is not correct, they should be reground to the recommended undersize.
SubjectValue
.Crankshaftmm
-Main journal undersize0,254 - 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.
SubjectValue
.Crankshaftmm
-Crankpin diameter56,515 - 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.
SubjectValue
.Crankshaftmm
-Crankpin undersize0,254 - 0,508
SubjectValue
.Crankshaftmm
-Ovality0,005
-Taper0,005
SubjectValue
.Crankshaftmm
-Main journal misalignment0,05
-Crankpin misalignment0,125
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.
SubjectValue
.Main bearing half thicknessmm
-Category A2,165 - 2,174
-Category B2,319 - 2,428
-Category C2,573 - 2,682
- Check that the thickness of the half-bearings corresponds to the recommended figures; if not, replace them.
SubjectValue
.Connecting rod bearing half thicknessmm
-Category A1,875 - 1,884
-Category B2,129 - 2,138
-Category C2,483 - 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 - daNmFasteningComponentØ  
1(engine crankcase side) 4.5 -5.5BoltLOWER CRANKCASEM14
1. Remove the lower crankcase and the half-bearings and measure the bearing clearance using the special gauge.
SubjectValue
.Crankshaft bearingsmm
-Radial clearance0,032 - 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.
SubjectValue
.Crankshaftmm
-End float0,049 - 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 - daNmFasteningComponentØ  
.(engine crankcase side) 4.5 -5.5BoltLOWER CRANKCASEM14
- 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 - daNmFasteningComponentØ  
1a4,5 - 5,5 + 63°BoltCONNECTING ROD CAPSM12
DescriptionCodeFunction
1bTorque wrench1.860.942.000Connecting rod cap bolt tightening
1. Remove the connecting rod cap and the half-bearing and measure the bearing clearance using the special gauge.
SubjectValue
1Engine connecting rod bearingsmm
-Radial clearance0,35 - 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.
DescriptionCodeFunction
1Drift1.860.479.002Gearbox 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 - daNmFasteningComponentØ  
1a4,5 - 5,5 + 63°BoltCONNECTING ROD CAPSM12
DescriptionCodeFunction
1bTorque wrench1.860.942.000Connecting rod cap bolt tightening
- Remove the tool.
DescriptionCodeFunction
.Flange1.860.815.000Crankshaft rotation
- Fit the engine oil intake and tighten the fixing bolts.- Apply silicon sealant to the entire perimeter of the crankcase sump.
DescriptionQty.ComponentTypeClassification
.Dow Corning 7091-OIL SUMPSilicone sealant-
- Fit the crankcase sump.- Tighten the bolts fixing the crankcase sump to the recommended torque.
Value - daNmFasteningComponentØ  
.1,8BoltOIL SUMPM8
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 - daNmFasteningComponentØ  
.(engine crankcase side) 2.5BoltREAR COVER CRANKSHAFTM8
1. Fit the tool.
DescriptionCodeFunction
1Counter-torque1.860.741.000Tool 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).
DescriptionQty.ComponentTypeClassification
2bLOCTITE 573FLYWHEEL (MECH.)Thread locking agent
Value - daNmFasteningComponentØ  
2b(engine crankshaft side) 2.7 -3.3 + 90° FLYWHEEL (MECH.)M12
DescriptionCodeFunction
2cTorque wrench1.860.942.000Flwheel retaining bolt tightening
1. Fit the clutch (1a) using the tool (1b)
DescriptionCodeFunction
1bClutch locating tool1.870.402.000Clutch installation
2. - Tighten the fixing bolts to the recommended torque.
Value - daNmFasteningComponentØ  
2(Engine crankshaft side) 13.6 -16.8BoltCLUTCH ASSEMBLYM12
3. Remove the tool.
DescriptionCodeFunction
3Counter-torque1.860.741.000Tool for preventing crankshaft rotation