1024A10 CRANKSHAFT - R.R. WITH ENGINE REMOVED - CHECK AND, IF NECESSARY, REPLACE CRANKSHAFT BEARINGS AND CRANKPINS - Lancia - THESIS - eLearn

752225 - 1024A10 CRANKSHAFT - R.R. with engine removed - Check and, if necessary, replace crankshaft bearings and crankpins

) 1. Disconnect the earth lead from the tappet cover for the left cylinder head.2. Disconnect the earth lead from the tappet cover for the left cylinder head.

	Description	Connector
2	Integrated throttle casing actuator	N075

- Disconnect the oil vapour recovery pipe.- Loosen the bolts fixing the bands securing the air intake ducts to the intake chamber.1. Undo the bolts (1a) and remove the intake chamber assembly (1b).

1. Disconnect the electrical connection for the cam angle sensor E (light blue).

	Description	Connector
1	Timing sensor	K047

2. Disconnect the electrical connection for the rpm and timing sensor E (black).

	Description	Connector
2	Rpm sensor	K046

3. Disconnect the electrical connection for the rear detonation sensor E (black).

	Description	Connector
3	Detonation sensor - 2	K050

4. Disconnect the electrical connection from the engine coolant temperature sensor E.

	Description	Connector
4	I.E. engine temperature sensor	K045

5. Disconnect the earth lead from the tappet cover for the left cylinder head.

1. Undo the bolts (1a) and remove the ignition coil cover on the left cylinder head (1b).

1. Disconnect the electrical connection from the front detonation sensor E.

	Description	Connector
1	Detonation sensor - 2	K051

2. Undo the bolts (2a) and remove the brackets (2b) fastening the electrical wiring.3. Disconnect the electrical connections from the injectors E.

	Description	Connector
3	Injector	N070A

	Description	Connector
.	Injector	N070B

	Description	Connector
.	Injector	N070C

	Description	Connector
.	Injector	N070D

	Description	Connector
.	Injector	N070E

	Description	Connector
.	Injector	N070F

4. Disconnect the electrical connections from the ignition coils E.

	Description	Connector
4	Ignition coil	A030A

	Description	Connector
.	Ignition coil	A030B

	Description	Connector
.	Ignition coil	A030C

	Description	Connector
.	Ignition coil	A030D

	Description	Connector
.	Ignition coil	A030E

	Description	Connector
.	Ignition coil	A030F

5. Remove the electrical wiring after having released it from the securing bands.

1. Undo the bolts (1a) and remove the timing belt guards (1b).

1. Loosen the timing belt tensioner bolts.2. Release the timing drive belt from the camshaft drive pullies.

1. Undo the bolts (1a) and remove the ignition coils (1b) E from the cylinder heads.

	Description	Connector
1b	Ignition coil	A030A

	Description	Connector
.	Ignition coil	A030B

	Description	Connector
.	Ignition coil	A030C

	Description	Connector
.	Ignition coil	A030D

	Description	Connector
.	Ignition coil	A030E

	Description	Connector
.	Ignition coil	A030F

1. Undo the bolts (1a) and remove the tappet covers (1b) from the cylinder heads.

1. Fit the tool A.

	Description	Code	Function
1	Counter-torque	1.860.779.000	-

2. Undo the nut (2a) and remove the engine components single drive belt pulley (2b).3. Remove the timing belt.4. Remove the timing belt drive pulley.

- Rotate the engine through 180° on the overhaul stand.1. Undo the bolts (1a) and remove the crankcase sump (1b) complete with engine rpm and timing sensor (1c) and fixed belt tensioner for the engine components single drive belt (1d).

To release the crankcase sump, tap it gently using a wooden or resin hammer, then use a screwdriver for leverage in the projections at the sides of the sump.

1. Undo the bolt fixing the oil pump drive chain to the oil pump.2. Move the drive chain away from the oil pump using the tool A.

	Description	Code	Function
2	Extractor	1.860.954.001	Tool for extracting chain from engine oil pump

1. Undo the bolts (1a) and remove the oil pump assembly (1b).

1. Remove the crankshaft key using a flat drift.2. Undo the bolts (2a) and remove the engine block front cover (2b).3. Remove the seal.4. Remove the oil pump drive chain.

1. Fit the tool A.

	Description	Code	Function
1	Counter-torque	1.860.779.000	-

2. Undo the bolts (2a) and remove the engine flywheel (2b).- Remove the tool A.

	Description	Code	Function
.	Counter-torque	1.860.779.000	-

1. Fit the tool A.

	Description	Code	Function
1	Flange	1.860.815.000	-

- Rotate the crankshaft so that the connecting rod cap bolts are accessible.2. Undo the nuts (2a) and remove the connecting rod caps (2b) complete with half bearings (2c).- Remove the tool A.

	Description	Code	Function
.	Flange	1.860.815.000	-

1. Undo the nuts (1a) and remove the front and centre crankshaft bearings.2. Remove the main journal half-bearings.

1. Undo the nuts (1a) and remove the flwyheel side bearing caps (1b) using tools (1c) and (1d) A.

	Description	Code	Function
1c	Mallet	1.846.011.000	-

	Description	Code	Function
1d	Extractor	1.860.953.000	-

	Description	Code	Function
1e	Extractor	1.860.782.000	-

2. Remove the rubber seals.3. Remove the main journal half-bearing.

1. Remove the crankshaft.2. Remove the crankshaft rear oil seal3. Remove the main journal half-bearings.4. Remove the thrust washers.5. Remove the crankpin half-bearings.

Refitting ( Removing

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

	Subject	Value
.	Crankshaft bearings	-
-	CL thickness A	1.833 - 1.839
-	CL. B	1.839 - 1.845
-	CL. C	1.845 - 1.851

- Check that the thickness of the connecting rod half-bearings M corresponds to the recommended figures; if not, replace them.- Fit the crankpin half-bearings.- Fit the main journal half-bearings in the cylinder block/crankcase.- Fit the thrust washers in the cylinder block/crankcase.

T he thrust washer lubrication ducts should be facing the crankshaft thrust washers.

- Fit the crankshaft on the crankcase.- Fit the main bearing caps complete with half-bearings.

The bearing caps are numbered from 1 to 4 starting from the front of the engine

- Tighten the bearing cap nuts to torque C.

	Value - daNm	Fastening	Component	Ø
.	(Engine crankcase side) 2.5 + 79°	Nuts in oil	MAIN BEARING CAPS	M12

	Value - daNm	Fastening	Component	Ø
.	2.4 - 2.6 + 77° - 81° (Engine crankcase side)	Nut	MAIN BEARING CAPS	M12

- Use the special tool for the angular tightening of the bearing cap bolts.

	Description	Code	Function
.	Torque wrench	1.860.942.000	Angular tightening of bearing cap bolts

1. Fit the crankshaft flywheel side oil seal (1a) using the tool (1b).

The oil seal should be fitted in the housing so that it covers the small openings (1c).

	Description	Code	Function
1b	Fitting tool	1.860.794.000	-

1. Apply the recommended sealant (1a) through the openings (1b) and check that it comes out about 5 mm through the openings (1c).

	Description	Qty.	Component	Type	Classification
1a	Dow corning 7091	-	ENGINE REAR MOUNT GASKETS	Silicone sealant	-

The oil sump should be fitted within 15 minutes of applying the sealant in the openings for sealing the crankshaft rear support.

If this is not the case, remove the excess sealant.

- Fit the tool A.

	Description	Code	Function
.	Flange	1.860.815.000	-

- Rotate the crankshaft and fit the connecting rod caps complete with half-bearings and tighten the nuts to torque C.

The connecting rod caps have the number of the cylinder to which they belong on the side: when refitting, this number should be on the usual side on the big end.

	Value - daNm	Fastening	Component	Ø
.	5.4 - 6.0	Nut	CONNECTING ROD CAPS	M9

	Value - daNm	Fastening	Component	Ø
.	2.1 + 48° ÷ 52°	Bolt	CONNECTING ROD CAPS	M9

- Use the special tool for the angular tightening of the connecting rod cap bolts.

	Description	Code	Function
.	Torque wrench	1.860.942.000	Angular tightening of bearing cap bolts

- Remove the tool A.

	Description	Code	Function
.	Flange	1.860.815.000	Crankshaft rotation

1. Fit the engine flywheel (1a) and secure it without tightening the bolts (1b).2. Fit the tool A.

	Description	Code	Function
2	Counter-torque	1.860.779.000	-

- Tighten the engine flywheel bolts to torque C.

	Value - daNm	Fastening	Component	Ø
.	3.0 + 50°	-	ENGINE FLYWHEEL	M10

- Remove the tool A.

	Description	Code	Function
.	Counter-torque	1.860.779.000	-

- Fit the oil pump drive chain.- Fit the front crankcase cover complete with gasket and secure it using the bolts.- Fit the crankshaft key.- Fit the oil pump assembly and secure it using the bolts.- Tighten the bolt fixing the oil pump drive chain to torque C.

	Value - daNm	Fastening	Component	Ø
.	8.0 - 9.7	Bolt	Engine oil pump drive chain	M14

- Apply the recommended 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 oil sump bolts to torque C.

	Value - daNm	Fastening	Component	Ø
.	1.4 - 2.0	Bolt	CRANKCASE SUMP	M7

- Rotate the engine through 180° on the overhaul stand.1. Remove caps 4 to 7 from the left cylinder head.2. Remove caps B and G from the right cylinder head.

- Engine tuning.1. Fit tool A in place of the camshaft caps removed.

	Description	Code	Function
.	Template Kit	1.860.820.000	Timing

1. Position the template for the right inlet cylinder no. 1 1.860.820.0012. Position the template for the right exhaust cylinder no. 1 1.825.040.0023. Position the template for the left exhaust cylinder no. 4 1.825.040.0034. Position the template for the left inlet cylinder no. 6 1.860.820.002

- Loosen the bolts for the camshaft drive pullies using the special tool for counter-torque.

	Description	Code	Function
.	Support for counter-torque	1.860.831.000	Loosen/tighten driven toothed pulley bolt

- Fit the timing belt drive pulley.1. Fit the tool A (1a) complete with dial gauge (1b) in the seat for the spark plug for cylinder no. 1.

	Description	Code	Function
1a	Extension	1.860.895.000	T.D.C. check

- Rotate the crankshaft through small rotations (in both directions) until the piston for the right head timing side cylinder no. 1 is at T.D.C. in the explosion stroke.

Take care that the last rotation of the crankshaft is in the direction of rotation of the engine.

1. Fit the timing drive belt starting from the drive pulley and continuing in an anti-clockwise direction making sure that the drive branches are properly taut.

1. Fit the tool (1a) and secure it using bolt (1b) for the alternator and bolt (1c) for the water pump.

A suitable spacer should be fitted on the bolt (1b) to regain the size of the alternator.

The tooth (1d) for the tool should engage with the moving part of the timing belt tensioner.

	Description	Code	Function
1a	Belt tensioner	1.860.950.000	Timing belt tensioning

2. Act on the belt tensioner tool nut (2a) until the moving reference for the belt tensioner (2b) is under the fixed reference.

1. Tighten the bolts (1a) for the camshaft drive pullies to torque C using tools (1b) A for counter-torque.

	Value - daNm	Fastening	Component	Ø
1a	7.3 - 10.6	-	CAMSHAFT DRIVE PULLIES	M10

	Description	Code	Function
1b	Support for counter-torque	1.860.831.000	Loosen/tighten driven toothed pulley bolt

- Remove the tool A.

	Description	Code	Function
.	Template Kit	1.860.820.000	Engine tuning

- Fit the camshaft caps in place of the tool removed and secure them by tightening the bolts to torque C.

	Value - daNm	Fastening	Component	Ø
.	1.8 - 2.5	Bolt	CAMSHAFT CAPS	M8

- Rotate the crankshaft through two revolutions in its direction of rotation to allow the timing belt to bed in.1. Check that the moving reference for the timing belt tensioner coincides with the fixed reference.2. If the references are not aligned, gently release the tensioner tension acting on the nut for the tensioning tool until the reference coincide.3. Tighten the bolts for the timing belt tensioner to torque C.

	Value - daNm	Fastening	Component	Ø
3	2.4 - 3.2	Bolt	TIMING BELT TENSIONER	M8

- Remove the tool A.

	Description	Code	Function
.	Belt tensioner	1.860.950.000	Timing belt tensioning

1. Fit the tool A.

	Description	Code	Function
1	Counter-torque	1.860.779.000	-

2. Fit the engine components single belt pulley (2a) and secure it tightening the nuts (2b) to torque C.

	Value - daNm	Fastening	Component	Ø
2b	23.2 ÷ 31.2	Nut	SINGLE ENGINE COMPONENTS DRIVE BELT PULLEY	M28

- Remove the tool A.

	Description	Code	Function
.	Counter-torque	1.860.779.000	-

- Fit the tappet covers and secure them using the bolts.- Fit the ignition coils and secure them using the bolts.- Fit the protective timing cover mounting bracket and secure it using the bolts.- Fit the timing belt guards and secure them using the bolts.- Place the electrical wiring in position and fasten it to the bands.- Connect the electrical connections to the ignition coils.- Connect the electrical connections to the injectors.- Fit the electrical wiring mounting brackets to the tappet covers and secure them using the bolts.- Connect the electrical connection for the front detonation sensor.- Fit the ignition coil cover for the left cylinder head and secure it using the bolts.- Connect the earth lead to the left cylinder head tappet cover.- Connect the electrical connection to the engine coolant temperature sensor.- Connect the electrical connection for the rear detonation sensor.- Connect the electrical connection for the engine rpm and timing sensor.- Connect the electrical connection for the cam angle sensor.- Fit the intake chamber assembly and secure it using the bolts.- Tighten the bands securing the air intake manifolds to the intake chamber.- Connect the engine oil vapour recovery pipe.- Connect the electrical connection for the throttle casing.- Connect the earth lead to the left cylinder head tappet cover.