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

) See in Op. 1004D40 ENGINE - Position on stand and Remove- Proceed with the removal1. Open the electrical connection holder case.2. Disconnect the electrical connection for the timing side knock sensor.

	Description	Connector
2	Detonation sensor - 2	K050

1. Loosen the bands securing the intake manifolds to the air chamber.2. Loosen the band securing the engine idle oil vapour recovery pipe, air capacity chamber side.3. Disconnect the electrical connection from the throttle casing with D.V.L.

	Description	Connector
3	Integrated throttle casing actuator	N075

1. Unscrew retaining bolt (1a) and disconnect earth lead (1b) from the air capacity chamber.

	Description	Connector
1b	Earth on engine	C040

2. Unscrew the bolt securing the stiffening rod to the reaction link mount on the engine.3. Undo bolts (3a) and remove air capacity chamber (3b).

1. Disconnect the electrical connections from the right cylinder head injectors.

	Description	Connector
1	Injector	N070A

	Description	Connector
.	Injector	N070B

	Description	Connector
.	Injector	N070F

	Description	Connector
.	Injector	N070D

	Description	Connector
.	Injector	N070E

	Description	Connector
.	Injector	N070C

2. Disconnect the electrical connections from the right cylinder head ignition coils.

	Description	Connector
2	Ignition coil	A030A

	Description	Connector
.	Ignition coil	A030B

	Description	Connector
.	Ignition coil	A030E

	Description	Connector
.	Ignition coil	A030D

	Description	Connector
.	Ignition coil	A030C

	Description	Connector
.	Ignition coil	A030F

3. Undo bolts (3a) and move electrical wiring duct (3b) aside.

1. Undo the bolts (1a) and remove the ignition coils (1b) from the right cylinder head.

1. Undo the nut (1a) and disconnect the earth lead (1b) from the left cylinder head.

	Description	Connector
1b	Earth on engine	C040

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

1. Disconnect the electrical connections from the left cylinder head injectors.

	Description	Connector
1	Injector	N070A

	Description	Connector
.	Injector	N070F

	Description	Connector
.	Injector	N070E

	Description	Connector
.	Injector	N070D

	Description	Connector
.	Injector	N070C

	Description	Connector
.	Injector	N070B

2. Disconnect the electrical connections from the left cylinder head ignition coils.

	Description	Connector
2	Ignition coil	A030A

	Description	Connector
.	Ignition coil	A030F

	Description	Connector
.	Ignition coil	A030E

	Description	Connector
.	Ignition coil	A030D

	Description	Connector
.	Ignition coil	A030C

	Description	Connector
.	Ignition coil	A030B

3. Undo bolts (3a) and move electrical wiring duct (3b) aside.

1. Undo the bolts (1a) and remove the ignition coils (1b) from the left cylinder head.

1. Undo the fixing bolts (1a) and remove the upper protective timing cover (1b).

1. Undo the fixing bolts (1a) and remove the lower protective timing cover (1b).

1. Loosen the bolts retaining the timing belt moving tensioner.2. Prise off the timing drive belt from the toothed driven pullies.

1. Undo the bolts (1a) and bolt (1b) remove bracket (1c).

1. Undo the bolts (1a) and remove the left cylinder head cam cover (1b) complete with gasket.

1. Undo the bolts (1a) and remove the right cylinder head tappet cover (1b) complete with gasket.

1. Loosen the bolts (1a) for the toothed driven pullies, using the tool (1b) for counter-torque.

	Description	Code	Function
1b	Counter-torque	1.822.146.000	Loosen/tighten driven toothed pulley bolts

- Rotate the engine through 180° on the overhaul stand.1. Undo the bolt (1a) and remove the engine components single belt fixed tensioner (1b).

1. Undo the fixing bolts (1a) and remove the rpm sensor shield (1b).2. Remove the rpm sensor complete with mounting.

1. Undo the bolts fixing the engine oil sump.2. Cut the crankcase sump sealant using the tool.

	Description	Code	Function
2	Blade	1.870.718.000	Cut the crankcase sump sealant

3. Remove the crankcase sump.

1. Fit the flywheel lock.

	Description	Code	Function
1	Counter-torque	1.860.779.000	Flywheel lock

1. Undo the nut (1a) and remove the crankshaft pulley (1b).2. Remove the toothed timing belt.3. Remove the toothed drive pulley

1. Undo the bolt fixing the engine oil pump drive chain to the oil pump.2. Move the engine oil pump drive chain (2a) away from the pump using the tool (2b).

	Description	Code	Function
2b	Extractor	1.860.954.001	Extracting engine oil pump drive chain

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

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

1. Undo the bolts (1a) and remove the engine flywheel (1b).

The bolts fixing the flywheel have been treated with a special agent; therefore they should be replaced each time they are removed.

2. Remove the flywheel lock.

	Description	Code	Function
2	Counter-torque	1.860.779.000	Flywheel lock

1. Fit the tool for rotating the crankshaft.

	Description	Code	Function
1	Flange	1.820.618.000	Crankshaft rotation

- Rotate the crankshaft so that the right bearing cap bolts are accessible.2. Undo the bolts (2a) and remove the bearing caps (2b) on the right side.3. Remove the crankpin half-bearings.

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

	Subject	Value
.	Crankshaft	mm
-	Crankshaft endfloat	0.080 ÷ 0.265

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 rear bearing cap (1b) using tools (1c) and (1d).

	Description	Code	Function
1c	Lever	1.821.006.001	Removing rear bearing cap

	Description	Code	Function
1d	Extractor	1.821.006.002	Removing rear bearing cap

2. Remove the main journal half-bearing.

1. Remove the crankshaft rear oil seal

1. Remove the crankshaft.2. Remove the main journal half-bearings.3. Remove the thrust washers.- Remove the crankpin half-bearings.

Refitting ( Removing

) - Wash all the dismantled components thoroughly.- Clean any sealant residues from the matching surfaces between the engine oil sump and the engine block.- Lubricate all the mechanical components with engine oil.- Check that the main journal diameter is within the recommended limits; if not, replace the crankshaft.

	Subject	Value
.	Crankshaft	mm
-	Main journal diameter - Category A	59.973 ÷ 59.979
-	Category B	59.967 ÷ 59.973
-	Category C	59.961 ÷ 59.967

The nitriding treatment that the crankshaft has undergone means that no regrinding operations can be carried out.

- Check that the crank pin diameter is within the recommended limits; if not, replace the crankshaft.

	Subject	Value
.	Crankshaft
-	Crank pin diameter - Grade A	51.990 ÷ 52.000
-	Category B	51.980 ÷ 51.990

The nitriding treatment that the crankshaft has undergone means that no regrinding operations can be carried out.

- Check that the half-bearings show no signs of grooves or traces of seizing; if this is not the case, they must be replaced.

No adjustment operations whatsoever should be carried out to the half-bearings.

- Place the half-bearings in their seats in the engine block.

The half-bearings and the main journals should be matched so that parts of the same grade are used (same distinctive colour).

Great care should be taken over cleanliness when refitting.

1. Place the crankshaft in its housing.2. Fit the calibrated wire (plastigage) for measuring the bearing clearance.

1. Place the bearing cap (1a), complete with half-bearings, back in its housing and secure it tightening the nut (1b) to the recommended torque.

The bearing caps are marked with a progressive number (from one to four starting from the timing side) which defines the fitting position.

The safety references on the cylinder block/crankcase and on the bearing caps should be on the same side.

	Value - daNm	Fastening	Component	Ø
1b	2.4 ÷ 2.6 + 77° ÷ 81°	Nut	MAIN BEARING CAPS	M12

2. Use the tool for the angular tightening of the bearing cap bolts.

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

1. Remove the bearing cap fitted previously and, using a suitable graduated measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).

Measure the clearance for all the bearings taking care to take the measurements one at a time without moving the crankshaft at any time.

	Subject	Value
1b	Crankshaft	mm
-	Main journal/bearing clearance, Grade A	0.000 ÷ 0.024
-	Category B	0.000 ÷ 0.024
-	Category C	0.000 ÷ 0.025

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

- Place the hafl-bearings in their seats.- Place the thrust washers (with the size depending on the crankshaft endfloat measured during the dismantling) in their housings in the rear bearing support.

The thrust washer lubrication ducts should be facing the crankshaft thrust washers.

- Place the hafl-bearings in their seats.- Place the crankshaft complete with the tool for rotating it in its housing.1. Place the bearing caps (1a), complete with half-bearing, back in their housings and secure them tightening the nuts (1b) to the recommended torque.

The bearing caps are marked with a progressive number (from one to four starting from the timing side) which defines the fitting position.

The safety references on the cylinder block/crankcase and on the bearing caps should be on the same side.

	Value - daNm	Fastening	Component	Ø
1b	2.4 ÷ 2.6 + 77° ÷ 81°	Nut	MAIN BEARING CAPS	M12

2. Use the tool for the angular tightening of the bearing cap bolts.

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

1. Fit the crankshaft rear 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	1.821.250.000	Fitting crankshaft rear oil seal

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	Loctite 5900	-	REAR ENGINE SUPPORT SEALING PLANES	Sealant	-

The oil sump should be fitted within 15 minutes of applying the sealant in the openings for sealing the rear bearing support. If this is not the case, remove the excess sealant.

- Rotate the crankshaft so that the connecting rod bearings are accessible.1. Fit the calibrated wire (plastigage) for measuring the bearing clearance.

1. Place the bearing cap (1a) in its seat complete with half-bearings (1b) and secure it by tightening the bolts (1c) to the recommended torque.

The safety references on the connecting rod cap and the big end should be on the same side.

	Value - daNm	Fastening	Component	Ø
1c	1.9 ÷ 2.1 + 48° ÷ 52°	Bolt	CONNECTING ROD CAPS	M9

- Use the 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

1. Remove the bearing cap fitted previously and, using a suitable graduated measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).

Measure the clearance for all the bearings taking care to take the measurements one at a time.

	Subject	Value
1b	Crankshaft	mm
-	-	Main journal/bearing clearance
-	Category A	0.020 ÷ 0.060
-	Category B	0.023 ÷ 0.063

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

- Rotate the crankshaft so that the connecting rod bearings are accessible.1. Place the bearing caps (1a) in their seats complete with half-bearings (1b) and secure them by tightening the bolts (1c) to the recommended torque.

The safety references on the connecting rod cap and the big end should be on the same side.

	Value - daNm	Fastening	Component	Ø
1c	1.9 ÷ 2.1 + 48° ÷ 52°	Bolt	CONNECTING ROD CAPS	M9

- Use the 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

- Remove the tool for rotating the crankshaft.

	Description	Code	Function
.	Flange	1.820.618.000	Crankshaft rotation

1. Position the engine oil pump (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Main bearing caps side) 4.5 - 5.5	Bolt	ENGINE OIL PUMP	M10

1. Position the engine oil pump drive chain in its housing and secure it without tightening the bolt to the recommended torque.2. Place the crankcase front cover (2a), complete with gasket (2b), back in its housing and secure it tightening the bolts (2c) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2c	(Engine crankcase side) 0.8 - 1.0	Bolt	FRONT COVER CRANKSHAFT	M6

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

	Description	Code	Function
1b	Fitting tool	1.860.949.000	Fitting crankshaft front oil seal

- Place the key in the housing in the crankshaft.- Place the toothed drive pulley in its housing.1. Carry out the initial timing of the camshafts. fit a spanner in the housing (1a) in the centre of the camshafts and rotate them until the references (1b) on the shafts are aligned with the references on the cylinder head upper plane.

The references should be facing the centre of each cylinder head

1. Remove caps 4 to 7 from the left cylinder head.2. Remove caps B and G from the right cylinder head.

1. Position the timing templates in place of the camshaft caps removed.

	Description	Code	Function
1	Templates	1.870.849.000	Engine tuning

1. Fit the tool (1a) complete with dial gauge (1b) in the seat for the spark plug for cylinder no. 1.

	Description	Code	Function
1a	Extension	1.821.225.000	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 operation.

1. Fit the toothed timing drive belt starting from the toothed 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 to the alternator bracket using bolt (1b) and to the water pump using bolt (1c).

The tooth for the tool should engage with the moving part of the timing belt tensioner.

	Description	Code	Function
1a	Belt tensioner	1.860.950.000	Toothed timing drive belt tensioner

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

1. Tighten the bolts (1a) fixing the toothed driven pullies to the recommended torque using the tool (1b) for counter-torque.

	Value - daNm	Fastening	Component	Ø
1a	(camshaft side) 7.2 - 8.8	bolt	TIMING DRIVEN PULLIES	M12

	Description	Code	Function
1b	Counter-torque	1.822.146.000	Loosen/tighten driven toothed pulley bolts

- Remove the tools for timing the camshafts.

	Description	Code	Function
.	Templates	1.870.849.000	Engine tuning

- Place the camshaft caps in their housings in place of the tools removed and tighten the bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	(Cylinder head side) 1.8 -2.0	Bolt	CAMSHAFT CAPS	M8

- Rotate the crankshaft through two revolutions in its direction of rotation to allow the toothed timing drive belt to bed in.1. Check that the moving reference for the moving 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 fixing the moving timing tensioner to the recommended torque.

	Value - daNm	Fastening	Component	Ø
3	(Cylinder head side) 1.9 - 2.3	Bolt	MOBILE TIMING TENSIONER	M8

- Remove the belt tensioner tool.

	Description	Code	Function
.	Belt tensioner	1.860.950.000	Toothed timing drive belt tensioner

- Rotate the engine through 180° on the overhaul stand.1. Fit the engine flywheel and secure it without tightening the bolts.

There is only one position for the engine flywheel as the openings for the fixing bolts are not equidistant.

2. Fit the flywheel lock.

	Description	Code	Function
2	Counter-torque	1.860.779.000	Flywheel lock

3. Tighten the new bolts securing the engine flywheel to the recommended torque.

The engine flywheel fixing bolts have been treated with a special agent; therefore they should be replaced each time they are removed.

	Value - daNm	Fastening	Component	Ø
3	(Crankshaft side) 2.9 -3.2 + 48° - 51°	Bolt	FLYWHEEL (MECH.)	M12

- Use the tool for the angular tightening of the flywheel bolts.

	Description	Code	Function
.	Torque wrench	1.860.942.000	Engine flywheel bolts angular tightening

1. Place the engine oil pump drive chain (1a) in position on the oil pump, then tighten the bolt (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Engine oil pump side) 4.5 - 5.5	Bolt	ENGINE OIL PUMP DRIVE CHAIN	M10

2. Position the crankshaft pulley (2a) in its housing and secure it tightening the nut (2b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2b	(Crankshaft side) 22.8 - 25.2	Left nut	CRANKSHAFT PULLEY	M28

- Remove the flywheel lock.

	Description	Code	Function
.	Counter-torque	1.860.779.000	Flywheel lock

- Apply the recommended sealant to the entire perimeter of the crankcase sump.

	Description	Qty.	Component	Type	Classification
.	Loctite 5900	-	OIL SUMP	Sealant	-

1. Position the crankcase sump (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Engine crankcase side) 1.4 - 1.7	Bolt	OIL SUMP	M7

- Place the rpm sensor complete with support in its housing- Place the rpm sensor guard in its housing and secure it using the bolts.1. Position the engine components single belt fixed tensioner (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Crankcase sump side) 2.3 - 2.8	Bolt	SINGLE BELT FIXED TENSIONER VARIOUS	M8

1. Place the cylinder head tappet covers (1a) in their housings complete with seals and secure them tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Cylinder head side) 1.4 - 1.7	Bolt	TAPPET COVERS	M7

- Place the bracket in its housing and secure it using the bolts.- Fit the timing belt lower protective covers and secure them using the bolts.- Fit the timing belt upper protective cover in its housing and secure it using the bolts.1. Place the ignition coils (1a) in their housings in the left cylinder head and secure them tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Cam cover side) 0.8 ÷ 1.0	Bolt	IGNITION COIL/REEL	M6

- Connect the electrical connection for the rpm sensor.- Place the electrical wiring duct in its housing and secure it using the bolts.- Connect the electrical connections to the ignition coils on the right cylinder head.- Connect the electrical connections to the injectors for the right cylinder head.- Place the ignition coil cover on the left cylinder head back in its housing and secure it using the bolts.- Connect the earth lead to the left cylinder head and secure it using the nut.1. Place the ignition coils (1a) in their housings in the right cylinder head and secure them tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Cam cover side) 0.8 ÷ 1.0	Bolt	IGNITION COIL/REEL	M6

- Place the electrical wiring duct in its housing and secure it using the bolts.- Connect the electrical connections to the ignition coils on the right cylinder head.- Connect the electrical connections to the injectors for the right cylinder head.- Place the air intake chamber in its housing and secure it using the bolts.- Tighten the bolt fixing the strengthening strut to the support on the engine for the reaction rod.- Connect the earth lead to the air intake chamber and secure it using the fixing bolt.- Connect the electrical connection to the throttle casing with D.V.L.- Tighten the band securing the engine oil vapour recovery pipe to the air intake chamber.- Tighten the bands securing the intake manifolds to the air chamber.- Connect the electrical connection for the timing side knock sensor.- Close the electrical connections box. See in Op. 1004D40 ENGINE - Position on stand and Remove