1028H34 SET OF CONNECTING RODS WITH PISTONS AND CYLINDER LINERS/BORES - R.R. WITH ENGINE AND CYLINDER HEADS REMOVED - Lancia - THESIS - eLearn

752229 - 1028H34 Set of connecting rods with pistons and cylinder liners/bores - R.R. with engine and cylinder heads removed

) - 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 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 nuts (1a) and remove the crankshaft pulley (1b).2. Remove the toothed timing belt.

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. 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.

- Rotate the engine through 180° on the overhaul stand.1. Remove the cylinder liner/bore lock tools from the right side.

	Description	Code	Function
1	Cylinder bore lock	1.820.279.000	Keep the cylinder liners/bores in their seats

2. Remove the cylinder liner/bore (2), piston and connecting rod assemblies (2b) for the right side.- Separate the connecting rod-piston assemblies from the cylinder liners/bores.3. Remove the crankpin half-bearings.- Carry out the same operations for the removal of the cylinder liner/bore, piston and connecting rod assemblies for the left side.

Refitting ( Removing

) - Fit new seals in the housings in the cylinder liners/bores.1. Fit the cylinder liners/bores (1a) in their housings complete with seals (1b).2. Fit the cylinder liner/bore lock tools (2a) and tighten the nuts to the recommended torque.

	Description	Code	Function
2a	Cylinder bore lock	1.820.279.000	Keep the cylinder liners/bores in their seats

	Value - daNm	Fastening	Component	Ø
2b	2.4 ÷ 2.6 + 228° ÷ 232°	Nut	CYLINDER LINER/BORE LOCK TOOLS	M12

1. Measure the projection of the cylinder liners/bores in relation to the cylinder block/crankcase (1a) plane using the tool (1b) fitted with a dial gauge (1c) and check that it corresponds to the recommended values.

	Subject	Value
1a	Engine block cylinder liners/bores	mm
-	Cylinder liner/bore projection in relation to the cylinder block/crankcase	0.01 ÷ 0.06

	Description	Code	Function
1b	Dial gauge support	1.825.003.000	Measure cylinder liner/bore projection

1. Place the piston/connecting rod assemblies (1a) in their housings in the cylinder liners/bores complete with half-bearings (1b) using a suitable tool (1c).

The piston-connecting rod assemblies should be fitted so that the arrows stamped on the piston crown are facing the timing side.

- Rotate the engine through 180° on the overhaul stand.- Rotate the crankshaft so that the connecting rod pins 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-bearing (1b) and secure it by tightening the bolts (1c) to the recommended torque.

The 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).

Carry out the operation of measuring the clearance for all the bearings, taking care to do it, 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

- Rotate the crankshaft so that the connecting rod pins 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 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 bolt (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. Place the flywheel in position and secure it without tightening the bolts.

The engine flywheel can only be fitted in one position because 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 bolts securing the engine flywheel to the recommended torque.

The bolts fixing the flywheel 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 fixing bolts.

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

1. Fit the engine oil pump drive chain (1a) 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

- Fit the toothed timing drive belt temporarily on the toothed drive pulley.2. Position the crankshaft pulley (2a) in its housing and secure it tightening the nuts (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 mounting 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