1028H34 PISTON/CYLINDER LINER SET - R R - Alfa - 156 - eLearn

3239076 - 1028h34 piston/cylinder liner set - r r

) Rotate the engine throughi 180° on the overhauling stand.1. Undo the bolt (1a) and remove the fixed single drive belt tensioner (1b).

1. Undo the bolts (1a) and remove the rpm sensor protection (1b).2. Remove the rpm sensor complete with support.

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

	Name	Country
2	Blade	1.870.718.000

3. Remove the crankcase sump.

1. Fit the flywheel lock.

	Name	Country
1	Counter-torque	1.860.779.000

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

	Name	Country
2b	Extractor	1.860.954.001

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

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

The engine flywheel bolts have been treated with an unscrewing prevention material; therefore they should be replaced each time they are removed.

2. Remove the flywheel lock.

	Name	Country
2	Counter-torque	1.860.779.000

1. Fit the tool for rotating the crankshaft.

	Name	Country
1	Flange	1.820.618.000

Turn the crankshaft to gain access to the big end bearing cap bolts on the right bank.2. Undo the bolts (2a) and remove the right big end bearing caps (2b).3. Remove the big end bearing shells.

Rotate the engine throughi 180° on the overhauling stand.1. Remove the right bank bore/liner locks.

	Name	Country
1	Liner/bore holder	1.820.279.000

2. Remove the cylinder liner/bore (2a), pistong and connecting rod (2b) assemblies for the right side.Separate the piston/connecting rod assemblies from the cylinder liners/bores.3. Remove the big end bearing shells.Do the same to remove the cylinder liner/bore, piston and connecting rod assemblies on the left side.

Refitting ( Removing

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

	Name	Country
2a	Liner/bore holder	1.820.279.000

	Fastening	Component	Ø	Value(daNm)
2b	Nut	LINER/BORE LOCK TOOLS	M12	2.4 ÷ 2.6 + 228? ÷ 232?

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 is within the recommended limits.

	Measurement		Value
1a	Cylinder bore/liner projection from crankcase plane (mm)		0.01 ÷ 0.06

	Name	Country
1b	Dial gauge mounting	1.825.003.000

1. Refit the piston-connecting rod assemblies (1a) in their seats in the cylinder liners complete with bearing halves (1b) using a suitable tool (1c).

Fit the piston-connecting rod assemblies so that the arrows stamped on the piston crowns face the camshaft end.

Rotate the engine through 180° on the overhauling stand.Turn the crankshaft to gain access to the big end bearing caps.1. Fit the calibrated wire (Plastigage) to measure the crankpin clearance.

1. Refit the connecting rod cap (1a) complete with half-bearing (1b) and fix it tightening the bolts (1c) to the recommended torque.

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

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	Connecting rod cap	M9	1.9 ÷ 2.1 + 48? ÷ 52?

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

	Name	Country
-	Protractor	1.860.942.000

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

Measure the clearance at all the bearings, taking care to do it one bearing at a time.

	Measurement		Value
1b	Main journals/bearing clearance (mm)	Category B	0.023 ÷ 0.063
Category A	0.020 ÷ 0.060

Turn the crankshaft to gain access to the big end bearing caps.1. Place the connecting rod cap (1a), complete with half-bearings (1b), back in its housing and tighten the bolts (1c) to the recommended torque.

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

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	Connecting rod cap	M9	1.9 ÷ 2.1 + 48? ÷ 52?

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

	Name	Country
-	Protractor	1.860.942.000

Remove the tool for rotating the crankshaft.

	Name	Country
-	Flange	1.820.618.000

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

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	ENGINE OIL PUMP	M10	(Main journal cap side) 4.5 ÷ 5.5

1. Refit the engine flywheel in its housing and secure it without tightening the bolts.

The flywheel can only be fitted in one position as the openings for the fixing bolts are not equidistant.

2. Fit the flywheel lock.

	Name	Country
2	Counter-torque	1.860.779.000

3. Tighten the engine flywheel fixing bolts to the recommended torque.

The engine flywheel bolts have been treated with an unscrewing prevention material; therefore they should be replaced each time they are removed.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	FLYWHEEL	M12	(Crankshaft side) 2.9 ÷ 3.2 + 48? ÷ 51?

Use the tool for the angular tightening on the flywheel bolts.

	Name	Country
-	Protractor	1.860.942.000

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

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

Position the toothed timing belt provisionally on the toothed drive pulley.2. Place the crankshaft pulley (2a) back in its housing and ecure it tightening the nut (2b) to the recommended torque.

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

Remove the flywheel lock.

	Name	Country
-	Counter-torque	1.860.779.000

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

	Type	Component	Name	Qty.
-	Sealant	OIL SUMP	LOCTITE 5900	-

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

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

Place the rpm sensor, complete with support, back in its housing.Place the rpm sensor protection back in its housing and secure it using the bolts.1. Place the engine components single drive belt fixed tensioner (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

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