1004E20 ENGINE - DISMANTLE AND RE-BUILD FOLLOWING OPERATION 1004E10 - WASH AND CHECK DISMANTLED PARTS - RE-FIT CYLINDER HEAD AND OIL SUMP - DOES NOT INCLUDE REPAIRS TO CYLINDER HEAD AND AUXILIARY UNIT - Alfa - 156 - eLearn

3239063 - 1004E20 engine - dismantle and re-build following operation 1004e10 - wash and check dismantled parts - re-fit cylinder head and oil sump - does not include repairs to cylinder head and auxiliary unit

) Rotate the engine through 180° on the overhauling stand.1. Undo the bolts (1a) and remove the air conditioning compressor (1b).2. Undo the bolts (2a) and remove the timing side rigid power unit support (2b).3. Undo the bolt (3a) and remove the engine components single drive belt automatic tensioner (3b).

1. Undo the bolts (1a) and remove the alternator (1b).2. Undo the bolt (2a) and remove the alternator rear bracket (2b).3. Undo the bolts (3a) and remove the alternator mounting (3b).4. Undo the bolt (4a) and remove the engine components drive belt fixed tensioner (4b).

1. Undo and remove the engine oil filter.2. Remove the water-oil heat exchanger complete with pipes.3. Undo the bolts (3a) and the nuts (3b) and remove the oil filter mounting and intermediate shaft (3c).4. Remove the gasket.

1. Remove the manifold for coolant return to the pump.2. Undo the bolt (2a) and remove the knock sensor (2b).

	Name	Connector
2b	Detonation sensor - 1	k50

	Name	Connector
2b	Knock sensor - 2	k51

3. Undo the bolts (3a) and remove the water pump cover (3b) and bracket (3c).4. Undo the bolts (4a) and remove the water pump drive pulley (4b).

1. Undo the bolts (1a) and remove the water pump (1b).2. Remove the water pump gasket.3. Fit the tool.

	Name	Country
3	Counter-torque	1.820.624.000

4. Undo the nut (4a) and remove the single drive belt (4b).5. Remove the timing drive belt.6. Remove the timing belt drive pulley.

Rotate the engine through 180° on the overhauling stand.1. Undo the bolt fixing the oil pump chain drive to the oil pump.2. Move aside the chain drive from the oil pump using the tool.

	Name	Country
2	Extractor	1.860.954.001

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

1. Undo the bolts (1a) and remove the engine block front cover (1b) complete with gasket (1c) and the crankshaft front oil seal (1d).2. Remove the crankshaft key using a suitable drift.

1. Remove the oil pump drive chain.2. Undo the bolt (2a) and remove the connector (2b) for engine oil delivery to the engine block.

1. Undo the bolts (1a) and remove the engine flywheel (1b).2. Remove the tool.

	Name	Country
2	Counter-torque	1.820.624.000

1. Fit the tool.

	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 nuts (2a) and remove the big end bearing caps (2b) complete with bearing shells (2c) from the right bank.

Rotate the engine through 180° on the overhauling stand.1. Remove the tools from the right bank.

	Name	Country
1	Liner/bore holder	1.820.279.000

2. Remove the cylinder liners (2a), the connecting rod-piston assemblies (2b) and the big end bearings (2c) from the right bank.Separate the connecting rod-piston assemblies from their cylinder liners.Do the same to remove the cylinder liners and connecting rod-piston assemblies of the left bank.Remove the tool.

	Name	Country
-	Flange	1.820.618.000

Rotate the engine through 180° on the overhauling stand.Check that the crankshaft end float is within the recommended values using a magnetic base fitted with a dial gauge.

	Measurement		Value
-	End float (mm)		0.080 - 0.265

1. Undo the nuts (1a) and remove the front and central main bearing caps (1b) using a suitable tool (1c).2. Remove the half-bearings.

1. Undo the nuts (1a) and remove the rear main bearing cap (1b) using the tools (1c) and (1d).

	Name	Country
1c	Lever	1.821.006.001

	Name	Country
1d	Extractor	1.821.006.002

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

1. Remove the crankshaft.2. Remove the crankshaft rear oil seal.3. Remove the half-bearings.4. Remove the thrust washers.5. Remove the piston cooling oil jets from the engine block.

- 1028H60 piston, pin set - replace - 1084B18 engine oil pump, removed - check at benchDrill and remove the water/oil sealing plugs from the crankcase to allow washing.

Reassembling ( Dismantling

) Wash the dismantled components.Fit the water/oil sealing plugs in the crankcase, using suitable fitting tools.Lubricate all the components for the mechanical couplings using engine oil.Check that the planarity of the cylinder head support surface is within the recommended values; if this is not the case, regrind the cylinder head support surface.

	Measurement		Value
-	Flatness of cylinder head supporting surface (mm)		< 0.1

Measure the cylinder liner diameter and check that it is within the specified values. If this is not the case, replace the cylinder liners/bores.

	Measurement		Value
-	Inner diameter (mm)	Category B	87.995 - 88.004
Category C	88.005 - 88.014
Classe A	87.985 - 87.994

Check that the ovality of the cylinder liners is within the recommended values.

	Measurement		Value
-	Ovalization (mm)		< 0.01

1. Fit the main bearing caps (1a) and tighten the nuts (1b) to torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	MAIN BEARING CAPS	M12	(Engine crankcase side) 2.5 + 79°

Use the special tool for the angular tightening of the main bearing cap nuts.

	Name	Country
-	Protractor	1.860.942.000

2. Check that the diameter of the bearing seats is within the recommended values.

	Measurement		Value
2	Main bearing seat diameter (mm)	Category B	63.663 ÷ 63.669
Category C	63.669 ÷ 63.675
Classe A	63.657 ÷ 63.663

Check that the crankshaft lubrication ducts are free from deposits.Check that the diameter of the main journals is within the recommended values; if this is not the case, replace the crankshaft.

	Measurement		Value
-	Main bearing journal diameter (mm)	Category B	59.967 ÷ 59.973
Category C	59.961 ÷ 59.967
Classe A	59.973 ÷ 59.979

Check that the diameter of the crankpins is within the recommended values; if this is not the case, replace the crankshaft.

	Measurement		Value
-	Crankpin diameter (mm)	Category B	51.980 ÷ 51.990
Classe A	51.990 ÷ 52.000

Check that the inner diameter of the small end bushes is within the recommended limits; if this is not the case, replace the connecting rod.

	Measurement		Value
-	Inner diameter (mm)		20.005 - 20.015

Check that the outer diameter of the gudgeon pins is within the recommended values; if this is not the case, replace the worn gudgeon pins.

	Measurement		Value
-	Outer diameter (mm)	Category B	21.997 - 22.000
Classe A	21.994 - 21.997

Fit the seals in the cylinder liner/bore and check that the opening between the ends is within the recommended values; if this is not the case, replace the piston seals.

	Measurement		Value
-	1° sealing ring gap (mm)		0.40 - 0.65

	Measurement		Value
-	2° sealing ring gap (mm)		0.40 - 0.65

	Measurement		Value
-	Scraper ring gap (mm)		0.40 - 0.60

Check that the outer diameter of the pistons is within the recommended values. if this is not the case, replace the piston complete with seals and gudgeon pin.

	Measurement		Value
-	Outer diameter (mm)	Category B	87.935 - 87.945
Category C	87.945 - 87.955
Classe A	87.925 - 87.935

Check that the endfloat between compression rings and their seats is within the specified values.

	Measurement		Value
-	1st° sealing ring end float (mm)		0.035 - 0.070

	Measurement		Value
-	2° sealing ring end float (mm)		0.035 - 0.070

	Measurement		Value
-	Oil scraper ring end float (mm)		0.025 - 0.060

1. Fit the caps (1b) on the connecting rods (1a) and fix them tightening the bolts (1c) to torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	BIG END BEARING CAPS	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

2. Check that the diameter of the big end is within the recommended values; if this is not the case, replace the connecting rods.

	Measurement		Value
-	Big end diameter (mm)		55.511 - 55.524

- 1084B18 engine oil pump, removed - check at bench - 1028H60 piston, pin set - replaceCheck that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it.Fit the piston cooling oil jets in the engine block.Fit the thrust washers on the rear bearing support.

The lubrication ducts in the thrust washers are fitted facing the crankshaft shoulder.Fit the main journal half-bearings in the cylinder block/crankcase.Fit the crankshaft on the cylinder block/crankcase.Thoroughly remove the sealant residues from the rear bearing cap seat, the small holes and the contact surfaces with the oil sump (only for car after engine no. 00709).Thoroughly remove all traces of engine oil using heptane or a similar solvent.Fit the main journal caps complete with half-bearings.

The main journal caps are numbered from 1 to 4 starting from the front of the engine.

Tighten the nuts for the bearing caps to the recommended torque using the special angular tightening tool.

	Fastening	Component	Ø	Value(daNm)
-	Nut	MAIN BEARING CAPS	M12	(Engine crankcase side) 2.5 + 79°

	Name	Country
-	Protractor	1.860.942.000

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

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

	Name	Country
1b	Fitting tool	1.821.150.000

1. Apply the recommended sealant (1a) through holes (1b).

	Type	Component	Name	Qty.
-	Sealant	ENGINE REAR MOUNT GASKETS	LOCTITE 5900	-

Check that the sealant emerges from the whole length of the contact area (1c) between the cap and the engine block and, (only for cars from engine no. 00709, from the holes (1d).

The oil sump should be fitted within 15 minutes of applying the sealant in the openings for the crankshaft rear support. If this is not the case, remove the edges of the sealant.Rotate the engine through 180° on the overhauling stand.1. Fit the cylinder liners (1a) complete with compression rings (1b) in the engine block and lock them with tool (1c) tightening the nuts (1d) to a torque of 1.0 - 1.5 daNm.

	Name	Country
1c	Liner/bore holder	1.820.279.000

1. Measure the cylinder liner projection from the engine block surface using tool (1a) fitted with a dial gauge (1b) and check that it is within the specified values.

	Measurement		Value
1	Projection from cylinder block surface (mm)		0.01 - 0.06

	Name	Country
1a	Dial gauge mounting	1.825.003.000

1. Fit the connecting rod-piston assemblies (1a) complete with bearing shells (1b) in the cylinder liners, using a suitable tool (1c).

The pistons are fitted with the arrow stamped on the crown facing the front of the engine.

Rotate the cylinder block 180° on the overhaul stand.1. Fit the tool.

	Name	Country
1	Flange	1.860.815.000

2. Rotate the crankshaft as appropriate and fit the big end bearing caps (2a) complete with bearing shells (2b) and tighten the bolts (2c) to torque.

The big end bearing caps have the number of the cylinder to which they belong on one side: when refitting, this number should be on the same side as the one on the small end.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	BIG END BEARING CAPS	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

Remove the tool.

	Name	Country
2c	Flange	1.860.815.000

Rotate the engine through 180° on the overhauling stand.1. Fit the flywheel and fix it using its bolts, without tightening them.2. Fit the tool.

	Name	Country
2	Counter-torque	1.820.624.000

3. Tighten the flywheel bolts to torque.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	FLYWHEEL	M10	11.6 ÷ 12.9

Remove the tool.

	Name	Country
-	Counter-torque	1.820.624.000

Rotate the engine through 180° on the overhauling stand.Fit the connector for engine oil delivery to the engine block, and tighten its bolt.Fit the oil pump drive chain.Fit the crankshaft key.Fit the engine block front cover complete with gasket and fix it using the bolts.Fit the complete oil pump and fix it using the bolts.Tighten the bolt on the oil pump chain drive to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ENGINE OIL PUMP DRIVE CHAIN	M10	4.3 ÷ 5.3

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