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

Dismantling ( Reassembling

) 1. Withdraw and remove the water pump rigid inlet pipe.

1. Undo the bolts (1a) and remove the water pump cover (1b) and gasket (1c).2. Remove the bracket.

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

1. Undo the bolts (1a) and remove the detonation sensors (1b).

1. Undo the nuts (1a) and remove the air conditioning compresor mounting (1b).2. Undo the bolt (2a) and remove the single drive belt tensioner (2b).

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.3. Remove the toothed drive pulley.

Rotate the engine throughi 180° on the overhauling stand.1. Unscrew the bolt securing the engine oil pump drive chain to the oil pump.2. Move the engine oil pump drive chain (2a) away from the pump using tool (2b).

	Name	Country
2b	Extractor	1.860.954.001

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

1. Remove the crankshaft key using a suitable drift.2. Undo the bolts (2a) and remove the crankcase front cover (2b).Remove the crankshaft front oil seal from the crankcase front cover.3. Remove the gasket.

1. Remove the engine 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).

The engine flywheel retaining bolts are treated with a compound to prevent them coming undone they should therefore be replaced whenever 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 liner retaining tools from the right bank.

	Name	Country
1	Liner/bore holder	1.820.279.000

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

Remove the tool for rotating the crankshaft.

	Name	Country
-	Flange	1.820.618.000

Rotate the engine throughi 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).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 half-bearing.

1. Remove the crankshaft rear oil seal.

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

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

Reassembling ( Dismantling

) Wash all the dismantled components carefully.Clean any residues of sealant from the matching surfaces of the engine oil sump and the rear bearing cap with the engine block.Place the water/oil sealing plugs back in their housings 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 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

Remove the seals from the cylinder liners/bores.Check that the inner diameter of the cylinder liners/bores is within the recommended values. if this is not the case, replace them.

	Measurement		Value
-	Cylinder liner/bore inner diameter (mm)	Category B	92.995 ÷ 93.004
Category A	92.985 ÷ 92.994
Category C	93.005 ÷ 93.014

Check that the ovality of the cylinder liners is within the recommended values. if this is not the case, replace them.

	Measurement		Value
-	Maximum permitted cylinder liner/bore ovality, X - Y (mm)		< 0.01

Remove the lubrication duct plugs in the crankshaft using a suitable drift, then remove any residues.Clean the lubrication ducts thoroughly using hot petroleum, then dry them with a compressed air jet.Apply sealant (LOCTITE 270 GREEN) to the new plugs, then place them in the housings in the crankshaft using a suitable fitting tool and bevel them.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

The nitriding treatment applied to the crankshaft does not allow grinding operations to be carried out.

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

The nitriding treatment applied to the crankshaft does not allow grinding operations to be carried out.

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 assemblies.

	Measurement		Value
-	Small end bushes inner diameter (reaming) (mm)		20.005 ÷ 20.015

Check the matching between the gudgeon pin and the housing in the piston: it should be possible to insert the gudgeon pin using slight pressure and it should not slip out.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
-	Gudgeon pin outer diameter (mm)		19.996 ÷ 22.000

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 seals.

	Measurement		Value
-	Piston ring gap (mm)	1° ring	0.30 ÷ 0.50
2° seal	0.40 ÷ 0.60

	Measurement		Value
-	Piston oil scraper ring gap (mm)	Oil scraper ring	0.20 ÷ 0.40

1. If necessary, reface the ends of the piston rings using a suitable tool.

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

	Measurement		Value
-	Piston outer diameter (mm)	Category B	92.915 ÷ 92.925
Category A	92.905 ÷ 92.915
Category C	92.925 ÷ 92.935

The measurement should be made perpendicular to the gudgeon pin axis, 13.1 mm from the skirt lower edge.

Check that the end float between the seals and the piston ring grooves is within the recommended limits. if this is not the case, replace the seals.

	Measurement		Value
-	Seal end float (mm)	1° ring	0.035 ÷ 0.070
2° seal	0.030 ÷ 0.075

	Measurement		Value
-	Piston oil scraper ring end float (mm)	Oil scraper ring	0.020 ÷ 0.065

Check that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it. Proceed with refitting - 1084B18 engine oil pump, removed - check at bench . Proceed with refitting - 1028H60 piston, pin set - replace . Check that the main bearing halves are not scored and that they do not show traces of binding. if this is not the case, replace them.

The bearing halves must not be adapted in any way.

Place the half-bearings back in their housings in the cylinder block/crankcase.

Main bearing halves and main journals must be matched by combining parts of the same dimension category (same identification colour).

Observe scrupulous cleanliness during assembly.

1. Place the crankshaft back in its housing.2. Fit the calibrated wire (Plastigage) to measure the main journal clearance.

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

Main bearing caps are numbered progressively (from one to four from the camshaft end) to determine their assembly position.

The safety notches on the crankcase and main bearing caps must all be on the same side.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	MAIN BEARING CAPS	M12	2.4 ÷ 2.6 + 77? ÷ 81?

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

	Name	Country
2	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 carry out this operation, one bearing at a time, without ever moving the crankshaft.

	Measurement		Value
1b	Main journal-bearing clearance (mm)	Category B	0.000 ÷ 0.024
Category A	0.000 ÷ 0.024
Category C	0.000 ÷ 0.025

If the readings are not within the specified range, replace the main bearing halves with new bearing halves of appropriate size and category.

Refit the main bearing halves.Refit the thrust ring halves (thickness dependent on crankshaft end float measured upon dismantling) in their seats on the rear engine block.

The lubrication ducts in the thrust washers are fitted facing the crankshaft shoulder.

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

Main bearing caps are numbered progressively (from one to four from the camshaft end) to determine their assembly position.

The safety notches on the crankcase and main bearing caps must all be on the same side.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	BIG END BEARING CAPS	M12	2.4 ÷ 2.6 + 77? ÷ 81?

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

	Name	Country
2	Protractor	1.860.942.000

1. Refit a new rear crankshaft front cover 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	1.821.250.000

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

	Type	Component	Name	Qty.
1a	Sealant	ENGINE REAR MOUNT GASKETS	LOCTITE 5900	-

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 edge of the sealant.

Rotate the engine throughi 180° on the overhauling stand.Refit new seals in their seats on the cylinder liners.1. Place the cylinder liners complete with seals (1b) back in their housings.2. Fit the cylinder liner retaining tools (2a) and tighten the nuts (2b) to the specified 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 in relation to the 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. Place the piston-connecting rod assemblies (1a), complete with half-bearings (1b) back in the cylinder liners/bores using a suitable tool (1c).

The piston-connecting rod assemblies should be fitted so that the arrows on the piston crown are facing the timing side and the marking on the connecting rod is facing the timing side on the right side and the flywheel side on the left side.

Rotate the engine throughi 180° on the overhauling stand.Fit the tool for rotating the crankshaft.

	Name	Country
-	Flange	1.820.618.000

Turn the crankshaft to gain access to the crankpins.1. Fit the calibrated wire (Plastigage) to measure the big end bearing clearance.

1. Fit the connecting rod caps (1a), complete with half-bearings (1b), and fix them tightening the bolts (1c) to the recommended torque.

The safety notches on the connecting rod cap and connecting rod head must 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 big end 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 without ever moving the crankshaft.

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

If the value measured does not correspond to the recommended figures, replace the connecting rod half bearings with new ones of appropriate size and category.

Turn the crankshaft to gain access to the crankpins.1. Refit the connecting rod caps (1a), complete with half-bearings (1b), and fix them tightening the bolts (1c) to the recommended torque.

The safety notches on the connecting rod cap and connecting rod head must be on the same side.

	Fastening	Component	Ø	Value(daNm)