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 crankcase through 180° on the overhauling stand.1. Disconnect the power assisted steering pump supply pipe.2. Remove the power assisted steering fluid reservoir, complete with pipe.

1. Undo the bolts (1a) and remove the alternator (1b).

1. Slacken the counter-balance shaft belt tensioner nut.2. Remove the counter-balance shaft belt.3. Remove the timing drive belt.4. Undo the bolts (4a) and remove the power steering pump mounting and intermediate shaft (4b) complete with power steering pump (4c) and engine components drive belt automatic tensioner (4d).

1. Undo the bolts (1a) and remove the power unit rigid support, timing gear side (1b).2. Undo the bolts (2a) and remove the mounting (2b) complete with timing belt tensioner (2c) and guide pulley (2d).3. Undo the bolts (3a) and remove the counter-balance shaft belt pulley (3b).

1. Fit the tool.

	Name	Country
1	Counter-torque	1.820.624.000

2. Undo the bolt (2a) (left-hand) and remove the timing belt pulley (2b).3. Undo the bolts (3a) and remove the flywheel (3b).

1. Remove the tool.

	Name	Country
1	Counter-torque	1.820.624.000

2. Fit the tool.

	Name	Country
2	Flange	1.820.618.000

1. Undo the bolts (1a) and remove the oil pump (1b) complete with water-oil heat exchanger (1c), oil filter (1d) and intake duct (1e).2. Remove the gasket.3. Undo the bolts (3a) and remove the detonation sensors (3b).

	Name	Connector
3b	Detonation sensor - 1	K50

4. Remove the engine oil pressure switch.

	Name	Connector
4	Engine oil pressure sensor	K30

5. Undo the bolt (5a) and remove the engine rpm and timing sensor (5b).

	Name	Connector
5b	Rpm sensor	K46

6. Undo the bolts (6a) and remove the exhaust manifold mounting brackets (6b).

Place the oil pump complete with water-oil heat exchanger, oil filter and intake duct in a vice fitted with protective jaws.1. Undo the bolts (1a) and remove the intake duct (1b).2. Remove the gasket.3. Remove the oil filter.4. Undo the bolts (4a) and remove the heat exchanger (4b) complete with pipes.5. Remove the gasket.

Rotate the crankcase 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)		0.059 - 0.221

If the end float of the crankshaft is not within the recommended values, when refitting, reface the seat in the cylinder block and use suitable oversize thrust washers.Rotate the crankshaft using the tool fitted previously until the pistons of cylinders no. 1 and no. 4 are at B.D.C.1. Undo the bolts (1a) and remove the connecting rod caps (1b) and bearing shells (1c) of cylinders no. 1 and no. 4.2. Remove the connecting rod-piston assemblies (2a) complete with bearing shell (2b) of cylinders no. 1 and no. 4.Do the same to remove the connecting rod-piston assemblies of cylinders no. 2 and no. 3.3. Remove the tool.

	Name	Country
3	Flange	1.820.618.000

4. Undo the bolts (4a) and remove the cylinder block rear cover with integrated oil seal (4b).

1. Undo the bolts (1a) and remove the main bearing caps (1b) complete with bearing shells (1c).2. Remove the crankshaft.3. Remove the main bearing shells.4. Remove the thrust washers.5. Undo the bolt and remove the engne oil jets (5b) from the cylinder block/crankase.

Undo the attachments and remove the cylinder block from the overhaul stand and place it on a suitable work bench.1. Undo the bolts (1a) and remove the flywheel guard (1b).

1. Undo the bolts (1a) on the counter-balance shaft pulleys using the tool (1b) for counter-torque.

	Name	Country
1b	Counter-torque	1.820.286.000

2. Remove the counter-balance shaft pulleys.3. Undo the bolts (3a) and remove the inlet side counter-balance shaft front cover (3b) complete with oil seal and O-ring.4. Undo the bolts (4a) and remove the exhaust side counter-balance shaft front cover complete with oil seal, O-ring and counter-balance shafts drive belt tensioner.5. Completely undo the nut (5a) and remove the counter-balance shafts belt tensioner (5b).

Remove the O-rings and oil seals from the counter-balance shafts front covers.1. Remove the spacers (1a) and O-rings (1b) from the counter-balance shafts.2. Remove the counter-balance shaft rear plugs.3. Remove the counter-balance shafts (3a) complete with rear bearings (3b) using a suitable drift (3c).

1. Remove the counter-balance shafts front bearings (1a) from the cylinder block using the tools (1b) and (1c).

	Name	Country
1b	Extractor	1.820.626.000

	Name	Country
1c	Counter weight	1.840.206.001

Position the counter-balance shaft in a vice fitted with protective jaws.1. Remove the circlip retaining the rear bearing to the counter-balance shaft.2. Remove the counter-balance shaft rear bearing (2a) using a suitable drift (2b).

- 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 there are no superficial cracks or grooves in the cylinder head support surface. 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.

	Measurement		Value
-	Cylinder bore diameter (mm)	Category B	83.010 - 83.020
Category C	83.020 - 83.030
Classe A	83.000 - 83.010

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

	Measurement		Value
-	Cylinder bore taper (mm)		< 0.010

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

	Measurement		Value
-	Cylinder bore ovalization (mm)		< 0.005

If the diameter of the cylinder liners/bores is not within the recommended values, ream the cylinder liners in accordance with the recommended oversizes.

If reboring is required, all the cylinder liners must be rebored to the same oversize.

	Measurement		Value
-	Cylinder liner oversize (mm)		0.1

1. Fit the bearing caps.

The bearing caps have progressive references (from zero to four starting from the front of the engine) which define their fitting position.

2. Tighten the main bearing cap bolts to torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	MAIN BEARING CAPS	M12	2.4 ÷ 2.6 + 100?

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

	Name	Country
-	Protractor	1.860.942.000

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

	Measurement		Value
-	Main bearing seat diameter (mm)		56.705 - 56.718

Check that the crankshaft lubrication ducts are free from deposits.Check that the diameter of the main journals is within the recommended values.

	Measurement		Value
-	Main bearing journal diameter (mm)	Category B	52.988 ÷ 52.994
Category C	52.982 ÷ 52.988
Classe A	52.994 ÷ 53.000

If the diameter of the main bearing journals is not within the recommended values, regrind them in accordance with the recommended undersize.

	Measurement		Value
-	Main bearing journal undersize (mm)		0.127

Undersizes for crankpins above the value mentioned adversely affect the structural resistance of the crankshaft (as a result of contact between the tool and the rolled connectors). As far as the above is concerned, if the regrinding requires undersizes above 0.127 mm, the crankshaft must be replaced with a new one ordered from the Parts Dept. The half-bearings used for undersizes above 0.127 mm should no longer be requested from the Parts Dept. (even if the number is still shown).

Check that the crankpin diameter is within the specified values.

	Measurement		Value
-	Crankpin diameter (mm)	Category B	50.793 ÷ 50.799
Category C	50.787 ÷ 50.793
Classe A	50.799 ÷ 50.805

If the diameter of the crankpins is not within the recommended values, regrind them in accordance with the recommended undersize.

	Measurement		Value
-	Crankpin undersize (mm)		0.127

Undersizes for bearings above the value mentioned adversely affect the structural resistance of the crankshaft (as a result of contact between the tool and the connectors). As far as the above is concerned, if the regrinding requires undersizes above 0.127 mm, the crankshaft must be replaced with a new one ordered from the Parts Dept. The half-bearings used for undersizes above 0.127 mm should no longer be requested from the Parts Dept. (even if the number is still shown).

Check that the inner diameter of the small end bushes is within the recommended limits; if this is not the case, replace the worn small end bush (refer to op. 1028H58 connecting rod small end bush - replace ).

	Measurement		Value
-	Inner diameter (mm)		20.006 - 20.012

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)		19.996 - 20.000

Fit the sealing rings in the cylinder liner/bore and check that the end gap is within the recommended values; if this is not the case, replace the piston sealing rings.

	Measurement		Value
-	1° sealing ring gap (mm)		0.25 - 0.50

From September 2003 sealing rings with modified profiles are used; the gap of the 1st ring becomes 0.20 0.35 mm.

	Measurement		Value
-	2° sealing ring gap (mm)		0.30 - 0.50

	Measurement		Value
-	Scraper ring gap (mm)		0.25 - 0.45

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
-	Outer diameter (mm) (**)	Category B	82.959 - 82.971
Category C	82.969 - 82.978
Classe A	82.952 - 82.962

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

	Measurement		Value
-	1st° sealing ring end float (mm)		0.030 - 0.070

	Measurement		Value
-	2° sealing ring end float (mm)		0.020 . 0.055

	Measurement		Value
-	Oil scraper ring end float (mm)		0.020 - 0.055

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	2.4 ÷ 2.6 +60?

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)		53.897 - 53.909

- 1028H60 piston, pin set - replace - 1084B18 engine oil pump, removed - check at benchCheck that there are no signs of seizing on the flywheel ring gear teeth; if this is not the case, replace it.Place the counter-balance shafts in a vice fitted with protective jaws.1. Fit the rear bearings (1a) on the counter-balance shafts using a suitable fitting tool (1b). Fix the rear bearings to the counter-balance shafts using the circlips.

1. Fit the counter-balance shaft front bearings (1a) on the cylinder block using the tool (1b).

	Name	Country
1b	Fitting tool	1.821.247.000

1. Fit the counter-balance shafts (1a) complete with rear bearings (1b) in the cylinder block using the tool (1c).

	Name	Country
1b	Fitting tool	1.821.247.000

Fit new O-rings and spacers on the counter-balance shafts.Fit the counter-balance shafts rear plugs.Fit new O-rings on the counter-balance shaft front covers.1. Fit new oil seals (1a) on the counter-balance shaft front covers using the tool (1b).

	Name	Country
1b	Fitting tool	1.821.247.000

2. Fit the counter-balance shaft front covers (2a) and tighten the bolts (2b) to torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	COUNTER ROTATING SHAFT FRONT COVER	M6	0.6 - 0.7

3. Fit the counter-balance shaft drive belt tensioner (3a) and fix it using the nut (3b) without tightening it.4. Fit the counter-balance shaft drive pullies (4a) and fix them with the bolts (4b) using the tool (4c) for counter-torque.

	Name	Country
4c	Counter-torque	1.820.286.000

Fit the flywheel guard and fix it to the cylinder block using the bolts.Mount the cylinder block on the overhaul stand.Fit the oil jets in the cylinder block and fix them using the bolts.Fit the thrust washers on the third main bearing.Starting from engine number 02030116, main journal half-bearings have been fitted on crankshafts which have been selected so that the matching clearance is optimum.

The crankshaft is supplied, by the Parts Dept., without the appropriate half-bearings for 'normal' dimension main journals and crank pins; it is therefore necessary to select the main journal half-bearings to be fitted identifying the grade for each main journal and crank pin for the new crankshaft.

The following is needed for selecting the main journal half-bearings: the code number stamped on the flywheel;the paint mark, if present, next to the main journals.Below is an example of the identification of main journal grades.

1. Crank pin identification number: the number on the left refers to the first timing side bearing; the final 'N' is a code that does not matter for 4 cylinder engines; for 5 cylinder engines the numerical code for the 5th crank pin is found in place of the 'N'.2. Main journal identification code: the first number on the left refers to the first timing side bearing; the final 'N' is a code that does not matter for 4 cylinder engines; for 5 cylinder engines the numerical code for the 6th main journal is found in place of the 'N'.3. Set of numbers (if present), in groups of two digits, which indicate the dimensions (thousandth part) of the main journals: the first two numbers on the left refer to the first bearing on the timing side.

Only use the codes in the key, all other codes on the flywheel should not be used.

For the identification of the main journal grade, refer to the numerical code for reference 2. In the case of the example, the numbers 11111N indicate that all five bearings are Grade A (red colour) as described below. A further method for identifying the grade of the bearings is to read reference 3 in the figure (if present). In the case of the example, the number 94 (first on the left) corresponds to the dimension 52.994 for the first bearing on the timing side which identifies Grade A (red colour); the same method can be used for all the other groups of two digits for the same reference 3 (97 - 95 - 95 - 94). Grade A bearing - Normal, diameter 52.994 - 53.000 mm, RED paint mark, code number 1 (94 00)°Grade B bearing - Normal, diameter 52.988 - 52.994 mm, BLUE paint mark, code number 2 (88 94)°Grade C bearing - Normal, diameter 52.982 - 52.988 mm, YELLOW paint mark, code number 3 (82 88)°Grade D bearing - Undersize, diameter 52.867- 52.873 (*) mm, BROWN paint mark, code number 6 (67 73)°Grade E bearing - Undersize, diameter 52.861 - 52.867 (*) mm, GREEN paint mark, code 7 (61 67)°Grade F bearing - Undersize, diameter 52.855 - 52.861 (*) mm, BLACK paint mark, code number 8 (55 61)° (*) 0.127 mm undersize (°) Last two numbers (thousandth part) of the dimensions of the main journalsIf a crankshaft is being used where the maximum bearing undersize through regrinding is 0.127 mm, then the grade should be selected by measuring the dimensions of the diameter of the bearing with reference to the above. Having defined the grade and colour for each new or reground crankshaft bearing, it is necessary to select the pair and the size for the bearings which should be the same colour as the corresponding bearing; at the Parts Dept. it is possible to go back to the part no. of the pair of half-bearings required. The above is designed to ensure the optimum operating clearance for all bearings. Lastly, we wish to point out that, generally, the clearance between the main journal and the half-bearing, obtained using the selection method indicated, should be between the following values: Minimum: 0.025 mm - Maximum: 0.052 mm; this value can be measured, as a final check, using the Plastic Gauge. 1. Fit the main bearing shells.2. Fit the crankshaft on the cylinder block/crankcase.3. Fit the main bearing caps (3a) complete with bearing shells (3b).