1028H34 PISTON/CYLINDER LINER SET - R R - Alfa - 147 - eLearn

3026013 - 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. Use the tool to cut the crankcase sump sealant.

	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. 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. 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.

Refitting ( Removing

) 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. 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 crankpins.1. Fit the calibrated wire (Plastigage) to measure the big end bearing 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 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

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)
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 power assisted steering 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 by tightening the bolts to the recommended torque.

The engine flyhwheel may only be refitted in one position because the retaining bolt holes are not equidistant.

2. Fit the flywheel lock.

	Name	Country
2	Counter-torque	1.860.779.000

3. Tighten the engine flywheel retaining bolts to the specified torque.

The engine flywheel retaining bolts are treated with a compound to prevent them coming undone they should therefore be replaced whenever they are removed.

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

Use the tool for angular tightening of the engine flywheelbolts.

	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 secure 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 fix 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

Refit the rpm sensor and mount.Replace the rear wheel rpm sensor in its housing and fix it using the bolts.1. Place the engine components single drive belt fixed tensioner (1a) back in its housing and fix it tightening the bolt (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