1004E20 ENGINE - DISMANTLE AND REASSEMBLE FOLLOWING OPERATION 1004E10 - WASH AND CHECK DISMANTLED PARTS - REFIT CYLINDER HEAD AND OIL SUMP - DOES NOT INCLUDE REPAIRS TO CYLINDER HEAD AND AUXILIARY UNIT - Alfa - 159 - eLearn

939010401 - 1004E20 ENGINE - DISMANTLE AND REASSEMBLE FOLLOWING OPERATION 1004E10 - WASH AND CHECK DISMANTLED PARTS - REFIT CYLINDER HEAD AND OIL SUMP - DOES NOT INCLUDE REPAIRS TO CYLINDER HEAD AND AUXILIARY UNIT

Removing ( Refitting

) 1. Remove the toothed drive pulley

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

1. Undo the bolt (1a) and remove the detonation sensor (1b).

1. Undo the bolt (1a) and remove the rpm sensor (1b).

- Undo the bolts and remove the connector holder bracket.1. Undo the bolts (1a) and remove the engine oil filter mounting (1b) complete with heat exchanger.

- Place the engine oil filter mounting complete with heat exchanger in a vice fitted with protective jaws.1. Undo the bolts and remove the water-oil heat exchanger (1a) from the engine oil filter mounting (1b).- Remove the gaskets.

1. Undo the plug (1a) and remove the oil filter cartridge (1b).

1. Undo the bolts (1a) and remove the rigid return pipe (1b) to the water pump complete with O-ring.2. Undo the bolts (2a) and remove the air conditioner compressor (2b).3. Undo and remove the engine oil pressure warning light switch.

1. Undo the bolt (1a) and remove moving tensioner (1b).2. Undo the bolt (2a) and remove fixed tensioner (2b).3. Undo the bolts (3a) and remove the crankshaft oil seal front cover (3b).- Remove the gasket.

- Place the crankshaft oil seal cover assembly in a vice fitted with protective jaws.1. Undo the bolts (1a) and remove the water pump pulley (1b).2. Undo the bolts (2a) and remove the cover (2b) complete with water pump impeller.- Remove the gasket from the water pump cover.- Remove the centering pins.

Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH - Rotate the crankshaft using the tool fitted previously until the piston concerned is at B.D.C.- Mark the connecting rod cap and the connecting rod to be removed.1. Undo the bolts (1a) and remove the connecting rod caps (1b) and lower half-bearings.2. Remove the pistons complete with connecting rods and upper half-bearings.

The arrow (a) on the piston crown facing the timing side indicates the fitting direction. The connecting rod-cap matching is the "BREAK" with a compulsory position. The projection (b) on the connecting rod and the cap should be facing the flywheel with the arrow on the crown pointing towards the timing side to ensure the correct piston-connecting rod matching.

Op. 1028H54 PISTON WITH CONNECTING ROD - DISMANTLING AT THE BENCH Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING - Release the rpm sensor support ring and remove it.- Remove the crankshaft rear seal.- Check that the crankshaft endfloat is within specified limits.

Measurement	Value	Validity
Crankshaft endfloat (mm)	0.100 ÷ 0.202	1.8

- If the value is not within the recommended limits, replace the half-bearings for main journal 3 and repeat the checking operation.

Measurement	Value	Validity
Main journal 3 width (mm)	26.000 ÷ 26.052	1.8

1. Undo the bolts (1a) and remove the main journal caps (1b) and lower half-bearings.

The bearing caps are numbered from 1 to 5 starting from the timing side.

2. Remove the crankshaft from the cylinder block/crankcase.3. Remove the upper main journal half-bearings.4. Remove the thrust washers from the centre support.5. Undo the bolts (5a) and remove the engine oil jets (5b).

1. Place the crankshaft in the cylinder block/crankcase on the supports and check that the radial clearance is within the recommended limits.

Measurement	Value	Validity
Crankshaft eccentricity (mm)	0.03	1.8

- Remove the crankshaft from the cylinder block/crankcase. Op. 1020A46 CRANKCASE OIL SUMP PARTITION - R.R. WITH CRANKCASE SUMP REMOVED Op. 1084A40 ENGINE OIL LEVEL SENSOR - R + R - Drill and remove the water/oil sealing plugs from the crankcase to allow for washing the ducts.

Refitting ( Removing

) - Clean the residues of sealant from the mating surfaces between the cylinder head and the engine block.- Clean the residues of sealant from the mating surfaces between the oil sump and the engine block.- Clean the parts removed thoroughly and check their condition visually.- Fit the water/oil sealing plugs in the engine block using suitable fitting tools.- Place the engine oil jets in their housings and tighten the bolts.- Lubricate all the mechanical components with engine oil.- Check that the cylinder head support surface does not have cracks or grooves.1. Using a calibrated metal rule and a feeler gauge, check the flexible yield, widthwise and lengthwise and the diagonal defromation of the upper engine block surface.

1. The following information is stamped on the engine block: production date (1a), cylinder liner/bore grade (1b), main journal bearing grade (1c).

1. Measure the inner diameter of the cylinder bores as illustrated in the diagram below using a gauge for the interior.

Measurement	Value	Validity
Cylinder liner inner diameter - Grade 00 (mm)	80.492 ÷ 80.508	1.8

Measurement	Value	Validity
Cylinder liner inner diameter - Grade 05 (mm)	80.542 ÷ 80.558	1.8

- If the cylinder bore internal diameter is not within the recommended limit, ream the cylinder bores following the recommended oversizes.

Measurement	Value	Validity
Cylinder liner bore diameter oversize (mm)	0.5	1.8

In the case of reaming, all the cylinder bores must have the same oversize.

After reaming the original code must be invalidated and the new oversize code stamped on the engine block.

- Check that the diameter of the main journals corresponds to the recommended figures.

Measurement	Value	Validity
Main journal diameter (brown)	54.980 ÷ 54.997	1.8

Measurement	Value	Validity
Main journal diameter (green)	54.980 ÷ 54.997	1.8

- If the diameter of the main journals is not correct, they should be reground to the recommended undersizes.

Measurement	Value	Validity
Main journal diameter undersize (mm)	0.25/0.50	1.8

- Check that the diameter of the crankpins corresponds to the recommended figures.

Measurement	Value	Validity
Crankpin diameter (mm)	42.971 ÷ 42.987	1.8

- If the diameter of the crankpins is not correct, they should be reground to the recommended undersizes.

Measurement	Value	Validity
Crankpin diameter undersize (blue) (mm)	0.25	1.8

Measurement	Value	Validity
Crankpin diameter undersize (white) (mm)	0.50	1.8

- Check that the length of main journal "3" (guide bearing) is within the recommended values.

Measurement	Value	Validity
Main journal 3 width (mm)	26.000 ÷ 26.052	1.8

- If the diameter of the main journal 3 is not correct, it should be reground to the recommended undersizes.

Measurement	Value	Validity
Main journal 3 width undersize (mm)	0.20/0.40	1.8

- Check the crankshaft and connecting rod bearings bearing in mind that no adjustment operations should be carried out on the half-bearings. Replace them if scoring or signs of binding are noted.- Fit the upper half-bearings on the engine block making sure that they are perfectly clean and have been lubricated with engine oil.

If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions.

- Fit the crankshaft into its seat on the crankcase.1. Fit the calibrated wire (plastigage) for measuring the bearing clearance.

- Fit the lower half-bearings on the connecting rod caps making sure that they are perfectly clean and have been lubricated with engine oil.

If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions.

- Fit the bearing caps following the fitting position marked on them and tighten the bolts to the recommended torque.

The fixing bolts removed previously can be reused just to check the bearing clearance.

Component	Fastening	dia	Value (daNm)	Validity
Bearing caps	Bolt (to be replaced)	-	5.0 + 45° + 15°	1.8

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

Check the clearance for all the main journals taking care to do it one bearing at a time without ever moving the crankshaft.

Measurement	Value	Validity
Clearance between main bearings - crankshaft bearings (mm)	0.005 ÷ 0.059	1.8

- If the values are not within the recommended limits, replace the half-bearings and repeat the operation of checking the clearance.- The size of the main journal half-bearings is given.

Measurement	Value	Validity
Main half bearing nominal thickness (brown) (mm)	1.987 ÷ 1.993	1.8

Measurement	Value	Validity
Connecting rod half-bearing thickness oversize (0.25) (brown/blue) (mm)	2.112 ÷ 2.118	1.8

Measurement	Value	Validity
Connecting rod half-bearing thickness oversize (0.50) (brown/white) (mm)	2.237 ÷ 2.243	1.8

Measurement	Value	Validity
Main half bearing nominal thickness (green) (mm)	1.993 ÷ 1.999	1.8

Measurement	Value	Validity
Connecting rod half-bearing thickness oversize (0.25) (green/blue) (mm)	2.118 ÷ 2.124	1.8

Measurement	Value	Validity
Connecting rod half-bearing thickness oversize (0.50) (green/white) (mm)	2.243 ÷ 2.249	1.8

- Apply adhesive putty in the side splining of main journal cap number 5 (flywheel side) and place it in position.- Fit the remaining main journal caps following the position marked on them.- Tighten the new connecting rod cap fixing bolts to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Bearing caps	Bolt (to be replaced)	-	5.0 + 45° + 15°	1.8

- Clean any carbon residues carefully from the pistons.- Check that the outer diameter of the pistons perpendicular to the gudgeon pin axis 14.5 mm from the lower edge is within the recommended values.

Measurement	Value	Validity
Piston outer diameter - Grade 00 (mm)	80.455 ÷ 80.465	1.8

Measurement	Value	Validity
Piston outer diameter - Grade 05 (mm)	80.505 ÷ 80.515	1.8

Measurement	Value	Validity
Piston outer diameter oversize (mm)	0.5	1.8

- If these values do not correspond to the recommended figures, replace the piston complete with piston rings and gudgeon pin.- The clearance between the piston and the liner/bore is given below.

Measurement	Value	Validity
Clearance between piston - cylinder liner/bore (mm)	0.045 ÷ 0.175	1.8

- Check that the outer diameter of the gudgeon pin corresponds to the recommended figures; if not, replace the piston complete with piston rings and gudgeon pin.

Measurement	Value	Validity
Gudgeon pin outer diameter (mm)	19.000	1.8

- Check that the clearance between the gudgeon pin and the housings in the connecting rod and piston are within the recommended values.

Measurement	Value	Validity
Gudgeon pin - connecting rod clearance (mm)	0.015 ÷ 0.021	1.8

Measurement	Value	Validity
Gudgeon pin - piston clearance (mm)	0.02 ÷ 0.06	1.8

- Check that the thickness of the piston rings is within the recommended limits.

Measurement	Value	Validity
Cylinder compression 1st piston ring thickness (mm)	1.170 ÷ 1.190	1.8

Measurement	Value	Validity
Cylinder compression 2nd piston ring thickness (mm)	1.170 ÷ 1.190	1.8

Measurement	Value	Validity
Piston oil scraper ring size (mm)	1.90 ÷ 1.98	1.8

- Fit the piston rings in the cylinder bore and, using a feeler guage, check that the gap between the two ends is within the recommended values, or else they must be replaced.

Measurement	Value	Validity
Cylinder compression 1st piston ring gap (mm)	0.20 ÷ 0.40	1.8

Measurement	Value	Validity
Cylinder compression 2nd piston ring gap (mm)	0.40 ÷ 0.60	1.8

Measurement	Value	Validity
Piston oil scraper ring gap (mm)	0.25 ÷ 0.75	1.8

1. Check that the backlash (1a) between the circlips (1b) and the housing in the piston (1c) corresponds to the recommeded figure; if this is not the case, replace the circlips.

Measurement	Value	Validity
Cylinder compression 1st piston ring endfloat (mm)	0.04 ÷ 0.08	1.8

Measurement	Value	Validity
Cylinder compression 2nd piston ring endfloat (mm)	0.03 ÷ 0.07	1.8

Measurement	Value	Validity
Oil scraper ring endfloat (mm)	0.20 ÷ 0.35	1.8

Op. 1028H60 SET OF PISTONS, GUDGEON PINS AND SEALS - REPLACE PISTONS AND CONNECTING RODS AT THE BENCH - INCLUDES ALIGNMENT AND BALANCING Op. 1028H54 PISTON WITH CONNECTING ROD - DISMANTLING AT THE BENCH 1. Fit the piston complete with connecting rod (1a) and half-bearings using the tool (1b) for compressing the circlips and then fitting them in the cylinder liner/bore.2. Position the piston with the arrow (2a) facing the timing side and the projection (2b) facing the flywheel.

1. Fit the calibrated wire (plastigage) for measuring the bearing clearance.2. Fit the lower connecting rod half-bearings on the caps making sure that they are perfectly clean and have been lubricated with engine oil.

If the crankshaft has been ground, fit new oversize half-bearings to restore the initial tolerance conditions.

Measurement	Value	Validity
Connecting rod half-bearing nominal thickness (mm)	1.485 ÷ 1.497	1.8

Measurement	Value	Validity
Connecting rod half-bearing thickness oversize (0.25) (blue) (mm)	1.610 ÷ 1.622	1.8

Measurement	Value	Validity
Connecting rod half-bearing thickness oversize (0.50) (white) (mm)	1.735 ÷ 1.747	1.8

3. Fit the connecting rod caps matching them with the connecting rod using the references made during the dismantling and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Connecting rod big end bearing caps	Bolt (to be replaced)	-	2.5 + 30° + 15°	1.8

The fixing bolts removed previously can be used just to check the bearing clearance.

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

Measurement	Value	Validity
Clearance between main ljournals - crankshaft bearings (mm)	0.019 ÷ 0.071	1.8

If the values are not within the recommended limits, replace the half-bearings and repeat the operation of checking the clearance.

- Fit the connecting rod caps and secure them by tightening the fixing bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Connecting rod big end bearing caps	Bolt (to be replaced)	-	2.5 + 30° + 15°	1.8

- Remove the tool for rotating the crankshaft.1. Place a new flywheel side oil seal (1a) in the housing using the tool (1b).

Tool	Description	Function	Validity
1860843000	Fitting tool	Fitting crankshaft rear oil seal	1.8

- Fit the rpm sensor support seal on the oil seal fitted previously.- Position the rpm sensor in its housing and secure it to the support seal using the bolt. Op. 1084B18 ENGINE OIL PUMP, REMOVED - CHECK AT BENCH - Place the crankshaft oil seal front cover in a vice fitted with protective jaws.- Fith the water pump cover with a new gasket and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Water pump	Bolt	-	0.8	1.8

- Position the water pump pulley in its housing and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Water pump pulley	Bolt	-	2.0	1.8

- Fit the crankshaft oil seal front cover centering bushes on the crankcase.- Fit a new crankshaft oil seal front cover gasket.- Place the crankshaft front oil seal cover in its housing and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Crankshaft oil seal front cover	Bolt	-	2.0	1.8

Component	Fastening	dia	Value (daNm)	Validity
AIR CONDITIONING COMPRESSOR	Bolt		2.25 ÷ 2.75	1.8 16v

- Place the engine oil pressure switch in position and tighten it to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Switch for engine oil pressure warning light	-	-	2.0	1.8

- Place the water pump rigid return pipe, complete with new gasket, in position and tighten the bolts.- Place the oil filter mounting in a vice fitted with protective jaws and replace the gaskets.- Place the water-oil heat exchanger in position on the engine oil filter mounting and secure it using the bolts.- Place a new oil filter cartridge in position and tighten the cover to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil filter cover	-	-	2.5	1.8

- Remove the engine oil filter mounting assembly from the vice, place it in position on the left side of the crankcase and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil filter and heat exchanger mounting	Bolt	-	2.5	1.8

- Position the detonation sensor in its housing and secure it tightening the bolt to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Detonation sensor	Bolt	M8	1.5 ÷ 2.5	1.8

- Place the connector holder bracket in position and fit the rpm sensor connector.- Place the alternator in position and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Alternator	Bolt	M10	4.5 ÷ 5.5	1.8 16v2.4 JTD 20v

- Place the toothed drive pulley in its housing on the crankshaft.- Apply a bead of silicon sealant about 2 mm thick to the contact areas between the engine block, 5th main bearing cap (flywheel side) and the crankshaft oil seal front cover.1. Apply a bead of silicon sealant about 3 mm thick to the edge of the sump and around the oil recirculation and inlet connectors as illustrated.

- Refit the oil sump in its seat and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump - crankcase side	Bolt	-	1.0	1.8

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump - gearbox side	Bolt	-	4.0	1.8

- Rotate the overhaul stand through 180 °.- Fit the locating bushes for the engine block.- Fit a new cylinder head gasket.- Place the cylinder head in position and tighten the fixing bolts to the recommended torque, following the order illustrated in the diagram.

Component	Fastening	dia	Value (daNm)	Validity
Cylinder head	Bolt (to be replaced)	-	2.5 + 90° + 90° + 90° + 45°	1.8

1. Fit the tool (1a) in the special splining on the camshafts (1b).

Tool	Description	Function	Validity
2000012000	Template	Camshaft timing	1.8

1. Fit the tool (1a) on the toothed driven pullies (1b).

Tool	Description	Function	Validity
2000012100	Template	Camshaft timing	1.8

Fit the inlet side template first and then the exhaust side one.

When the templates have been fitted, check that:- the reference (a) on the exhaust side pulley is aligned with the reference (b) on the corresponding timing template;- the pin (c) on the inlet side pulley is in the position illustrated, in relation to the reference (d) on the corresponding timing template.

- Using the special tool, rotate the crankshaft and place the reference on the toothed drive pulley in line with the reference (triangle) on the crankshaft oil seal front cover.- Using a spanner, rotate the timing belt moving tensioner in a clockwise direction until the tensioner locking pin can be placed inside the opening.- Fit a new timing belt in place, taking care not to move the crankshaft timing references.1. Check the crankshaft timing by checking that the references illustrated in the diagram are aligned.

- Fit the timing belt definitively adjusting the moving tensioner to remove the locking pin.- Remove the templates used for timing the camshafts.- Place the cam cover in position and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Tappet cover	Bolt	-	0.8	1.8

- Place the ignition coil module in its housing and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Ignition coil module	Bolt	M6	0.6 ÷ 1.0	1.8

- Place the ignition coil cover in its housing and secure it using the retaining clips.- Fit the timing belt lower protective cover and secure it using the bolts.- Place the auxiliary belt pulley and washer in position and tighten the bolt to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Services pulley on crankshaft	Bolt (to be replaced)	-	9.5 + 30° + 15°	1.8

Prevent the crankshaft from rotating using the flange fitted previously on the crankshaft.

Check that the timing reference on the auxiliary drive pulley is aligned with the reference on the timing belt lower protective cover.

- Place the water pump rigid rear return pipe, complete with new seals in position and secure it to the thermostat tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Rigid pipe on thermostat	Bolt	-	0.8	1.8

- Fit the new exhaust manifold gasket on the cylinder head studs.- Place the exhaust manifold - catalytic converter in its housing with the mounting bracket on the crankcase and tighten the fastenings to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Exhaust manifold with catalytic converter	Nut (to replace)	-	(cylinder head side) 2.0	1.82.2

Component	Fastening	dia	Value (daNm)	Validity
Bracket side caztalyzer	Bolt	-	2.0	1.8

- Place the exhaust pipe heat shield in its housing and secure it using the bolts.- Place the oil dipstick pipe back in its housing and fasten it to the cylinder head using the bolt.- Place the modular intake chamber in its housing and secure it to the cylinder head tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Modular intake manifold	Bolt	-	2.0	1.8

- Place the injection control unit in its housing on the modular intake chamber and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Injection/ignition system control unit	Bolt	M6	0.8 ÷ 1.0	1.8

- Place the throttle body in position and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Throttle body built into DVL	Bolt	M6	0.8 ÷ 1.0	1.8

- Connect the water supply and return pipes to the throttle body and secure them using the bands.- Connect the corrugated oil vapour hose to the tappet cover and to the throttle body and secure it using the retaining clips.- Connect the rapid connector for the throttle body coolant supply pipe, thermostat mounting side.- Place the wiring in its housing on the engine and secure it using the retaining clips.- Connect the electrical connection for the injection control unit.- Connect the electrical connections for the injectors.- Connect the electrical connection for the phase transformer solenoid, inlet side.- Connect the electrical connection for the fuel vapour flow enablement solenoid valve.- Connect the electrical connection for the throttle casing.- Connect the electrical connection for the modular intake manifold control actuator solenoid valve.- Connect the electrical connection for the rpm sensor.- Connect the electrical connection for the detonation sensor.- Connect the electrical connection for the engine oil level sensor.- Place the starter motor in its housing and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Starter motor	Bolt		2.5	1.8 16v

- Connect the earth lead to the cylinder head and secure it using the bolt.- Connect the electrical connection of the ignition coil module.- Connect the electrical connection for the water temperature sensor on the thermostat.- Connect the electrical connection for the water temperature regulator on the thermostat.- Connect the electrical connection for the inlet side timing sensor.- Connect the electrical connection of the exhaust side timing sensor.- Connect the electrical connection for the upper Lambda sensor and secure it to the mounting bracket.- Fasten the wiring retaining duct to the tappet cover using the clips.- Connect the electrical connection for the phase transformer solenoid, exhaust side.- Connect the electrical connection for the minimum engine oil pressure switch.- Connect the electrical connection for the air conditioning compressor.- Place the intermediate timing belt protective cover in position.- Fit the upper timing belt protective cover and secure it using the bolts.- Place the power unit rigid support in position and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support	Bolt	M10	5.0 ÷ 6.0	1.8

- Position the auxiliary drive belt moving tensioner in its housing and secure it tightening the bolt to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine components single belt moving tensioner	Bolt	M10x1.5	5.0	1.81.9 JTD 16v1.9 JTD 8v2.4 JTD 20v

- Adjust the moving tensioner with a wrench and fit the auxiliary drive belt.