pAag7aBrt6voce (S55 T.SPARK ieV REPAIR MANUAL ® ENGINES (A) Hy GROUP 01 - ENGINE MAIN MECHANICAL UNIT | Se = es ) SP aS SF re ae ~~ 1. Slacken the oil sump fastening screws using tool no. 1.822.144.000 and no. 1.822.1 45,000 for those to which access s not possible, Pa1. Slacken the fastening screws and remove the suction device. = Remove the seal. CHANGING THE CRANKSHAFT FRONT OIL SEAL = Set the car ona lit. = Disconnect the battery () terminal ~ Remove the right front wheel and mud fap. 1. Raise the car and working as illustrated on the belt tensioner, loosen the tension ofthe auxliary components five belt prise it oft 2, Slacken the four fastening screws and remove the auxliry components drive pulley. 2.4=3.0 kgm 1. Slacken the fastening screw and remove the belt tensioner. 2. Siacken the fastening screw and remove the auxiliary components drive belt guide pulley. PA497881°~"001 01-19 3. Slacken the fastening screws and remove the lower cover of the timing gear and counter-rotating shaft drive belts. At oH Vp = )) 7 I i aN + Slacken the lower screws of the upper cover of the timing gear and courter-rotating shait drive belts. 1. Lower the car, siacken the fastening screws and remove the upper cover. ij ENGINE MAIN MECHANICAL UNIT 1, Sacken the fastening screw and remove the socket forthe ol vapour recovery pipe. DSR LLY 1. Slacken the fastening screws and remove the ignition coils cover 2. Disconnect the electrical connections trom the ignition 1. Slacken the fastening screws and remove the ignition coils. 2, Slacken the fastening screws and remove the ignition ‘ails support bracket. 01 - 1/20 1. Slacken the fastening screws and remove the cylinder head cover complete with gasket. +. Loosen the tension of the counter-rotating shaft belt slackening the fastening nut of the coresponding bet tensioner, then prise and remove the bet. 1, Slacken the two fastening screws and remove the ‘counter-rotating shaft belt criving pulley Pad97e8 116002| ENGINE MAIN MECHANICAL UNIT +1, Working on the timing gear belt tensioner, loosen the tension of the belt, then prise it of 21-25 Nm| 2.4227 kgm Solution for engines before change 4. Using too! no. 1.820.617.000 slacken the screw (lett rand) fastening the timing gear belt drive pulley, then remove the pulley. 340~378 Nm Solution for engines after change + Slacken and remove the flynheel cover. 1. Install the flywheel stopper tool no. 1.820.630.000 as ilustrated, slacken the screw (left-handed), then remove the timing gear drive pulley. Weal Spe Y Ya20.630.000 SY _// ik fh PAS97EB: O41 - 1/21 1, Remove the oll seal and install a new one using tool 19, 1.821.247.000, = Re-assemble reversing the sequence followed for removal. Refer to GROUP 00 for revassembly of the timing gear belts, counter-rotating shaft belts and their timing and fer assembly of the auxiliary components drive belt. CHANGING THE COUNTER-ROTATING SHAFT SEALS = Proceed as described in the procedure for “Chang- ing the crankshaft front oil seal" up toremoval of the upper cover for the timing gear and counter-retating shaft betts. 1. Loosen the tension of the counter-rotating shatt belt slackening the nut fastening the corresponding belt ten- sioner, then prise and remove the bett. - Slacken the serews and move the header tank to one side without cisconnecting the piping. 1. Using tcol no, 1.820.288.000 slacken the screw fastening the counter-rotating shaft pulley and remove it an 1. Remove the oil seal and install a new one using tool no, 1.821,251.000. Wi WH \ \ \ og \1.821.251.000 = “OM = Carry out reassembly reversing the sequence de- seribed for removal referring to GROUP 00 for as- sembly of the counter- rotating shaft belt and for assembly of the auxiliary components drive belt. CHANGING THE CAMSHAFT OIL SEALS = Proceed as described n the procedure “Changing _) the crankshatt front oll seal" up to removing the timing gear drive belt. PAs7eBTIEV ENGINE MAIN MECHANICAL UNIT 01 - 1/22 1. Using tool no, 1.822.146.000 compiete wth tool no. .000 eiacken the screw fastening the camshatt the exhaust side end remove it 2, Slacken the ‘our screws and remove the camshaft drive pulley on the intake side. 100+ 1241Nm_ 102-126 kgm - Remove the camshatt oil seals. 1. Install a new camshait front oil seal on the exhaust side using tool no. 1.821.228.000. 2, Install a new camshaft front oll seal on the intake side using tool no, 1.821.252.000. Soy 1.821.252.000 12. 1995Hi scribed for removal and counter- rotating shaft belts and for assembly of the auxiliary components drive belt. CHANGING THE FLEXIBLE BUSHING OF THE ENGINE STAY ROD ANCHOR BRACKET 1. Slacken the fastening screws and remove the engine stay rod. aaa PE LEN ~ Slacken the fastening screws and.move the header tank to one side without disconnecting the piping 1. Using too! no. 1.821.175.000 (A 3.0640) asilustrated remove the flexible bushing from the engine stay rod ENGINE MAIN MECHANICAL UNIT 01 - 1/23 1. Refit a new flexible bushing still using tool no. 1.821.175.000 (A.3,0840) as illustrate. = Complete re-assembly reversing the sequence fol. lowed for removal CHANGING THE REAR CRANKCASE COVER (with oil seal) - Remove to gearbox (00 specie paragrap, ~ Remove the clutch (see specific paragraph). 1. Fille! stopper tool no. 1.820.624.000 2. Sacton the fastening screws and remove hefywneel [Waa we | 129-162 kom oy / 1.820.624.000 oY, Cc hy 1. Slacken the screws fastening the oil sump to the crankcase, then remove the rear crankcase cover with imegrated cil seal ning, ENGINE MAIN MECHANICAL UNIT PAsg78B176V001 01 - 1/24 + Refit the rear cover proceeding as iollows: © Fit tool no. 1.820.619,000 on the cil seal cf the rear crankcase cover. @ Assemble the tool - rear cover assembly and tighten the screws fastening the crankcase and the of sump. © Remove the centering tool no. 1.820.619.000.Ht TECHNICAL CHARACTERISTICS AND - ENGINE MAIN MECHANICAL UNIT. 01-2 SPECIFICATIONS ENGINE TECHNICAL CHARACTERISTICS Engine AR 67208 Cycle Otto é-stroke ial Spaeea aa Mull-Point Motronic M72.10.3 | Muti-Point Motronic M 2.10.4 bok: sonli seal ((95 version) ((96 version) Finng order Toss 8 Displacement om 1870) Number of eviinders ‘ining Bore mm 23 ‘Stroke mm st Masirnuan pourse, (CV EEC (KW EEC) 150 (170) om 200 ~ + har oie kgm EEC (Nm EEC) 79 (187) pm 4000 Compression ratio to:4 Engine oil pressure At idle speed bei 215, At 4000 rpm 245 Ide speed pm 840= 50 I 3002 50 COMPLETE CRANKCASE Crankcase Diameter of main joumals 21.720 = 21.800 halts journals Length of centre main bearing shoulder Class A- Blue 3000-83010 Diameter cfeyinders ‘et [Class B= Pink 83.010 = 83020 [Class C- Green 83.020 - 83,030 Oversize 0.4 Front Diameter ol counterctaing [Orta 45.975 - 47.000 [Centre 39.973 - 40,009, Unit: mm Grearance between pur casing sect and ios Bi8s driven Da Clearance between pump cover rest surtace Barn sas e 0.025~0.070 HZaESS and upper side of aears, | t Engine ol pressure limiting [Control load 68K9 _ _ valve [Length of spnng | % "8B 116V002 12-18 ify ENGINE MAIN MECHANICAL UNIT ul -3 Crankshaft Unit: enn (Glass A- Red 52.994 - 59.000 Diameter of main bearing Class 8 - Blue 52.988 ~ 52.994 journals ‘at (Class 0 - Yellow 52.982 = 52.988 Undersize 0.127 [Glass A-Red 50,789 = 50,805 Diameter of connecting (Class B - Blue 50.783 + 50.799 fod pins “b* Class C - Yellow 50.787 + 50.793 Undersize 0.127 Length of centre bearing journal “&™ 26.575 = 25.625 _Manimum taper of main and connecting rod joumals_| 0.0085. Maximum error of concentriety between 5.003 main joumals and connecting rod journals Main half bearings Unit: ren [Class A- Reo 1.836 «1.840 Thickness of main half [Class B - Blue 1.839 + 1.843 a earings “at [Class G- Yellow 1.842 + 1.885 Undersize 0.127 [Operating clearance between main joumals and hal] 9 95. ggcy bearings Counter-rotating shafts Unit: mem Pago788 156000 Diameter of counter-rotating fEfonta” AO 12a, [Gante 36.945 + 36.960 shatt pins eer 19,990 + 20.010 Diameter of centre bushes inside “et 82.000 257.090 lOwsice = 40.055 » 40.090 Diameter of ball bearings inside 49.990 = 20.000 [ousiceg 36.989 ~ 47.000 intererence between centre bushes and 058 ont nei seats on crankcase i ete an bushes and carve Racial dearance Bushes a tn bes journals IClearance / Interference between ball bearings land their seats on crankcase 40.011 +-0.025 IClearance / interference [Front +0.020 + 0.003 _| lbetween ball bearings and lcounter-rotating shatt pins [°F 12-1994oy Half thrust rings Piston ENGINE MAIN MECHANICAL UNIT ‘Thickness of naif thrust rings *a* 2.343 Oversize 0.127, [Crankshaft end float 0.088 + 0.221 Inside diameter of centre bush (bore) * 47.010 ~ 47.035 mm [Heating temperature of ring gear tor assembly on tiywhaat eee CONNECTING ROD - PISTON ASSEMBLY Unit: mm [Class A- Blue | 62.952 + 82.962 ———— ee Se [ [class C- Green 2.968 + 82.978 | Tight of fiat seal tng seats 1220-=1.240 BLS Heightot second seal ring seats 7510 = 1.530 ight of oil seraper ring seats 010+ 3.080 Diameter of gudgeon pin holes in pistons 20.002 + 20.007 . (Clearance between cylinders and pistons 0,038 + 0,062 NI Difference in weight beiween pisions =59 (1) To be measured perpendicular to the gudgeon pin hole al a distance of 12.5 mm trom lower edge of skin. Uni: mm Diameter of smal end = 2001 6 a bushing bore "a® 20,008;2:20: | inside ameter rod big ends "= 3e.a97 = 58.908 4 Diference in waight berwaen roas | es ‘Clearance between small end | 0.008 = 0.016 bushings and pins | Small end end floa: i 0.25 = 0.6 12+ 1908 ENGINE MAIN MECHANICAL UNIT Connecting rod half bearings Seal rings 01-5 Head Unit: mm (Glass A~ Red 1.507 = 1.581 Thickness of connecting rod [Class B- Blue EN iss a hailoaeanas “= (Class C- Yellow 1.595 + 1.537 Undersize 0.127 [Operating clearance [Clase A- Red connecting rod pins end their [Class 8 -Blue aecene halt bearings Cass C- Yellow Unit: mm 4.170+ 1.190 be Oversize 0.1 tat 1.475 + 1.490 Thickness of rings “a seond fi ° Lanka ‘Oversize 0.1 ow comsper a 2.975 +2.950 phaiecpiciis ‘Oversize 0.1 First ring, [0.25 +0.50 Ring gap "b" (1) Second ring (030=0.50 (Oi scraper ing 025+ 0.45 [Fist ring [0.030 = 0.070 pee iy aber Beal [Second ring [0.020 + 0.055 iaheahenies [Oilscraperring | _0.020 0.058 Gi To be measured in the checking ring nut or im the oviinder Gudgeon pins at mn | Outside dameter of gudgeon pins 19.986 = 20.000 al (Clearance between gudgeon pins wees tet f land their coats on pistons CYLINDER HEAD Unit: mn Diameter of sedi valve guide seats “a° [1285012977 ‘Valve guide proinision "b [Fras 475 Diameter of valve cup seats “ [33,000 ~ 93.025; Diameter of valve seat intake [34.989 - 35.014 housing "¢* [Exhaust [_ 26.981 - 29.072 Minimum death of combustion chamber "e* [1s z02 Maximum error of flainass of head lower surface Ot 449786 116V000 Diameter of camshait supcerts ‘Diameter of timing varlator suppor "g 26.045 = 26.070 ors 55.99001-6 Hy ENGINE MAIN MECHANICAL UNIT 01-7 i fy ENGINE MAIN MECHANICAL UNIT Valve guides Camshafts Unit: mm : Diameter of camshaft journals "a" 26.000 - 26.015 > a Outside diameter ofvave guides a" |___18.010= 18080 raced “Sarraoral tiny rotor erg = 2.10. ' ameter of tiring varaterumal 9985 - 1588020 po £9985 ~ 50,000 a Unit: mm Nominal eam it [intake 90 Inside diameter of valve guides [Exnaust 9.50 7.022 ~7.040 (bore) b+ Se eccbameanake ge Delween valve guides | oss voea [Clearance between camshaft joumals and their seals | 0030.07 land their seats Ms ‘ | [Camshaft end float 0.10 0.23 + i Valve seats Unit: mm Timing variator half bearings Outside Glameter of nae 35:15 = 35.150 Unit: mm valve seats “a* Exhaust 29.182 + 29.157 a Thickness of timing variator ae 2,992 « 2.998 \Valve contact area taper “a” ‘30° +10" half bearings *a’ |seats and their housings Exhaust 0.130 + 0.166 land bearings Cylinder head heating temperature for fiting 900" ~ a valve seats ANGLES OF ACTUAL TIMING DIAGRAM Valves Unit: mm i Diameter of valve stems patos eRe 960 + 6.975 Opens (belore T.D.C.) 0° 25°) : ~ intake 334537 Intake (Closes (after 8.0.6) to | 55" 30°C Diameter of valve mushrooms "ot Fo aes ais aoeie a [Radial clearance between Intake 0.032 « 0.065 [Opens (before B.D.C.) 50" valve stem and guide [Eeaust 0.047 - 0.060 Exhaust (Closes (after D.C.) = Exhaust angle or | ae 7 {> Values obtained with tiring variator engaged. Valve springs Outer saring | tnner sping ~ Free lengih "Ui 46mm | ___ 38mm i | Length with vaives closed "Lo" | 34mm | 29.5 mm. | | L —y 4 — Re Corresponding load at "Le ioe lseey | eaceeey ® eu @ rn ert Length with vaives open "Lat 24.5 mm cone (a) TOC. r 485 « 526 N 201 = 221N stesponting led at ‘Ls" Corresponding load at "Ls donee | Ean Hydraulic tappets Unit: mm Ouiside diameter of | nysrauli tappets "3° Radial clearance between hydraulo lrappets and their seats || sia i wc O1-s FLUIDS AND LUBRICANTS ‘Specified ication Name Quy i Berta TP | classification | pone Arse ‘SELENIA 54) Engine . SPECIAL FORMULA i MGS (Refiling) oF Som ALFA ROMEO aa SAE 10W/40 HOMO: (FF For decidedly sporive use of the ca’ fully synthetic SELENIA Racing 10W/60 engine oils recommended (1): Total capacity (2]: Sump + fiter (for periodical replacement) SEALANTS AND ADHESIVES ‘Application [type | Name ‘Qty “licone |Mascherpa -7037 Oil sump - erankeace a acai a3 IRHONE PULENC - CAF 5552, Timing variator Sealant |Loctie 270 - ABRASIVES ‘Application T_T Name Toey fr ISIPALAREXONS Valve seat grinding ICarbosilicium for valves. Vw fi ENGINE MAIN MECHANICAL UNIT TIGHTENING TORQUES Qi-9 Pan [hm kam Screws fastening main bearing caps (in oil) | 96-119 | 9asta1 ‘Seres fastening fywhee! 1213 149 123-152 ‘Scrows fastening connecting tod caps (in oil) [4453 45-54 ‘Screws fasiening auxiliary components drive bek pulley 24-29 2.4230 ‘Screw fastening tming gear belt drve pulley (left-handed) [340-378 347-965 ‘Szrens fasiening water pump [__i7=21 47-24 Engine oll minimum pressure waming light sensor 2-31 | 25-92 ‘Screws fastening counter-rotating shaft front covers 6-7 | o6+07 ‘Screws fastening oll samp 33-18 13248 (Gil sump érain plug 3721 17224 Sciews fastening oil pump 6-8 06+08 Screws fastening EGR. valve 17-21 17724 Nuts fastening intake box to cylinder head 17+21 A7+21 ‘Screw fastening exhaust side timing gear pullay 100 124 10.25 125 Nut fastening tiring gear belt tensioner 21726 21226 Nuts fastening exhaust manifold to cylinder head q7a2t 17224 ‘Screws fastening thermostatic cup to cylinder head a7=21 | 4.724 ‘Screws fastening camshatt caps (in oil) 13 +16 | 1.3416 [Centre iarge e395 | 36 Spaccplogs [Side smail ‘ 30-12 Engine coolant temperature gauge sender and max. temperature waming a Daiess: light contact Engine coolant temperature sensor (NTO) 12=15 I 12515 7 ‘Cylinder head tightening ORS BE | i el Tighten the screws to a preliminary torque of: 40 a Tum all the screws by an angle of 90° + 90° + 90° PAdg7EB1Hf ENGINE MAIN MECHANICAL UNIT SPECIAL TOOLS 01 - 10 1.820.011.000 (A.2.0182), 4,820.012,000 (A.2.0195) 7.820,049,000 (A.2.0359) 7.820.145.000 (R.4.0178) [Valve support tool |Suppor ior cylinder head suppor tool [Nut for vaive suger tol [Engine support brackets for assembly on overhauling stano iy ENGINE MAIN MECHANICAL UNIT REMOVING/REFITTING ENGINE REMOVAL Proceed as des 1. Position a hydraulic jack compiete with tools no. VAIS Vay law 1.820,228.000__|Suppor or removingrefting te power un Epa li ts ceamucn'er nc isis 1.820.256.000 [Cylinder head susport 1.820.267.000_ [Spacer for valve cisassembiyire-assembiy 1.820.277.000 [Graduated disk for angle torque tightening Satis ng pe eS re 7.820.286.000 | Counter torque ior counter-rtating shat pula 1.820.617.000 |Crankshait pulley counter-torque {for engines before change) Th 1.820.616.000___[Adapiater for tuming crankshaft £00, 1:820.619.000 [Disk for centering crankshaft rear oll seal A 1.820.623.000 | Supports for removinglrefiting the power unit = 7.820,624.000 [Flywheel stopper tool (to be used on the bench) “820,626,000 [iting for mallat 7.820,630.000 [Flywheel stopper (for engines aller change) 1.821.058.000 (A.3.0324) 141.821.124.000 (A.9.0522) 1.827.161.000 (A.3.0617) 1.821.177,000 (A.3.0635) 4.821.175.000 (A.3.0640) 4.827.176.000 (3.0641) Lever for valve disassembly/e-assembly |Support for valve disessembly/e-asserbly Mallet [Suppor grip for installing tools [Pullerinstalling tool for engine stay connecting rod silent-block. Puller tool for valve guides 4.821.203.000 instaling tool for courter-rotating shaft front oll seals (to be used on the bench) 4.821.205,000 [Cage for ber valve disassembiy/re-assembly 7.821.208,000 Installing tool for vaive guide oil seal 1.821.208.0090 Puller tool for vaive guide il seal 7,821 228.000, Installing tool for exhaust side camshaft oll seal 4.821 247.000 Installing tool for crankshatt front cil seal 1.821.251.000, Installing for balance shaft oil seal 1.821.252,000 Installing tool for intake side camshafi cll seal 1.821.253.000 Puller tool for counter-rotating shaft ‘ront bearings: 1.821.254,000 Installing tool for valve guides 1.822.144.000 [Hexagon grooved wrench for removingirefiting cil sump) 1.802.145.000 [Hexagon grooved wrench for removing/refiting oil sumo 1.822.146,000 [Support for pulley wrenches 1.822.147.000 [Wrench for timing variator 4.822.149,000 [Wrench for tensioning timing belts 4.822.154.000 Wrench for tensioning counter rotating shat belt 1.822.155 .000 [Wrench for timing gear pulley intake side 1,822.156.000 1.822.160.000 (000 (6.6.0783) 1,828.041.000 1825. PAGSTEBTIEVOO? [Wrench for timing gear pulley exhaust side Wrench ior removing/efiting enaine oil pressure sensor [Tool for checking T.6. Templates for tming camsnatts NOTE: the part of the timing gear side engine sup- port of tool no. 1.820.628.000, is 1 be relieved in the area illustrated to prevent interference with the oll filter support. for removing the {ah en- 01-11 Complete removal,of the engine from the car as described for the Kaa) engine, Then, on the bench, remove the components as described below to enable positioning of the engine on the overhauling stand, = Release the power unit from the support tools then Posttion itn a suitable workbench. 1. Slacken the festering screws and remove the starter motor. C\ EC ean a Vila 1. Slacken the fastening cuts and remove the gearbox and ciferential unitLi i ENGINE MAIN MECHANICAL UNIT 1. Slacken the three fastening screws and remove the lay shat. 2, Remove the dust guard ring 3, Remove the lower fywhee! cover. 1, Siacken the fastening screws and remove the press- ure plate body and clutch plate. ew 1. Slacken the fastening screw and remove the pinging censor trom the crankcase. 2. Slacken and remove the engine oll pressure meter. O41 - 12 1. Slacken ang remove the engine cil temperature sen- sor. 2. Slacken and remove the engine oil mnimum level sensor. 3, Slacken and remove the engine cil minimum pressure sensor. 1. Slacken the fastening screw and remove the rpm sensor. REFITTING Scribe: SE engine. Proceed as described for the Kah engin« Hy ENGINE MAIN MECHANICAL UNIT ON-VEHICLE OPERATIONS Below only the procedures which differ from the engine are given. Refertothe KGB}. ensine forthe items not men- tioned below. REMOVING/REFITTING CYLINDER HEAD Proceed as described for the ‘engine up to and including removing the auxiliary components drive pulley. 1. Slacken the fastening screw and remove the auxiliary ‘components drive bait guide pulley. Slacken the lower screws of the cover for the timing gear cme bets, 1. Lower the car, slacken the remaining fastening screws and remove the cove: for the timing gear drive belts. 1. Working on the timing gear belt tensioner, loosen the tension of tho batt, then prise it off the camshaft driving CSS [ff | sacattan 5 Complete the cylinder head removing/refitting pro- Ser 12-1995ty ENGINE MAIN MECHANICAL UNIT REMOVAL/REFITTING OF OIL SUMP ina cede ee cota sancena drive pulley. 1, Slacken the fastening screw and remove the auxiliary components drive belt guide pulley. = Slacken the lower screws of the cover for the tiring gear drive belts. 1. Lowerthe car, siacken the remaining fastening screws and remove the cover for the timing gear drive bets. 01-14 compe sun emowngreteng poser menarbet oro Bk abe = Bis CHANGING THE CRANKSHAFT FRONT OIL SEAL = Set the car ona lit = Disconnect the battory (-) terminal. = Remove the right front wheel and mud flap. 1. Raise the car and working as illustrated on the bett tensioner, loosen the tension of the auxiliary components, rive bett prise it of. 2. Slacken the four fastening screws and remove tha auxiliary components drive pulley. oth] 1. Slaoken the fastening screw and remove the auxiliary components drive belt guide pulley. - Slacken the lower screws of the cover for the timing gear drive batts. 1, Lower the car, slacken the remaining fastening screws and remove the cover for the timing gear drive betts. _ 1. Slacken the fastening screw and remove the socket oF the oll vapour recovery pipe. 102 1. Slacken the ‘estering screws and remove the ignition calls cover. 2. Disconnect the electrical connections from the igrition 1. Slacken the fastening serews and remove the igrition| 2. Slacken tne fastening screws and remove the igrition coils support bracket.Ht et 1. Slacken the fastening screws and remove the cylinder head cover complete with gasket. ES 1. Working on the timing gear bett tensioner, loosen the tension of the bel, then prise it of. 1. Slacken the two fastening nuts and remove the fly- wheel protection piate. % | 1. Install the flywheel stopper t9c! no, 1.820.630,000. as ilstrated, Pass7, = -yoo2 01-16 Ss | UO ] pS & J YY Q1 -17 te ENGINE MAIN MECHANICAL UNIT TECHNICAL CHARACTERISTICS AND 1. Slacken the fastening screw (left-handed) timing gear bet drive pulley, then remove it 1, Remove the oll sea and install a new one using too! no, 1.821.247,000, \— (\V), 1.621.247.000 Lop; = Fe-assemble reversing the sequence followed for removal, Refer to GROUP 00 for refitting the timing gear belt and timing operations. = SPECIFICATIONS } a ENGINE TECHNICAL CHARACTERISTICS i) Cycle Oto Astroke ry Fuel yer londion Wail Point Mevonie M2104 Firing order 129-4-2 Displacement on 1598 1747 Number of evinders| ain ne Bore mm 82 | Be Stok mm 75.65 a7 - waanan pamer GV EEC (KW EEC) 720 (88) 740 (103) ~ rom 6300 6900 a (Nm EEC) TAT (148) 163 (185) om 4500 4000 Comoression ratio 103:4 409:1 Engine ol prescure - Atisle speed bar 215 215 At 4000 rpm 245 245 lele speed pm | 80060 80050 COMPLETE CRANKCASE Crankcase Diameter of main journals Length of contre main bearing shoul (Class A T Diameter of evinders “c" (CURE. 82.070 - 62.020 [Ctass 82.020 ~ 82.030 Qversize 0.1 Oil pump Unit: men Ciszrance belween pump casing seat ee oe ae mie | creme ape gine oil pressure liming [Control load il valve Length of soning 12-1Hi Crankshaft ENGINE MAIN MECHANICAL UNIT Unit: mm Class A-Red | 52.994 ~ 53.000 Diameter ofmain [Class 8-Biue | 52.988 ~- 52.994 d bearingjoumals"a’[Gjass C - Yellow _| 52,962 - 52.088 t Undersize 0.127 Diameterot [Class A= Red 48.298 - 48.244 | 50.799 50.505 coneenng [GassB-Biue | 48.232~ 48.238 | 50.793 50.708 Kopne {GiaseC=Yelow | 48.26 - 48.282 [60.787 60733 Undersize 0.127 eae 26.575 = 26.505 Length of centre bearing journal ‘c* a a ‘Oversize 0.254 Mesimum teper of main cae and connecting rod journals Maximum error of concentrcty between main joumals and connecting 0.03 rod joumals Main half bea Unit: mm a [ 1.896 = 1.640 | 1.851 - 1.857 ‘Side main half bearing \CassB- Blue | 1.839 + 1.843] 1.836- 1.844 shim "at [Crass C- Yelow| 1.842 + 1.845 |1.843- 1.840 Undersize 0.127 (ClassA-Red_[1.831 = 1.835] 1626-1852 Centre main hatt [Ciass 8 -Biue_| 1.894 ~ 1.698] 1.891 1.599 bearing shim ‘a* [Class G- Yelow| 1.837 ~ 1.861]1.836~ 1.804 Undersize 0.127 Play between pin Side [0.025 ~ 0.052] 0.019-~0.082 land main haif bearing [Centre [0.035 = 0.062] 0.029 + 0.972 Half thrust rings Unit: mm a Oversize 0.127 [Crankshat end float 0.059 + 0.201 Engine flywheel a inside diameter of centre b I eee snes 10 = 47.035 mm ot (bore) "2 I aS eT owes gear for assembly on flywhest PAI788116V002 1995 ty ENGINE MAIN MECHANICAL UNIT CONNECTING ROD - PISTON ASSEMBLY Piston See Unit: mm [Gass A- Blue 1.952 = 81.962 (ED Diameter of pistons ‘a (1) [Class.8 = Pink 81.960 = 81.970 | Glass C- Green 81.958 = 81.978 {oI (Oversiz8 0.1 Height of fret seal ring seat “o" 1.580 = 1.540 Height of second seal ring seats ‘c* [151041530 1 { Height of oil scraper ring seats “a” [3.010 - 3.030 Hy Diameter of cudgeon pin holes in pistons "e* 20.002 ~ 20.007 RN (Clearance between eyinders and pistons 0.088 « 0.082 Oy [Diference in weight between pistons 259 Connecting rods (1) To be measured perpendicular to the gudgeon pin hole ata distance of 12.5 mm from lower edge of skirt, Unit: mm b a 2; Diameter of small end . | j bushing bore tat 20.006 - 20.012 =. Inside ciametar of SESE KT eecemercttti | core siase | soner-ssote 7 ends Ditlerence in weight beiween <9 1 rods (Celarance between email nd peer bushings and pine ene = Os [Small end end float I 025-06 Connecting rod half bearings fe < 88 116V002 [Class A- Red Unit: mm 1.536 = 1.540 | 1.527 = 1.531 Thickness of connecting rod|Ciass 8 - Blue 7.539 = 1.543] 1.531 = 1 half bearings *a" [Class C- Yellow] 1.542 = 1.546 | 1.535 ~ 1.539 Undersize 0.127 [Play between connecting [Class A~Red rodpins andtheirhalt [Class B - Blue bearings [Class C- Yellow] 0.030 ~ 0.056Hid 01 Hi ENGINE MAIN MECHANICAL UNTT O1 - 21 ENGINE MAIN MECHANICAL UNIT -20 Valve seats Seal rings tint: mm a fa ae ee oe ee UMM " tr Ouiside Giameter of Intake [35.135 = 35.150 Fisting ae 1 valve seats "at Exhaust [29.742 = 29.157 versie ; - aT aw TE Valve contact area taper "a" 90° = 10 | Picks of rings Second ting eae : interterence between valve [lake 0091=0.351 a 2075 + 2.090 ‘ |seats and their housings Exhaust 0.100 + 0.136 (Oil scraper ring od | iti of per ting EEE Oa « inde Peace toate fing 20°C [First ring 0.25 +0.50 so ing gap ‘b* (1) [Second nn 20-050 at = Valves [Oil scraper ring 0.25 +045 ate ie [aipay een cca RS 0500070 1 ieee amie lings and seats ae mb one Soe 4 i 6 Hameter of val Exhaust 6.960 ~ 6.975 sesePor ing ee —— Si meter of val Intake 33.4= 337, 7] Te be measured in the checking ring nut or in the oylinder. = = i ooo Each aacise ° Radial clearance between [Intake 0.032 + 0.065 Gudgeon pins [valve stem and guide: Exhaust 0.047 ~ 0.080 Unit: mm ‘Outside Giameter of gudgeon pine “a 719.996 ~ 20.000 Valve springs | between ia geeamgald 0.002 -0.011 ‘Outer soning Taner spring ene their seats on pistons Free length "Li" 46mm 39mm | T Length with valves closed "Lz 34mm 29.5 mm Li F 1, 271 +204N ‘95 = 106 N 2 “Le CYLINDER HEAD i bb Hi ‘Corresponding lead at “Le” 276-304) | (98-108 ks) Head Length with valves open *L3" 24,5 mm 20mm Unit: mam 6. ead at 485 ~ 524 N 201 =221N Diameter of valve guide seats a" 12,950 + 12.97 rrmeeporeting feed sts (49.4~53.4kg)_| (20.5 + 22.5 kg) Valve guide protrusion "bt 11.25 + 1175 Diameter of valve cup seats “c" 33,000 + 33.025. Hydraulic tappets Diameter of valve seat intake 35.019 = 35.044 a Unit: mm housing " Exhaust 29.021 + 29.042 | ‘Outside diameter of | 92.950 - 32.975 ‘Minimum depth of combustion chamber ‘e" I 13 rdf (hydraulic tappets "a" | Maximum error of flatnass of head lower surface on | [Radial clearance between hydraulic | err Diameter of camshaft supports “Tr 26.045 = 26.070 Co tappets and their seats i Diameter of timing variator suppor" | 55.990= 56.015 Unit: mm Valve guides | SS Unit: mm Diameter of camshatt joumals ‘at [26.000 ~ 26.015 b T 7 Diameter of timing variator journal " 48.985 ~ 50.000 i SSSSESESST 7 Outside diameter of valve cuides "a" 12.010 78.090 Scar earn ga Fo BRE GS i ——— se ‘Oversize 0.20 ‘Nersinal carat wee ies} _te SSE + nside diameter of vaive guices JExhaust 75 9. SSS Tee cameterchvanewues | cascrnnl (bore) *o° |and sheir seats [interierense between valve guides lend their seats 0.083 ~ 0.080 ~ | Camsnaft end float PASSTEBTIGVODE [Clearance between camshat journals | COS .007 | 010-023 PASTE VOOR 12. 1995Hi ENGINE MAIN MECHANICAL UNIT Timing variator halt bearings rn Thickness of timing variator half bearings 'a* 01 - 22 2.992 + 2.998 Unit: mm [Actual operating play between |tming variator and Ithe corresponding bearings ANGLES OF ACTUAL TIMING DIAGRAM (Obtained with control clearance 0.45 mm) 0.034 + 0.086 FLUIDS AND LUBRICANTS 01 - 23 sai Specified - Application Tyee | oyarciication Name Qty litres APIS SELENA 25 Engine ‘SPECIAL FORMULA ? (Refing) ’ cemes ‘ALFAROMEO sal SAE 1oWi40 rowsse () Ui: For decizedly sporive use of the car fully synthetic SELENIA Racing 10W/60 engine oll s recommended (1): Tota capacity @: Sump + fit (for periodical replacement) JOpens (before T..C.) ce Te rc > “~ SEALANTS AND ADHESIVES. Intake [Closes (after B.0.C.) | 40° 15°) Y Intake angle |B ‘Application Type Name ay [Opens (betore 8.D.C. “e | ae Oil sump - crankcase Silicone |Mascherpa - 7081 Exhaust (Closes (after 10.0.) ee 03__|RHONE PULENC- CAF 5552 = Exhaust angle I 207 ‘Timing variator Sealant |Loctite 270 (): Values obtained with timing variator engaged. ABRASIVES Application Type Name | Qty ns (before T.D.C.) -3*_ 22° () |SIPAL AREXONS: me Intake eee (ater 8.0.0) Sir 26° c eles seat cnn Abrasive |Carsosiicium for vanes [Ietake angle 28° Opens (before TDC) ae C Exhaust \Cioses (after 8.0.C.) 2 Exhaust angie 231° (): Values obtained with timing variator engaged.oy TIGHTENING TORQUES ENGINE MAIN MECHANICAL UNIT O1 -24 Hy ENGINE MAIN MECHANICAL UNIT SPECIAL TOOLS 01 - 25 Part a a) Screws fastening main bearing caps (no) [e-ne | 38-124 THOTT G00 (AZ.01S2) Valve suDpOR to) Serene fastening fiwrheel [oar= 1497] 2a 182 7.820.012.000 (&.2.0105| [Support fr eyinder head suppor foal ‘Ssrews fastening connecting rod caps Gn ol 453 45054 7.820.049,000-(A.2.0659) [Nut for valve suppor tool ‘Soren fastening auxiliary comoonenis onve belt pulley 24429 2450 0) [Engine suppor brackets for assembly on overhauling stand ‘Screw fastening timing gear belt drive pulley (left-handed) 340-378 | 34.7+98.5 3.820.225.000 |Support for removing/retitting the power unit Serene fastening water pump 17-21 4724 7.820258.000 Cylinder head suopot Engine oil minimum pressure waming light sensor 25-31 25+32 4.620.267.000 |Spacer for valve disassembly/re-assembly Sctens tasesing ol auiTg Ngee | agate 71220277.000 [Grasuated disk for angle tomue ighienng Oil eump érain plus 7221 ayeat 1.200.817.000__ |Crankshait pulley counter torque Screws fastening ol pump se aseos 4.820.518.000__[Adaotater for ting crankshaft Screws fastening EGR. valve ea ea 7.820.518.000 _[isk for centering crankshait rear oll seal ‘us fasening intake box to oyfndevFead Weer | uyeet 3.820,623.000 [Suncor for removingtefting the power unt See teri achat Sits WT od py Soc sme 1.3 524.600 [Feel stopper ol fo be use on he bee Nat fastening timing gear bek tensioner Za] 1,820,526.000_[Fiting for mallet_ a za Been nee ‘Screws fastening thermostatic cup to oyinger heed . i 821 124,000 (AB support for v ar ae pen - = a “ a i 7.821.161.000 (A.3.0617) [Mallet | 1.821.171,000 (A.3.0635) [Suppor gin for installing tools Spark plugs |Centre large 25-35 | 1.821.175.000 (A.3.0640) |Puller/installing tool for engine stay connecting rod silent-block side nat W212 1.821,176,000 (A3.0881) [Puller tool for valve guides Engh Snares gigs err a mk. temp vara 5 921205200 [Cape or eave sassy STD 1:821,206,000 installing ool for valve guide cll seal Engine coolant temperature sensor (NTO) a5 7.821.208.000 | Pulor tool for vaive guide cil scat Cylinder head tightening 1.821.228.000 installing tool for exhaust side camshaft oil seal | 5.821.247.000 __linstaling tool for crankshaft front cil seal Set ol the screws to a torque of: 2 20 71821.252.000 |Instaling too! for intake side camshaft oll seal | 7.821.254,000____|Inetallnc too! for valve ques % 7.822.144.000 Hexagon grooved wrench for removing/rfiting oil sumo Tighten the earews to a preliminary torue of: | «0 44 he 71822-145.000 Hexagon grooved wrench forremovingfeiting oil sump | 7.822,746,000____|Supoor for pulley wrenches “Tum all tho serews by an angle of | pee 71.822.147.000___[Wrench for timing variator ! 71822.149.000___ Wrench for tensioning timing belis 1.£22.155.000 Wrench fortiming gear pulley intake SiGe = 1,€22.156.000 [Wrench for timing gear pulley exhaust side 7.822.160.000 Wrench for removingefiting engine oll pressure sensor TH2E.013,000 (66.0183) [Tool fr eneciang TDC. 1.825.041.000 [Templates for timing camshafts (for 1747 enaine) 1.825,042.000 Hemplates for timing camshafts (for 1598 engine) (CY Not available at time of asgrsBt1E Voc? going to press. 12-1995