Professional Machining of the Engine In this segment, the engine block is followed to the professional machine shop where it is cleaned, checked for condition and machined to bring it to within the proper critical specs. Following are highlights from the process as shown in the episode. - The engine block is cleaned in a dip tank (figure A), and hosed off so that the machining process can begin with a good, clean engine.
- The cylinder liners are carefully removed from the engine (figure B). Cylinder liners uncommon, and these are unique to this particular engine. The entire cylinder can be removed, and is not cast into the block itself. In this way during the machining process, the cylinders can essentially be replaced if necessary -- eliminating the need for engine boring.
- All four cylinder liners are removed from the engine (figure C).
- Key measurements are taken inside the engine block, such as inside the crankshaft mains (figure D), before the actual machining process begins.
- After internal measurements have been taken, the crankshaft itself is polished (figure E) to proper specs.
- Measurements are then taken to ensure that the crankshaft journals have been polished to within exact parameters (figure F).
- Taking apart the valves requires the initial step of removing the valve-keepers by unloading the spring pressure (figure G) so that the retainer and valve-spring top can be removed, followed by the spring.
- With all of the springs removed, the engine head can be turned over for removal of the valves (figure H). The valves are removed and kept in their original order.
- The engine block is then professionally cleaned of carbon buildup to allow for an accurate evaluation of the cylinder head.
- With the valves removed, the top of the cylinder head can be checked for specs using a feeler gauge (figure I).
- With measurements taken and recorded, the cylinder head is bolted into an engine planer (figure J) so that exact amounts of metal can be removed to bring the head within proper specifications. This may require one or more passes on the planer.
- The planer ultimately brings the cylinder head down to the desired finish and square fit (figure K).
- The inside of the engine block is then sprayed with a cleaner and hosed off ( figure L). Cleaning the engine with water is permissible as long as all of the water is removed from the block afterward.
- With the engine back from the machine shop, it can be bolted back onto the engine stand (figure M) in preparation for re-assembly. Note that, because this is an alloy engine block, it can be lifted onto engine stand with only one person.
- The next step is a thorough cleaning of the crank saddles (figure N) and bearings, making certain there is no lint.
- The refurbished crank can then be lowered into position (figure O) to begin re-assembly.
In the segment that follows, the re-assembly of the Alfa engine gets fully underway.
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Alfa Romeo Owner's Bible: A Hands-On Guide to Getting the Most from Your Alfa
Model: 0837607078
Author: Pat Braden
Order this book from Amazon.com
Bentley Publishers
Alfa Romeo Spider: The Complete Story
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Crowood Press
Original Alfa Romeo Spider (Bay View Original Series)
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Essential Alfa Romeo Guilia & Giulietta Coupes & Spiders: The Cars and Their Story 1954-95
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Alfa Romeo: The Spirit of Milan
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Sutton Publishing
Classic Car Restorer's Handbook: Restoration Tips and Techniques for Owners ...
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