Engine Re-Assembly With the engine block professionally machined, and all major engine parts carefully inspected, cleaned and -- where necessary -- reconditioned, the re-assembly of the Alfa's engine can now get underway. The engine is back in the shop, and securely attached on the engine stand. Following are highlights from the process as shown in the episode. - The most critical factor in engine re-assembly is attention to detail. As the assembly progresses, removed parts that have been carefully cleaned, stored and cataloged, are laid out methodically when the time approaches for their re-installation (figure A).
- Careful measurements and pre-fits are conducted at critical points during the process to make sure that parts fit together exactly as they should.
- For example, in our demonstration re-assembly begins with the pistons. Piston clips are fitted carefully into each piston (figure B), being careful not to cause damage.
- Connecting rods and pistons are assembled with great care, using specialized lubricant where needed (figure C).
- A unique feature to this engine is the presence of cylinder liners. Sealer is used at the bottom of each cylinder liner, where it connects to the water jacket, as the O-ring is installed (figure D). This will prevent oil and water from coming into contact.
- Applying some oil to the piston helps it slide into the liner.
- Assembly lube is applied to the connecting rod bearings (figure E).
- With protective rubber caps installed on the connecting-rod bolts (figure F), each piston and cylinder-liner assembly can be lowered into its corresponding cylinder (figure G). The rubber caps protect the crankshaft from damage as the bolts are inserted.
- As each connecting rod is inserted into the engine, it is carefully guided from underneath the engine to minimize any contact between the connecting rod and crank journals.
- With the cylinder liners all re-installed, they are carefully measured to ensure that they are positioned to within exacting specs with reference to the upper surface of the block. Proper positioning at this point will ensure that they will be held in place once the head is bolted on.
- On the Alfa's high-performance engine, the valves are installed so that they contact the pistons at notched surfaces (figure H) to keep the engine running within exact tolerances.
- The engine block is rotated on the stand so that the connecting rods can be bolted in place. The nuts holding the connecting rods in place are installed carefully, and torqued to established specifications using a torque wrench (figure I).
- Assembly of components outside the block can now begin with the chain (figure J), drive for distributor and thrust washer.
- The front timing-cover is assembled and fit with the necessary gaskets (figure K).
- The assembled cover, including the oil-pump installed (figure L) is then bolted onto the engine.
- The water pump is fitted with its gasket (figure M) which is secured with glue.
- Once the water-pump gasket is installed, the pump can be bolted in place on the engine block (figure N).
- Next, the distributor-tack drive (figure O) is installed.
- With the engine block inverted on the engine stand, the reconditioned oil-pan can be reinstalled. The Alfa's oil pan is baffled inside (figure P) to help prevent the oil from sloshing to one side during extreme cornering -- another feature owing to the car's racing heritage.
- Valve installation begins next with the insertion of the valve (figure Q), retainer, spring and seal into the cylinder head.
- With the valve spring inserted, the retainer is installed using a specialized tool (figure R), and then locked in place.
- Making notes of measurements with respect to the valves helps to determine which shims should be used when installing the follower device.
- The cams are inspected and reinstalled (figure S), making certain that each is installed on the proper of the engine.
- With the cams in place, the cam caps can be installed, and their bolts torqued to proper specs.
- A dowel pin installed on the cylinder head (figure T) is critical in that it guides the head gasket as it is positioned.
- The head gasket is installed by lowering it down over the studs and placed precisely on the cylinder head (figure U) so that it will have the proper crush-effect on the liners.
- The timing chain is installed into the cylinder head by fishing it carefully into position using a bent piece of wire. In this case, a bent coat-hanger came in handy for this operation.
- With the head gasket in place, the cam can be lowered into position (figure V).
- The ends of the timing chain are then connected using a locking link (figure W) that must be installed from the correct side. A metal tab on the outside of the chain locks the link in place.
- The bolts that hold the cylinder head are torqued to spec, including the one that also holds the strap used in hoisting the engine (figure X).
- Tightening the nuts on the bolts to proper torque, and installing the valve cover (figure Y) finishes the installation of the cylinder head to the block.
- Specialized 4-gap, 4-electrode sparkplugs are installed into the engine block. This is a performance plug that is unique to this particular engine.
- Engine ducts are sealed with tape to prevent dust and debris getting inside the engine as it's re-mounted in the car. Once the clutch is bolted back in place, the engine is ready to reinstall in the vehicle.
In the segment that follows, the transmission is installed back onto the engine.
RESOURCES :
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
Model: 1861261225
Author: John Tipler
Order this book from Amazon.com
Crowood Press
Original Alfa Romeo Spider (Bay View Original Series)
Model: 0760311625
Author: Chris Rees, James Mann
Order this book from Amazon.com
Motorbooks International (MBI Publishing)
Essential Alfa Romeo Guilia & Giulietta Coupes & Spiders: The Cars and Their Story 1954-95
Model: 1870979591
Author: David Hodges
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Motorbooks International (MBI Publishing)
Alfa Romeo: The Spirit of Milan
Model: 0750919582
Author: David G. Styles
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Sutton Publishing
Classic Car Restorer's Handbook: Restoration Tips and Techniques for Owners ...
Model: 1557881944
Author: Jim Richardson
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H.P. Books
Classic Car Restoration Guide: The Complete Illustrated Step-By-Step Manual
Model: 1850108900
Author: Lindsay Porter
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Haynes Publishing
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