3239083 - 1088C20 water pump - r + r with engine removed

Removing ( Refitting ) Proceed with the removal  - 1004D40  engine - position on stand and remove . 1. Open the cover of the electrical connection box. 2. Disconnect the electrical connection for the knock sensor timing side.

NameConnector
2Detonation sensor - 1  K50 
1. Loosen the bands fixing the inlet ducts to the air chamber.2. Loosen the band securing the engine oil vapour recovery pipe to the air chamber. 3. Disconnect the electrical connection from the throttle casing integrated with the D.V.L.

NameConnector
3Throttle body actuator  N75 
1. Undo the fixing bolt (1a) and disconnect the earth lead (1b) from the air capacity chamber.

NameConnector
1bEarth on engine  C40 
2. Undo the bolt fixing the reinforcement strut to the support on the engine for the reaction rod.3. Undo the bolts (3a) and remove the air chamber (3b).
1. Disconnect the electrical connections from the right cylinder head injectors.

NameConnector
1Injector  N70 
2. Disconnect the electrical connections from the right cylinder head ignition coils.

NameConnector
2Ignition coil  A30 
3. Undo the bolts (3a) and move the electrical wiring (3b) aside.
1. Undo the bolts (1a) and remove the ignition coils (1b) from the right cylinder head.
1. Undo nut (1a) and disconnect earth lead (1b) from the left cylinder head.

NameConnector
1bEarth on engine  C40 
1. Undo the bolts (1a) and remove the left cylinder head ignition coils cover (1b).
1. Disconnect the electrical connections from the left cylinder head injectors.

NameConnector
1Injector  N70 
2. Disconnect the electrical connections from the left cylinder head ignition coils.

NameConnector
2Ignition coil  A30 
3. Undo the bolts (3a) and move the electrical wiring (3b) aside.
1. Undo the bolts (1a) and remove the ignition coils (1b) from the left cylinder head.
1. Undo the bolts (1a) and remove the upper protective timing cover (1b).
1. Undo the bolts (1a) and remove the lower protective timing covers (1b).
1. Loosen the bolts fixing the moving timing tensioner.2. Release the timing drive belt from the driven pullies.
1. Undo the bolts (1a), the bolt (1b) and remove the bracket (1c).
1. Undo the bolts (1a) and remove the tappet cover for the left cylinder head (1b), complete with gasket.
1. Loosen the bolts (1a) fixing the driven pullies using the tool (1b) for counter-torque.

NameCountry
1bCounter-torque1.822.146.000
1. Undo the bolts (1a) and remove the right cylinder head tappet cover (1b), complete with gasket.
1. Undo the bolt (1a) and remove the fixed timing belt tensioner (1b).2. Undo the fixing bolts (2a) and remove the water pump (2b) complete with cover (2c) and bracket (2d).
Whilst removing the water pump take care not to release the rigid water pump inlet pipe from the thermostat.
3. Remove the seal.
Refitting ( Removing ) 1. Place the water pump (1a), complete with cover, bracket and gasket, back in its housing, then tighten the bolts (1b) to the recommended torque.

FasteningComponentØValue(daNm)
1bBoltCOOLANT PUMPM6(Engine crankcase side) 0.8 ÷ 1.0
2. Fit the fixed timing belt tensioner (2a) and secure by tightening the bolt (2b) to the recommended torque.

FasteningComponentØValue(daNm)
2bBoltFIXED TENSIONERM10(Cylinder head side) 4.5 ÷ 5.5
1. Carry out a preliminary check on the camshaft timing: fit a spanner in the special opening (1a) in the centre of the camshafts and rotate them until the reference marks (1b) on the actual shafts coincide with the cylinder head upper surface.
The reference marks should be facing the centre of each cylinder head.
1. Remove the camshaft caps 4 and 7 from the left cylinder head.2. Remove the camshaft caps B and G from the right cylinder head.
1. Position the timing templates in place of the camshaft caps removed.

NameCountry
1Gauge1.870.849.000
1. Fit the tool (1a), complete with dial gauge (1b), in the housing of the spark plug for cylinder no. 1.

NameCountry
1aFitting tool1.821.225.000
Rotate the crankshaft, using small movements (in both directions), until the piston for cylinder no. 1 is at T.D.C. at the power stroke.
Make sure that the last crankshaft rotation is in the direction of operation.
1. Fit the timing drive belt starting from the drive pulley and continuing in an anti-clockwise direction, making sure that the drive sections are firmly taut.
1. Fit the tool (1a) and secure it with the bolt (1b) to the alternator bracket and with the bolt (1c) to the water pump.
The tool tooth should press on the moving part of the timing belt tensioner.

NameCountry
1aBelt tensioner1.860.950.000
2. Act on the nut (2a) for the belt tensioner tool until the moving reference on the belt tensioner (2b) is under the fixed reference.
1. Tighten the bolts (1a) fixing the driven pullies to the recommended toruqe using the tool (1b) for counter-torque.

FasteningComponentØValue(daNm)
1aBoltTIMING GEAR DRIVEN PULLEYSM12(Camshaft side) 7.2 ÷ 8.8

NameCountry
1bSupport for counter-torque1.860.831.000
Remove the tool for timing the camshafts.

NameCountry
-Gauge1.870.849.000
Place the previously removed camshaft caps back in their housings and secure them tightening the bolts to the recommended torque.

FasteningComponentØValue(daNm)
-BoltCAMSHAFT CAPS/M8(Cylinder head side) 1.8 ÷ 2.0
Rotate the crankshaft through two revolutions in its direction of rotation to allow the timing belt to bed in.1. Check that the moving reference on the timing belt moving tensioner lines up with the fixed reference.2. If the references do not line up, slightly discharge the tensioner acting on the tensioning tool nut and make sure that the references are aligned. 3. Tighten the bolts fixing the moving tensioner to the recommended torque.

FasteningComponentØValue(daNm)
3BoltMOBILE TIMING TENSIONERM8(Cylinder head side) 1.9 ÷ 2.3
Remove the belt tensioner tool.

NameCountry
-Belt tensioner1.860.950.000
1. Place the cylinder head tappet covers (1a), complete with gaskets, back in their housings and secure them tightening the bolts (1b) to the recommended torque.

FasteningComponentØValue(daNm)
1bBoltCAM COVERSM7(Cylinder head side) 1.4 ÷ 1.7
Place the bracket back in its housing and secure it using the bolts.Place the lower protective timing covers back in their housings and secure them using the bolts.Fit the upper protective timing gear cover and fix it using the bolts.1. Place the ignition coils (1a) back in their housings on the left cylinder head and secure them tightening the bolts (1b) to the recommended torque.

FasteningComponentØValue(daNm)
1bBoltIGNITION COIL/REELM6(Tappet cover side) 0.8 ÷ 1.0
Place the electrical wiring back in its housing and fasten it using the bolts.Connect the electrical connections to the left cylinder head ignition coils.Connect the electrical connections to the left cylinder head injectors.Fit the ignition coils cover in the housing on the left cylinder head and fix it using the bolts.Connect the earth lead to the left cylinder head and secure using the nut.1. Place the ignition coils (1a) back in their housing on the right cylinder head and secure them tightening the bolts (1b) to the recommended torque.

FasteningComponentØValue(daNm)
1bBoltIGNITION COIL/REELM6(Tappet cover side) 0.8 ÷ 1.0
Place the electrical wiring back in its housing and fasten it using the bolts.Connect the electrical connections to the right cylinder head ignition coils.Connect the electrical connections to the right cylinder head injectors.Place the air chamber back in its housing and secure it using the bolts.Tighten the bolt fixing the reinforcement strut to the support on the engine for the reaction rod. Connect the earth lead to the air chamber and secure it using the bolt.Connect the electrical connection to the throttle body integrated with the D.V.L.Tighten the band fastening the engine oil vapour recovery pipe to the air chamber.Tighten the bands fixing the inlet ducts to the air chamber.Connect the electrical connection for the knock sensor timing side.Close the electrical connections box. Proceed with the refitting  - 1004D40  engine - position on stand and remove .