1020D17 ENGIND FRONT COVER - R R - Alfa - 156 - eLearn

3239088 - 1020D17 engind front cover - r r

) Adjust the automatic belt tensioner with a wrench to slacken the tension of the single engine component drive belt.1. Remove the single drive belt.

1. Undo the bolts (1a) and remove the crankshaft pulley (1b).2. Undo the bolt (2a) and remove the single drive belt fixed guide pulley (2b).3. Undo the bolts (2a) and remove the power unit reaction rod attachment bracket (2b).

1. Undo the bolts (1a) and remove the timing drive belt guard (1b).2. Loosen the timing belt tensioner nut.3. Remove the timing drive belt.

1. Fit the tool.

	Name	Country
1	Counter-torque	1.820.624.000

1. Undo the bolt (left) (1a) and remove the drive pulley (1b).2. Undo the bolts (2a) and remove the timing side power unit support (2b).3. Disconnect the water inlet and outlet pipes from the water-oil heat exchanger.4. Undo the bolt (4a) and remove the timing belt fixed tensioner (4b).

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

	Name	Connector
1b	Alternator	A10

2. Undo the bolt (2a) and remove the auxiliary shaft drive belt automatic tensioner (2b).3. Undo the bolts (3a) and remove the support (3b), complete with power steering pump (3c) and timing belt tensioner.

1. Undo the bolts (1a) and remove the complete oil dipstick (1b).2. Disconnect the condensation oil return pipe to the sump.

Rotate the engine through 180° on the overhauling stand.1. Undo the bolt connecting the crankcase sump to the intermediate shaft support.2. Undo the front and rear bolts (2a) for the crankcase sump using the tool (2b).

	Name	Country
2b	Key	1.822.145.000

3. Undo he side bolts (3a) for the crankcase sump using the tool (3b).

	Name	Country
3b	Key	1.822.144.000

4. Remove the crankcase sump.

To release the crankcase sump, tap it gently with a a resin hammer, then use a screwdriver to lever on the special projections at the side of the crankcase sump.

1. Remove the oil filter.2. Remove the pin (2a) and remove the water-oil heat exchanger (2b).3. Undo the bolts (3a) and remove the crankcase front cover with the built-in oil pump (3b) complete with inlet.Remove the crankshaft front oil seal.

Refitting ( Removing

) 1. Fit a new crankshaft front oil seal (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.821.247.000

Fit the crankcase front cover with built-in oil pump, complete with inlet, and tighten the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CRANKSHAFT FRONT COVER	M6	0.8 ÷ 1.0

Place the heat exchanger back in its housing.Tighten the connector securing the heat exchanger to the recommended torque.

For versions prior to engine n° 1586000, replace the connector securing the heat exchanger with the one supplied by the Parts Dept. which has a flexible, tapered washer in addition to the O-Ring.

	Fastening	Component	Ø	Value(daNm)
-	Connector	ENGINE OIL HEAT EXCHANGER	-	6.0

Fit the oil filter, tightening it fully by hand, after having lubricated the gasket using engine oil.Apply sealant to the entire perimeter of the crankcase sump.

	Type	Component	Name	Qty.
-	Silicon sealant	ENGINE REAR MOUNT GASKETS	Dow Corning 7091	-

Fit the crankcase sump.Tighten the side bolts for the crankcase sump to torque using the tool.

	Fastening	Component	Ø	Value(daNm)
-	Side bolts	OIL SUMP	M6	(engine crankcase side) 0.7 ÷ 0.9

	Name	Country
-	Key	1.822.144.000

Tighten the front and rear bolts for the crankcase sump to torque using the tool.

	Fastening	Component	Ø	Value(daNm)
-	Front and rear bolt	OIL SUMP	M8	(Engine crankcase side) 2.1 ÷ 2.6

	Name	Country
-	Key	1.822.145.000

Tighten the bolt securing the oil sump to the intermediate shaft support.Rotate the engine through 180° on the overhauling stand.Connect the condensate oil return pipe to the crankcase sump and fix it using the band.Fit the engine oil dipstick assembly and fix it using the bolts.Fit the support complete with power steering pump and timing belt tensioner and fix it using the bolts.Fit the auxiliary shaft belt tensioner and fix it using the relevant bolt.Fit the alternator and fix it using the bolts.Fit the fixed timing belt tensioner and secure it using the bolts.Connect the water inlet and outlet pipes from the water-oil heat exchanger and fix them using the bands.Fit the power unit support, timing gear side, and fix it using the bolts.1. Fit toothed drive pulley (1a) and tighten bolt (anticlockwise) (1b) to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt with left hand thread	TOOTHED DRIVE PULLEY	M16	30.6 - 37.8

Remove the tool.

	Name	Country
-	Counter-torque	1.820.624.000

1. Remove the bolt for the oil pump shown.Temporarily fit the single toothed timing drive belt to the drive pulley.2. Fit the tool.

To allow the engagement of the locating dowel on the timing drive belt drive pulley in the opening in the tool, rotate the crankshaft using small movements.

	Name	Country
2	Template	1.860.905.000

1. Rotate the driven pulley so that the timing references line up.2. Completely fit the timing belt.3. Use a screwdriver to lever in the hole (3a) until the reference on the tensioner (3b) lines up with the reference hole (3c) and, in this position, tighten the belt tensioner nut (3d) to torque.

	Fastening	Component	Ø	Value(daNm)
3d	Nut	MOBILE TIMING TENSIONER	M10	4.2 ÷ 5.2

Remove the tool.

	Name	Country
-	Template	1.860.905.000

Rotate the crankshaft through two revolutions.Check once again that the timing references and the tensioning references on the timing belt tensioner coincide.

Fit the timing drive belt guards and fix them using the bolts.Fit the power unit reaction rod attachment bracket and fix it using the bolts.Fit the engine component single drive belt guide pulley and fix it using the bolt.Fit the crankshaft pulley.Fit the single engine component belt by adjusting the automatic belt tensioner using a wrench.