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

3239088 - 1020D17 engind front cover - r r

) 1. Use the tool on the automatic belt tensioner to loosen the single engine components drive belt.

	Name	Country
1	Key	1.860.966.000

2. Insert the tool in the special opening to keep the automatic tensioner in the 'fixed' position.

	Name	Country
2	Clip	1.870.645.000

3. Remove the engine components single drive belt tensioner plug.4. Loosen the bolt for the engine components single drive belt bolt.5. Remove the single drive belt.6. Remove the engine components single drive belt tensioner pulley plug.7. Undo the bolt (7a) and remove the engine components single drive belt pulley (7b).

1. Undo the bolts (1a) and remove the timing drive belt guard (1b).2. Undo the bolts (2a) and remove the power unit reaction rod attachment bracket (2b).3. Undo the bolts (3a) and remove the crankshaft pulley (3b).4. Loosen the timing belt tensioner nut.5. Remove the timing drive belt.

1. Undo the bolts (1a) and remove the air conditioning compressor (1b) complete with mounting.2. Release and remove the engine oil filter using a suitable tool.3. Unscrew the fitting.

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 single belt automatic belt tensioner (2b).

Rotate the engine on the overhauling stand.1. Disconnect the oil outlet pipe from the turbocharger from the crankcase sump.

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

1. Undo the bolts (1a) and remove the plates (1b) 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. Undo the bolts (1a) and remove the engine oil inlet (1b).2. Remove the O-ring.

1. Undo the bolts (1a) and remove the oil pump (1b) complete with gasket (1c).

Refitting ( Removing

) Fit the oil pump, complete with gasket, and tighten the bolts to torque.

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

Fit the engine oil inlet complete with O-Ring and fix it using the bolts.Apply sealant to the entire perimeter of the crankcase sump.

	Type	Component	Name	Qty.
-	Silicon sealant	OIL SUMP	-	-

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 bolts and the plates connecting the crankcase sump to the intermediate shaft support.Connect the condensation oil return pipe to the crankcase sump.Fit the complete oil dipstick and tighten the bolts.Connect the oil outlet pipe from the turbocharger to the crankcase sump.Fit the single belt tensioner. Fit the drive pulley and tighten the bolt (left) 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

Tighten the connector securing the engine oil heat exchanger to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Connector	ENGINE OIL HEAT EXCHANGER	-	3.0

Place the engine oil filter back in its housing and tighten it fully by hand after having lubricated the gasket using engine oil.Fit the air conditioning compressor complete with mounting and secure it using the bolts.1. Remove the bolt for the oil pump shown.2. Temporarily fit the timing drive belt on the drive pulley.3. 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
3	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.Recheck that the timing references and the tensioning references on the timing belt tensioner are aligned.

1. Fit the tool in the special hole to keep the automatic belt tensioner for the drive belt in a 'fixed' position.

	Name	Country
1	Clip	1.870.645.000

Fit the crankshaft pulley and tighten the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CRANKSHAFT PULLEY	M8	2.1 - 2.6

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 single belt pulley.Fit the single belt.1. Rotate the fixed tensioner (1a) for the drive belt using the tool (1b) A until the tool (1c) comes out, then tighten the bolt (1d) for the cam tensioner to torque.

	Name	Country
1b	Key	1.860.968.000

	Name	Country
1c	Clip	1.870.645.000

	Fastening	Component	Ø	Value(daNm)
1d	Bolt	VARIOUS S D BELT CAM TENSIONER	M10	4.2 - 5.2

Remove the tool.

	Name	Country
-	Clip	1.870.645.000

Fit the plugs on the pulley and the belt tensioner for the single belt.