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

3239088 - 1020D17 engind front cover - r r

) 1. Fit the flywheel retainer into its seat on the engine block.

	Name	Country
1	Counter-torque	1.860.846.001

1. Undo retaining bolts (1a) and remove engine crankshaft pulley (1b).2. Undo the fixing bolt (2a) and remove the automatic tensioner (2b) for the auxiliary drive belt.

1. Undo the fixing bolts (1a) and remove the camshaft shields (1b).

1. Undo the bolt (1a) and remove the complete engine oil dipstick tube (1b).

1. Slacken the nut on the timing belt moving tensioner.2. Remove the timing drive belt.

Rotate the engine through 180° on the overhauling stand.1. Undo and remove the engine oil level sensor.2. Undo the bolts (2a) using tools (2b).

	Name	Country
2b	Spanner	1.860.833.001

	Name	Country
2b	Spanner	1.860.834.001

3. Using a special tool (3a) cut the bead of sealant for the enigne oil sump (3b), then remove it.

1. Undo the fixing nuts and bolts (1a) and remove the engine oil intake chamber (1b).

Rotate the engine through 180° on the overhauling stand.1. Undo the bolt (1a) and remove the single drivel belt cam automatic tensioner (1b).2. Unscrew retaining bolts (2a) and remove automatic drivebelt tensioner bracket (2b).

1. Release and remove the engine oil filter cartridge.2. Unscrew connector (2a) and remove heat exchanger (2b).

1. Undo the bolt (1a) and remove the toothed drive pulley (1b).

The toothed drive pulley bolt is left-threaded.

1. Undo the bolts (1a) and remove the crankshaft front cover oil seal (1b) with the engine oil pump incorporated. Remove the underlying gasket .

Refitting ( Removing

) Rotate the engine through 180° on the overhauling stand.Fit the engine oil intake chamber and gasket and tighten the retaining bolts and nut.

	Fastening	Component	Ø	Value(daNm)
-	Bolts and nut	OIL SECTION PUMP	M6	0.9 ÷ 1.3

Fit the crankshaft front oil cover with integrated oil pump and tighten the bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CRANKSHAFT FRONT COVER	M6	0.9 - 1.2

Replace the engine oil sump sealant bead.

	Type	Component	Name	Qty.
-	Silicon sealant	OIL SUMP	Dow Corning 7091	-

Fit the engien oil sump in its seat and tighten the bolts.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	OIL SUMP	M6	(Side bolts) 0.9 ÷ 1.2

	Fastening	Component	Ø	Value(daNm)
-	Bolt	OIL SUMP	M8	(Front and rear bolts) 2.3 ÷ 3.3

	Name	Country
-	Spanner	1.860.833.001

	Name	Country
-	Spanner	1.860.834.001

Fit the engine oil level sensor and tighen in place.Rotate the engine through 180° on the overhauling stand.Fit a new gasket.Fit the toothed drive pulley and tighten the bolts.

The toothed drive pulley bolt is left-threaded.

	Fastening	Component	Ø	Value(daNm)
-	Bolt with left hand thread	TOOTHED DRIVE PULLEY	M16	32.9 ÷ 44.1

Fit the heat exchanger and tighten the fitting.

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

Place the engine oil filter back in its housing and tighten it fully by hand after having lubricated the gasket using engine oil.

	Fastening	Component	Ø	Value(daNm)
-	-	CARTRIDGE OIL FILTER	-	1.4 - 2.0

Fit the automatic tensioner bracket and tighten the fixing nuts.Fit the automatic tensioner and tighten the fixing bolts.Remove the flywheel lock.

	Name	Country
-	Counter-torque	1.860.846.001

1. Remove the plug (1a) and fit the camshaft timing tools (1b) to the cylinder head extension.

Check that the tools, marked with the letter 'A', are correctly inserted in the housings in the camshafts.

	Name	Country
1b	Gauge	1.870.896.900

1. Undo the bolt for the crankcase front cover shown in the diagram.Temporarily fit the timing drive belt on the drive pulley.2. Fit the tool (2a) and secure it gauged bolts (2b)

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
2a	Template	1.860.905.000

	Name	Country
2b	Calibrated screw	1.860.905.010

1. Tighten the bolt securing the timing belt pulley.2. Completely fit the timing belt.3. Apply leverage with a screwdriver to the tab of tensioner (3a) until pointer (3b) is in the position of maximum tension. Then tighten mobile tensioner nut (3c) while in this position. Remove the timing tools.

	Name	Country
-	Template	1.860.905.000

	Name	Country
-	Calibrated screw	1.860.905.010

	Name	Country
-	Gauge	1.870.986.900

Rotate the crankshaft through two revolutions.4. Check the timing references are aligned again, slacken the mobile tensioner bolt and move mobile pointer (4a) to hole (4b), i.e. the specified tensioning position. Then tighten belt tensioner nut (4c) to torque.

	Fastening	Component	Ø	Value(daNm)
4c	Nut	MOBILE TIMING TENSIONER	M8	2.5

Tighten the exhaust side camshaft toothed drive pulley fixing bolt to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	TIMING GEAR DRIVEN PULLEYS	M12	12

Remove the timing tools.Rotate the crankshaft through two revolutions.Check once again that the timing is correct by refitting the timing tools.

Fit only the exhaust side camshaft template because the intake side template is not accessible.

Check that the tensioning references on the timing belt tensioner are aligned.Tighten the bolt for the crankcase front cover previously removed.Tighten the plug in the camshaft housing for fitting the exhaust side timing tool.Fit the engine oil dipstick pipe and tighten the bolts.Fit the toothed timing belt protective covers and tighten the bolts.Fit the flywheel retainer.

	Name	Country
-	Counter-torque	1.860.846.001

Fit the crankshaft pulley in place and tighten the fixing bolts.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CRANKSHAFT PULLEY	M8	2.3 ÷ 3.3

Fit the single belt fixed tensioner and fix it using its bolt.Remove the flywheel lock retainer.

	Name	Country
-	Counter-torque	1.860.846.001