1088C20 WATER PUMP - R + R WITH ENGINE REMOVED - Alfa - 156 - eLearn

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

) 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.

	Name	Connector
2	Detonation 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.

	Name	Connector
3	Throttle body actuator	N75

1. Undo the fixing bolt (1a) and disconnect the earth lead (1b) from the air capacity chamber.

	Name	Connector
1b	Earth 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.

	Name	Connector
1	Injector	N70

2. Disconnect the electrical connections from the right cylinder head ignition coils.

	Name	Connector
2	Ignition 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.

	Name	Connector
1b	Earth 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.

	Name	Connector
1	Injector	N70

2. Disconnect the electrical connections from the left cylinder head ignition coils.

	Name	Connector
2	Ignition 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.

	Name	Country
1b	Counter-torque	1.822.146.000

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.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	COOLANT PUMP	M6	(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.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	FIXED TENSIONER	M10	(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.

	Name	Country
1	Gauge	1.870.849.000

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

	Name	Country
1a	Fitting tool	1.821.225.000

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.

	Name	Country
1a	Belt tensioner	1.860.950.000

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.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	TIMING GEAR DRIVEN PULLEYS	M12	(Camshaft side) 7.2 ÷ 8.8

	Name	Country
1b	Support for counter-torque	1.860.831.000

Remove the tool for timing the camshafts.

	Name	Country
-	Gauge	1.870.849.000

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

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAMSHAFT 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.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	MOBILE TIMING TENSIONER	M8	(Cylinder head side) 1.9 ÷ 2.3

Remove the belt tensioner tool.

	Name	Country
-	Belt tensioner	1.860.950.000

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.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CAM COVERS	M7	(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.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	IGNITION COIL/REEL	M6	(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.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	IGNITION COIL/REEL	M6	(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 .

Removing ( Refitting

) 1. Undo the bolt (1a) and the nut (1b) and remove the single drive belt guard (1c).2. Adjust the automatic belt tensioner with a wrench to slacken the tension of the single drive belt.3. Remove the single drive belt.4. Undo the bolt (4a) and remove the fixed single drive belt tensioner (4b).

1. Undo the bolts (1a) and remove the upper timing belt guard (1b).2. Undo the bolts (2a) and remove the single drive belt drive pulley (2b).3. Undo the bolts (3a) and remove the lower timing belt guard (3b).4. Slacken the counter-balance shafts belt tensioner nut and remove the counter-balance shafts drive belt.5. Loosen the timing belt tensioner nut.6. Remove the timing belt.

1. Undo the bolt (1a) and remove the left side timing belt guard (1b).2. Undo the bolts (2a) on the inlet side camshaft pulley, using the tool (2b) for counter-torque.

	Name	Country
2b	Counter-torque	1.822.155.000

3. Remove the inlet side camshaft pulley.4. Undo bolts (4a) and remove water pump (4b) complete with O-ring (4c).

Refitting ( Removing

) 1. Fit the water pump (1a) complete with new O-ring (1b) and fix it tightening the bolts (1c) to torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	ORDINARY PREPARATION	M6	1.7 - 2.1

2. Fit the inlet side camshaft pulley (2a) and fix it using the bolts (2b) without tightening them.3. Fit the left side timing belt guard (3a) and fix it using the bolt (3b).Loosen the bolt on the exhaust side camshaft pulley using the tools for counter-torque.

	Name	Country
-	Counter-torque	1.822.146.000

	Name	Country
-	Counter-torque	1.822.156.000

1. Disconnect the electrical connections from the ignition coils.

	Name	Connector
1	Ignition coil	A30

2. Disconnect the earth lead from the cylinder head.3. Disconnect the high-tension leads (3a) from the spark plugs using the tool (3b).

	Name	Country
3b	Pliers	1.820.636.000

4. Disconnect the oil vapour recovery pipe from the rocker cover.

Undo the bolts and remove the bracket complete with ignition coils and high-tension leads.Undo the bolts and remove the rocker cover complete with gasket.1. Fit the tool (1a), complete with dial gauge (1b), in the housing of the spark plug for cylinder no. 1.

	Name	Country
1a	Extension	1.825.013.000

Rotate the crankshaft until the piston for cylinder no. 1 is at T.D.C. at the power stroke. Undo the bolts an remove the third caps from the inlet and exhaust camshafts.2. Fit the tool (2a) in place of the removed camshaft caps, and fix it tightening the bolts (2b) to torque.

Check that the camshaft cam profile matches the tool perfectly.

	Name	Country
2a	Gauge	1.825.041.000

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	ENGINE TIMING ADJUSTMENT TEMPLATES	M7	1.0

Fit the timing belt.1. Apply maximum tension to the timing belt using the tool.

	Name	Country
1	Key	1.822.149.000

2. Tighten the timing belt tensioner nut to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	MOBILE TIMING TENSIONER	M8	2.1 - 2.6

3. Tighten the bolts (3a) of the inlet side camshaft pulley, using the tool (3b) for counter-torque.

	Name	Country
3b	Counter-torque	1.822.155.000

4. Tighten to torque the bolt (4a) on the exhaust side camshaft pulley, using the tools (4b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
4a	Bolt	TIMING GEAR DRIVEN PULLEYS	M12	10.0 - 12.4

	Name	Country
4b	Counter-torque	1.822.146.000

	Name	Country
4b	Counter-torque	1.822.156.000

Undo the bolts and remove the tool.

	Name	Country
-	Gauge	1.825.041.000

Fit the camshaft caps removed previously and tighten the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAMSHAFT CAPS	M7	1.3 - 1.6

Rotate the crankshaft through two revolutions.Slacken the timing belt tensioner nut.5. Line up the moving reference (5a) on the timing belt tensioner with the reference hole (5b) using the tool (5c).

	Name	Country
5c	Key	1.822.149.000

Tighten the timing belt tensioner nut to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	MOBILE TIMING TENSIONER	M8	2.1 - 2.6

Rotate the crankshaft until the piston of cylinder no. 1 is at T.D.C.1. Position the counter-balance shafts so that the references on the pullies line up with those on the front covers.2. Fit the counter-balance shafts drive belt.

1. Tension the counter-balance shafts drive belt using the tool (1a) so that the reference hole (1b) on the belt tensioner is at the centre of the rotation sector.

	Name	Country
1a	Key	1.822.154.000

2. Tighten the counter-balance shafts belt tensioner nut.

Remove the tool complete with dial gauge.

	Name	Country
-	Extension	1.825.013.000

Fit the spark plug for cylinder no. 1.Fit the rocker cover complete with gasket and fix it using the bolts. Connect the oil vapour recovery pipe to the rocker cover.Fit the bracket complete with ignition coils and high-tension cables and fix it using the boltsConnect the high-tension leads to the spark plugs.Connect the earth lead to the cylinder head.Connect the electrical connections to the ignition coils.

	Name	Connector
-	Ignition coil	A30

Fit the lower timing belt guard and fix it using the bolts.Fit the upper timing belt guard and fix it using the bolts.Fit the single drive belt pulley and tighten the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CRANKSHAFT PULLEY	M8	2.4 - 2.9

Fit the fixed single drive belt tensioner and fix it with its bolt.Fit the auxiliary components drive belt, using a spanner to lever on the automatic belt tensioner.Fit the single drive belt guard and fix it using the nut and bolt.