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

3239088 - 1020D17 engind front cover - r r

) 1. Fit the tool.

	Name	Country
1	Counter-torque	1.820.624.000

1. Slacken the bolt securing the timing belt pulley.Remove the tool.

	Name	Country
-	Counter-torque	1.820.624.000

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 bolts (1a) and remove the counter-balance shafts belt drive pulley (1b).2. Fully undo the bolt (2a) previously slackened and remove the timing belt drive pulley (2b).3. Undo the bolts (3a) and remove the timing side rigid power unit support (3b).4. Disconnect the water outlet pipe from the water-oil heat exchanger.5. Disconnect the water inlet pipe to the water-oil heat exchanger.

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 sump, tap it gently with a wooden or resin hammer, then use a screwdriver to lever against the specific projections on the sides of the sump.

1. Undo the bolts (1a) and remove the oil pump (1b) complete with intake duct (1c), water-oil heat exchanger (1d) and oil filter (1e).2. Remove the seal.Remove the crankshaft front oil seal.

Refitting ( Removing

) Fit the oil pump complete with intake duct, water-oil heat exchanger, oil filter and a new gasket and tighten the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CRANKSHAFT FRONT COVER	M6	0.6 - 0.8

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

	Name	Country
1b	Fitting tool	1.821.247.000

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	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	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 water inlet pipe to the water-oil heat exchanger and fix it using the clip.Tighten the connector on the water outlet pipe from the water-oil heat exchanger.Fit the power unit support, timing gear side, and fix it using the bolts.Fit the timing belt drive pulley and fix it using the bolt, without tightening it.Fit the counter-balance shafts belt drive pulley and fix it using the bolts.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. Slacken the bolt (1a) on the exhaust side camshaft pulley, using the tools (1b) for counter-torque.

	Name	Country
1b	Counter-torque	1.822.146.000

	Name	Country
1b	Counter-torque	1.822.156.000

2. Slacken 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

1. Fit the tool (1a), complete with dial gauge (1b), in the housing in the spark plug for the 1st cylinder.

	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 belt tensioner nut to torque.

	Fastening	Component	Ø	Value(daNm)
2	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	1.2 - 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.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.Fit the tool.

	Name	Country
-	Counter-torque	1.820.624.000

Tighten the timing belt pulley bolt to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt with left hand thread	TOOTHED DRIVE PULLEY	M16	34.0 ÷ 37.8

Remove the tool.

	Name	Country
-	Counter-torque	1.820.624.000

Removing ( Refitting

) Proceed with the removal - 1004D40 engine - position on stand and remove . 1. Disconnect the electrical connections from the ignition coils.

	Name	Connector
1	Ignition coil	A30

2. Undo nut (2a) and disconnect earth lead (2b) from the cam cover.3. Undo the bolts (3a) and move the wiring duct (3b) aside.

1. Undo the bolts (1a) and remove the ignition coil (1b).

1. Undo the bolts (1a) and remove the tappet cover (1b), complete with seal.

1. Undo the bolts (1a) and remove the crankshaft pulley (1b).2. Undo the bolts (2a) and rmeove the lower timing cover (2b).

1. Loosen the nut for the counter-balance shaft toothed drive belt tensioner.2. Release and remove the counter-balance shaft drive belt.

1. Undo the nut securing the timing belt mobile tensioner.2. Prise off and remove the timing belt.

1. Undo the plug and drain the engine oil.

Recover the engine oil in a suitable container.

Rotate the engine through 180° on the overhauling stand.1. Undo the front and rear bolts (1a) securing the crankcase sump using tool (1b).

	Name	Country
1b	Spanner	1.860.833.001

2. Undo the side bolts (2a) securing the crankcase sump using tool (2b).

	Name	Country
2b	Spanner	1.860.834.001

3. Cut the crankcase sump sealant using the tool.

	Name	Country
3	Blade	1.870.718.000

4. Remove the crankcase sump.

1. Undo the nuts (1a) and remove the timing side rigid engine support (1b).2. Undo the bolts (2a) and remove the counter-rotating balancer shaft drive belt drive pulley (2b).

1. Fit the flywheel lock.

	Name	Country
1	Counter-torque	1.860.846.001

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

1. Undo the bolt securing the engine oil intake chamber to the main bearing cap.

1. Undo bolts (1a) and remove the crankshaft front cover (1b) with built-in oil pump complete with inlet (1c), engine oil heat exchanger (1d) and engine oil filter (1e). 2. Remove the gasket.

1. Position the front crankcase cover assembly in a vice with protective jaws.2. Undo the bolts (2a) and remove the engine oil inlet (2b).3. Remove the gasket.4. Remove the engine oil filter using a suitable tool.5. Undo pin (5a) and remove the heat exchanger (5b), complete with pipes (5c).6. Remove the gasket.7. Prise out the oil seal from the front crankcase cover.

Take care not to damage the oil seal seat during removal.

Refitting ( Removing

) 1. Refit oil seal (1a) in the front crankcase cover using tool (1b).

	Name	Country
1b	Fitting tool	1.821.147.000

Fit the front crankcase cover in a vice with protective jaws.Place the engine oil heat exchanger, complete with gaskets and pipes, back in its housing and secure using the pin.Place the intake chamber, complete with gasket, back in its housing and secure it using the bolts.Rotate the engine throughi 180° on the overhauling stand.1. Fit the engine block front cover (1a) with built-in oil pump complete with gasket (1b), intake chamber (1c) and engine oil heat exchanger (1d). 2. Tighten the crankcase front cover bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	CRANKSHAFT FRONT COVER	M6	(Engine crankcase side) 0.8 ÷ 1.0

Tighten the bolt securing the engine oil intake chamber to the main bearing cap.Lubricate the gasket with engine oil and fit the engine oil filter, tightening fully by hand.1. Place the toothed drive pulley (1a) back in its housing and secure it by tightening the bolt (left hand thread) (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt with left hand thread	TOOTHED DRIVE PULLEY	M16	(Crankshaft side) 20.9 ÷ 23.1

Remove the flywheel lock.

	Name	Country
-	Counter-torque	1.860.846.001

1. Refit the timing side rigid engine support (1a)and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	ENGINE MOUNT TIMING SIDE	M10	(Crankcase side) 4.5 ÷ 5.5

Apply silicone sealant around the edge of the crankcase sump.1. Position the sump on the crankcase.2. Tighten the front and rear bolts (2a) fixing the crankcase sump to the recommended torque using the tool (2b).

	Fastening	Component	Ø	Value(daNm)
2a	Front and rear bolts	OIL SUMP	M6	(Engine crankcase side) 0.8 ÷ 1.0

	Name	Country
2b	Spanner	1.860.833.001

3. Tighten the side bolts (3a) for the crankcase sump to the recommended torque using the tool (3b).

	Fastening	Component	Ø	Value(daNm)
3a	Side bolts	OIL SUMP	M8	(Engine crankcase side) 2.3 ÷ 2.8

	Name	Country
3b	Spanner	1.860.834.001

Tighten the engine oil drain plug to the crankcase sump to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	ENGINE OIL DRAIN PLUG	M18	(Crankcase sump side) 1.8 ÷ 2.2

Rotate the engine through 180° on the overhauling stand.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	1.860.895.001

Rotate the crankshaft in a clockwise direction until the piston for cylinder no. 1 is at T.D.C. on the combustion stroke.

If T.D.C. is exceeded, do not turn backwards, but proceed by rotating the crankshaft through a further two revolutions in the same direction until the piston for cylinder no. 1 is at T.D.C.

1. Undo the bolts (1a) of the timing driven pulley, inlet side, using the tool (1b) for counter-torque.

	Name	Country
1b	Counter-torque	1.860.856.001

2. Loosen the bolt (2a) for the camshaft driven pulley, exhaust side, using tools (2b) and (2c) for counter-torque.

	Name	Country
2b	Spanner for camshaft pulley rotation	1.860.831.002

Undo the bolts and remove the 4th inlet side camshaft cap and the 2nd exhaust side camshaft cap.1. Fit the tool (1a) in place of the camshaft caps removed and fix it tightening the bolts (1b) to the recommended torque.

Check that the camshaft cam profile matches the tool correctly.

	Name	Country
1a	Gauge	1.870.859.000

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	ENGINE TIMING ADJUSTMENT TEMPLATES	M7	(Cylinder head side) 1.0

1. Fit the toothed timing belt following the order shown in the diagram:toothed drive pulley (1a)fixed tensioner (1b)exhaust side toothed driven pulley (1c)

Before fitting the belt on the exhaust side driven pulley, rotate it in a clockwise direction (see diagram) until the end of travel position.

intake side toothed driven pulley (1d)

Before fitting the belt on the inlet side driven pulley, rotate it in a clockwise direction (see diagram) until the end of travel position.

mobile tensioner (1e)coolant pump pulley (1f).

When fitting, ensure that the arrow stamped on the belt is facing in the direction of engine rotation (clockwise - timing side).

1. Using the tool, rotate the timing moving tensioner until the maximum tension is applied to the timing belt.

	Name	Country
1	Key	1.822.149.000

2. Tighten the nut for the moving tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Nut	MOBILE TIMING TENSIONER	M8	2.3 ÷ 2.8

1. Tighten the bolts (1a) for the camshaft driven pulley, inlet side, to the recommended torque using the tool (1b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	TIMING GEAR DRIVEN PULLEYS	M6	(Inlet camshaft side) 0.8 ÷ 1.0

	Name	Country
1b	Counter-torque	1.860.856.001

2. Tighten the bolt (2a) fixing the exhaust side timing driven pulley to the recommended torque, using tool (2b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	TIMING GEAR DRIVEN PULLEYS	M12	(Exhaust camshaft side) 10.8÷13.2

	Name	Country
2b	Spanner for camshaft pulley rotation	1.860.831.002

Remove the tool for timing the camshafts.

	Name	Country
-	Gauge	1.870.859.000

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 SUPPORTS	M7	(Cylinder head side) 1.4 ÷ 1.7

Rotate the crankshaft through two revolutions in its direction of rotation (clockwise - timing side) and ensure that the piston for cylinder no. 1 is at TDC.1. Fit the tool (1a) for keeping the moving timing tensioner still and loosen the tensioner nut (1b).

	Name	Country
1a	Key	1.822.149.000

2. Rotate the tool (2a) in an anti-clockwise direction (timing side) until the tensioner moving reference (2b) coincides with the reference opening (2c).

	Name	Country
2a	Key	1.822.149.000

3. Tighten the nut for the moving tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3	Nut	MOBILE TIMING TENSIONER	M8	2.3 ÷ 2.8

Rotate the crankshaft through two revolutions in its direction of rotation (clockwise - timing side) until cyllinder no. 1 is at TDC in the explosion stroke and check that the engine timing is correct using the tool.

	Name	Country
-	Gauge	1.870.859.000

Remove the tool to check T.D.C. from the cylinder 1 spark plug socket.

	Name	Country
-	Extension	1.860.895.001

Place the spark plug for cylinder no. 1 back in its housing and tighten it to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	SPARK PLUGS	M14	(Cylinder head side) 2.4 ÷ 3.0

Place the counter-balance shaft drive belt drive pulley back in its housing and secure it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	COUNTER-ROTATING SHAFT DRIVE PULLEY	M6	(Timing drive pulley side.) 0.8÷1.0

1. Rotate the counter-balance shafts so that the references (1a) on the pullies are aligned with the ribs (1b).2. Temporarily fit the lower timing cover and the crankshaft pulley and check the alignment of the references. Fit the counter-balance shaft toothed drive belt.

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

	Name	Country
1a	Key	1.822.154.000

2. Tighten the nut fixing the counter-balance shaft drive belt tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Nut	COUNTER-ROTATING SHAFT BELT TENSIONER	M6	(.Left. counter balance shaft front) cover side 0.8÷1.0

1. Fit the lower protective timing cover (1a) and secure using the bolts (1b).2. Place the crankshaft pulley (2a) back in its housing and secure it tightening the nut (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	CRANKSHAFT PULLEY	M8	2.3 ÷ 2.8

1. Place the tappet cover (1a), complete with gasket, back in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CAM COVER	M6	(Cylinder head side) 0.8 ÷ 1.0

1. Place the ignition coils (1a) back in their housings and secure them by 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 wiring duct back in its housing and secure it using the bolts.Connect the earth lead to the cam cover and secure using the corresponding bolt.Connect the electrical connections to the ignition coils. Proceed with the refitting - 1004D40 engine - position on stand and remove .