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

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

) 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.

Removing ( Refitting

) 1. Secure and support the engine (1a) using a hydraulic hoist (1b) fitted with suitable chains (1c).

1. Adjust the moving tensioner to loosen the engine components single drive belt tension.2. Remove the engine components single drive belt.

1. Remove the cap (1a), undo the bolt (1b) and remove the single belt fixed tensioner (1c).2. Undo the bolts (2a) and remove the upper protective timing cover (2b).

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 cable 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 bolts (1a) and remove the counter-balance shaft drive belt drive pulley (1b).2. Undo the nut securing the timing belt mobile tensioner.3. Prise off and remove the timing belt.

1. Undo the bolts (1a) and remove the side protective timing cover (1b).2. Undo the bolts (2a) and remove the water pump (2b) complete with O-ring (2c).

Refitting ( Removing

) 1. Place water pump (1a), complete with O-ring (1b), back in its housing and fix it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	COOLANT PUMP	M8	(Cylinder head side) 2.3 ÷ 2.8

2. Fit the side cover (2a) protecting the timing belt and secure with bolt (2b).

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. in the explosion 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 exhaust -side driven toothed pulley, using tool (2b) for counter-torque.

	Name	Country
2b	Spanner for camshaft pulley rotation	1.860.831.002

Undo the bolts and remove the 4th cap for the inlet side camshaft and the 2nd cap for the exhaust side camshaft.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) securing the exhaust side timing driven pulley to the recommended torque, using the 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 them 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 by tightening bolts (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.1. Fit the upper protective timing gear cover (1a) and secure using the bolts (1b).2. Place the engine components single drive belt fixed tensioner (2a) back in its housing and secure by tightening bolt (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	FIXED SINGLE SERVICE BELT TENSIONER	M8	2.2 ÷ 2.8

3. Replace the single drive belt fixed tensioner plug.

Adjust the moving tensioner and fit the engine components single drive belt.Release the engine from the hydraulic lift.