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

) 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