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

125000925 - 1020D17 ENGIND FRONT COVER - R R

) Proceed with the removal Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE.1. Disconnect the electrical connections from the ignition coils.

	Description	Connector
1	Ignition coil	See A30 IGNITION ''COIL

2. Undo the bolt (2a) and disconnect the earth lead (2b) from the cam cover.3. Undo the bolts (3a) and remove the bulkhead coupling (3b) aside.

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

1. Undo the bolts (1a) and remove the cam cover (1b) complete with gasket.

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

1. Loosen the counterrotating shaft toothed drive belt tensioner nut.2. Release and remove the counterrotating shaft toothed timing drive belt.

1. Loosen the nut retaining the timing belt moving tensioner.2. Release and remove the toothed timing drive belt.

1. Undo the plug and drain the engine oil.

Collect the engine oil in a suitable container.

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

	Description	Code
1b	Spanner	1.860.833.001

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

	Description	Code
2b	Spanner	1.860.834.001

3. Cut the crankcase sump sealant using the tool.

	Description	Code
3	Blade	1.870.718.000

4. Remove the crankcase sump.

1. Undo bolts (1a) and remove the timing side rigid engine mount (1b).2. Undo bolts (2a) and remove the counterrotating shaft toothed belt drive pulley (2b).

1. Fit the flywheel lock.

	Description	Code
1	Counter-torque	1.860.846.001

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

1. Unscrew the bolt securing the engine oil intake duct to the main bearing cap.

1. Undo the bolts (1a) and remove the engine block front cover (1b) with the built-in oil pump complete with intake chamber (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 intake duct (2b).3. Remove the gasket.4. Remove the engine oil filter using a suitable tool.5. Undo the nut (5a) and remove the engine oil heat exchanger (5b) complete with pipes (5c).6. Remove the gasket.7. Prise up the crankcase front cover oil seal.

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

Refitting ( Removing

) 1. Fit the crankshaft front oil seal (1a) on the front crankcase cover using the tool (1b).

	Description	Code
1b	Fitting tool	1.821.147.000

Position the front crankcase cover assembly in a vice with protective jaws.Replace the engine oil heat exchanger complete with gasket and pipes in its seat and secure it using the pin.Position the intake duct complete with gasket in its housing and secure it using the olts.Rotate the engine through 180° on the overhaul stand.1. Refit the front crankcase cover (1a) with built-in oil pump with gasket (1b), inlet duct (1c) and engine oil heat exchanger (1d).2. Tighten the bolts securing the crankcase front cover to the recommended torque.

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

Srew the bolt securing the engine oil intake duct to the main bearing cap.Lubricate the seal with engine oil and fit the engine oil filter tightening it fully by hand.1. Position the toothed timing drive pulley (1a) in its housing and secure it tightening the bolt (anticlockwise) (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Left hand bolt	DRIVE PULLEY(PULLIES) TIMING	M16	(Crankshaft side) 20.9 - 23.1

Remove the flywheel lock.

	Description	Code
-	Counter-torque	1.860.846.001

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

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	RIGID ENGINE MOUNT, TIMING SIDE	M10	(Engine crankcase side) 4.5 - 5.5

Apply silicon sealant to the entire perimeter 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

	Description	Code
2b	Spanner	1.860.833.001

3. Tighten the side bolts (3a) fixing 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

	Description	Code
3b	Spanner	1.860.834.001

Tighten the engine oil drain plug 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 overhaul stand.1. Fit the tool (1a) complete with dial gauge (1b) in the seat for the spark plug for cylinder no. 1.

	Description	Code
1a	Extension	1.860.895.001

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

If TDC is exceeded, do not turn backwards but proceed with the rotation in the same direction rotating the crankshaft through another two revolutions and return the piston for cylinder no. 1 to TDC.

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

	Description	Code
1b	Counter-torque	1.860.856.001

2. Undo the exhaust side driven timing pulley bolt (2a) using the tool (2b) for counter-torque.

	Description	Code
2b	Spanner for rotating timing pullies	1.860.831.002

Undo the bolts and remove the inlet side camshaft fourth cap and the exhaust side camshaft second cap.1. Fit the tool (1a) in place of the camshaft caps that have been removed and secure them tightening the bolts (1b) to the recommended torque.

Check that the camshaft cam profile and the tool are correctly aligned.

	Description	Code
1a	Templates	1.870.859.000

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

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

Before fitting the belt on the exhaust side toothed driven pulley, turn it clockwise (see figure) to the end of its travel.

inlet side toothed driven pulley (1d)

Before fitting the belt on the intake side toothed driven pulley, turn it clockwise (see figure) to the end of its travel.

moving tensioner (1e)water pump pulley (1f).

Fit the belt with the arrow stamped on it facing the direction of rotation of the engine (clockwise - timing side).

1. Use the tool to rotate the moving timing tensioner until the timing belt is completely taut.

	Description	Code
1	Spanner	1.822.149.000

2. Tighten the nut fixing the moving timing 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 inlet side toothed timing driven pulley to the specified torque using tool (1b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	TIMING DRIVEN PULLIES	M6	(Inlet camshaft side) 0.8 - 1.0

	Description	Code
1b	Counter-torque	1.860.856.001

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

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	TIMING DRIVEN PULLIES	M12	(Exhaust camshaft side) 10.8 - 13.2

	Description	Code
2b	Spanner for rotating timing pullies	1.860.831.002

Remove the camshaft timing tools.

	Description	Code
-	Templates	1.870.859.000

Place the camshaft caps previously removed 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

Turn the crankshaft through two turns in its direction of rotation (clockwise - timing side) and move the cylinder no. piston to TDC.1. Insert tool (1a) to hold the mobile timing tensioner still and loosen tensioner nut (1b).

	Description	Code
1a	Spanner	1.822.149.000

2. Turn tool (2a) anticlockwise (timing side) to align tensioner mobile pointer (2b) with reference hole (2c).

	Description	Code
2a	Spanner	1.822.149.000

3. Tighten the nut fixing the moving timing tensioner to the recommended torque.

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

Turn the crankshaft through two revolutions in its direction of rotataion (clockwise - timing side) to move the first cylinder to TDC in the combustion phase and check the engine timing is correct using the tool.

	Description	Code
-	Templates	1.870.859.000

Remove the tool for checking T.D.C. from the housing for the spark plug for cylinder no.1.

	Description	Code
-	Extension	1.860.895.001

Place the spark plug for cylinder no.1 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

Position the counterrotating shaft toothed belt drive pulley 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 belt drive pulley side) 0.8÷1.0

1. Turn the counterrotating shafts so that the notches (1a) on the pulleys are aligned with ribs (1b).2. Fit the lower timing belt protective cover and the crankshaft pulley and check the notches stamped on them are aligned.Fit the counterrotating shaft toothed drive belt

1. Tension the counterrotating shaft drive belt using tool (1a) to move reference hole (1b) on the tensioner to the centre of the rotation sector.

	Description	Code
1a	Spanner	1.822.154.000

2. Tighten the nut fixing the counterrotating shaft toothed belt tensioner to the recommended torque.

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

1. Refit the lower timing belt covers (1a) and secure them using the bolts (1b).2. Position the crankshaft pulley (2a) in its housing and secure it tightening the bolts (2b) to the recommended torque.

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

1. Place the cam 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. Replace the ignition coils (1a) in their housings and secure them tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	IGNITION COIL/REEL	M6	(Cam cover side) 0.8 ÷ 1.0

Fit the bulkhead coupling in its housing and secure it using the bolts.Connect the battery earth lead to the cam cover and secure it using the bolt.Connect the electrical connections to the ignition coils.Proceed with the refitting Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE.