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

125001178 - 1088C20 WATER PUMP - R + R WITH ENGINE REMOVED

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

1. Adjust the mobile tensioner to slacken the auxiliary drivebelt.2. Release and remove the auxiliary drivebelt.

1. Remove plug (1a), unscrew bolt (1b) and remove the fixed auxiliary drivebelt tensioner (1c).2. Undo the fixing bolts (2a) and remove the upper protective timing cover (2b).

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 move 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 counter-rotating shaft toothed drive belt tensioner nut.2. Release and remove the toothed timing drive belt.

1. Unscrew bolts (1a) and remove the counterrotating shaft toothed drive belt drive pulley (1b).2. Loosen the nut retaining the timing belt mobile tensioner.3. Release and remove the toothed timing drive belt.

1. Undo the fixing 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. Position the water pump (1a) , complete with O-ring (1b), in its housing and secure 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 it using the bolt (2b).

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 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 bolt (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 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 clockwise (see figure) to the end of its travel.

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

The belt is fitted with the arrow facing the direction of rotation of the engine (clockwise - timing end).

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 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 the direction of rotation (clockwise - timing end) and move the cylinder 1 piston to TDC.1. Insert tool (1a) to hold the mobile timing belt tensioner still and loosen tensioner nut (1b).

	Description	Code
1a	Spanner	1.822.149.000

2. Turn tool (2a) anticlockwise (timing end) to align the 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 turns in the direction of rotation (clockwise - timing end) to move cylinder 1 to TDC in combustion stage and check that 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 crankshaft 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 until the notches (1a) on the pulleys are aligned with the ribs (1b).2. Fit the lower protective timing cover and the crankshaft pulley provisionally and check the alignment of the notches stamped on the parts.Fit the counterrotating shaft toothed drive belt

1. Tension the counterrotating shaft toothed drivebelt using tool (1a) to move alignment hole (1b) on the tensioner to the middle of the rotation sector.

	Description	Code
1a	Spanner	1.822.154.000

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

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

1. Fit 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 with gaskets 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.1. Fit the lupper timing belt covers (1a) and secure them using the bolts (1b).2. Position the auxiliary drivebelt fixed tensioner (2a) in its housing and secure it tightening the bolt (2b) to the recommended torque.

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

3. Refit the plug on the auxiliary drivebelt fixed tensioner

Adjust the mobile tensioner and fit the auxiliary drivebelt.Release the engine from the hydraulic lift.