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

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

) Proceed with the removal Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE.1. Open the electrical connection holder case.2. Disconnect the electrical connection for the timing side knock sensor.

	Description	Connector
2	Detonation sensor -1	See K50 DETONATION SENSOR 1 ( CONNECTORS )

1. Loosen the bands securing the intake manifolds to the air chamber.2. Loosen the band securing the engine idle oil vapour recovery pipe, air capacity chamber side.3. Disconnect the electrical connection from the throttle casing with D.V.L.

	Description	Connector
3	Throttle body actuator	See N75 THROTTLE BODY ACTUATOR ( CONNECTORS )

1. Unscrew retaining bolt (1a) and disconnect earth lead (1b) from the air capacity chamber.

	Description	Connector
1b	Earth on engine	See C40 ENGINE EARTH

2. Unscrew the bolt securing the stiffening rod to the reaction link mount on the engine.3. Undo bolts (3a) and remove air capacity chamber (3b).

1. Disconnect the electrical connections from the right cylinder head injectors.

	Description	Connector
1	Injector	See N70 INJECTOR

2. Disconnect the electrical connections from the right cylinder head ignition coils.

	Description	Connector
2	Ignition coil	See A30 IGNITION ''COIL

3. Undo bolts (3a) and move electrical wiring duct (3b) aside.

1. Undo the bolts (1a) and remove the ignition coils (1b) from the right cylinder head.

1. Undo the nut (1a) and disconnect the earth lead (1b) from the left cylinder head.

	Description	Connector
1b	Earth on engine	See C40 ENGINE EARTH

1. Undo the bolts (1a) and remove the ignition coil cover on the left cylinder head (1b).

1. Disconnect the electrical connections from the left cylinder head injectors.

	Description	Connector
1	Injector	See N70 INJECTOR

2. Disconnect the electrical connections from the left cylinder head ignition coils.

	Description	Connector
2	Ignition coil	See A30 IGNITION ''COIL

3. Undo bolts (3a) and move electrical wiring duct (3b) aside.

1. Undo the bolts (1a) and remove the ignition coils (1b) from the left cylinder head.

1. Undo the fixing bolts (1a) and remove the upper protective timing cover (1b).

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

1. Loosen the bolts retaining the timing belt moving tensioner.2. Prise off the timing drive belt from the toothed driven pullies.

1. Undo the bolts (1a) and bolt (1b) remove bracket (1c).

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

1. Loosen the bolts (1a) for the toothed driven pullies, using the tool (1b) for counter-torque.

	Description	Code
1b	Counter-torque	1.822.146.000

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

1. Undo the bolt (1a) and remove the fixed timing tensioner (1b).2. Undo the fixing bolts (2a) and remove the water pump (2b) complete with cover (2c) and bracket (2d).

Take care when removing the water pump not to release the rigid water pump inlet pipe from the thermostat.

3. Remove the seal.

Refitting ( Removing

) 1. Place the water pump (1a) , complete with cover, bracket and gasket in position, then tighten the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	COOLANT PUMP	M6	(Engine crankcase side) 0.8 - 1.0

2. Position the fixed timing tensioner (2a) in its housing and secure it tightening the bolt (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	FIXED TENSIONER	M10	(Cylinder head side) 4.5 - 5.5

1. Carry out the initial timing of the camshafts. apply a wrench into seat (1a) in the centre of the camshafts and turn to align reference marks (b) on the shafts with the upper cylinder head surface.

The reference marks must face the middle of each cylinder head.

1. Remove caps 4 to 7 from the left cylinder head.2. Remove caps B and G from the right cylinder head.

1. Repalce the removed camshaft caps with the timing templates.

	Description	Code
1	Templates	1.870.849.000

1. Fit the tool (1a) complete with dial gauge (1b) in the seat for the spark plug for cylinder no. 1.

	Description	Code
1a	Fitting tool	1.821.225.000

Rotate the crankshaft through small rotations (in both directions) until the piston for the right head timing side cylinder no. 1 is at T.D.C. in the combustion stroke.

Take care that the last rotation of the crankshaft is in the direction of operation.

1. Fit the timing drive belt starting from the drive pulley and continuing in an anti-clockwise direction making sure that the drive branches are properly taut.

1. Fit the tool (1a) and secure it using bolt (1b) for the alternator bracket and bolt (1c) for the water pump.

The tooth for the tool should engage with the moving part of the mobile timing belt tensioner.

	Description	Code
1a	Belt tensioner	1.860.950.000

2. Act on the belt tensioner tool nut (2a) until the moving reference on the belt tensioner (2b) is under the fixed reference.

1. Tighten bolts (1a) for the right head toothed driven pullies to the specified torque using the tool (1b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	TIMING DRIVEN PULLIES	M12	(camshaft side) 7.2 - 8.8

	Description	Code
1b	Support for counter-torque	1.860.831.000

Remove the tools for timing the camshafts.

	Description	Code
-	Templates	1.870.849.000

Place the camshaft caps in their housings to replace the removed tools and secure them tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAMSHAFT CAPS	M8	(Cylinder head side) 1.8 - 2.0

Rotate the crankshaft through two revolutions in its direction of rotation to allow the toothed timing belt to bed in.1. Check that the moving reference for the timing belt tensioner coincides with the fixed reference.2. If the references are not aligned, gently release the tensioner tension acting on the nut for the tensioning tool until the reference coincide.3. Tighten the nut fixing the moving timing tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	MOBILE TIMING TENSIONER	M8	(Cylinder head side) 1.9 - 2.3

Remove the belt tensioner tool.

	Description	Code
-	Belt tensioner	1.860.950.000

1. - Place the cylinder head cam covers (1a) in their housings with gaskets and secure them tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	TAPPET COVERS	M7	(Cylinder head side) 1.4 - 1.7

Fit the bracket in its housing and secure it using the bolts.Fit the lower timing belt covers and secure them using the bolts.Fit the upper timing belt covers and secure them using the bolts.1. Replace the left cylinder head 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

Refit the electrical wiring conduit and secure with bolts.Connect the electrical connections to the left cylinder head ignition coils.Connect the electrical connections to the left cylinder head injectors.Place the ignition coil cover on the left cylinder head back in its housing and secure it using the bolts.Connect the earth lead to the left cylinder head and secure it using the nut.1. Replace the right cylinder head 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

Refit the electrical wiring conduit and secure with bolts.Connect the electrical connections to the right cylinder head ignition coils.Connect the electrical connections to the right cylinder head injectors.Fit the air capacity chamber and secure it using the bolts.Tighten the bolt securing the stiffening rod to the reaction link mount on the engine.Connect the earth lead to the air capacity chamber and secure with the bolt.Connect the electrical connection to the throttle casing with D.V.L.Tighten the band securing the engine idle oil vapour recovery pipe, air capacity chamber side.Tighten the bands securing the intake manifolds to the air chamber.Connect the electrical connection for the timing side knock sensor.Close the electrical connection holder casing.Proceed with the refitting Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE.