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

125000925 - 1020D17 ENGIND FRONT COVER - R R

) 1. Fit the tool.

	Description	Code
1	Counter-torque	1.820.624.000

1. Loosen the bolt retaining the timing pulley.Remove the tool.

	Description	Code
-	Counter-torque	1.820.624.000

1. Adjust the automatic belt tensioner using the tool to slacken the auxililary drivebelt.2. Remove the auxiliary drive belt.3. Undo the bolt (3a) and remove the auxiliary drive belt fixed tensioner (3b).

1. Undo the bolts (1a) and remove the upper timing belt guard (1b).2. Undo the nut (2a) and remove the auxiliary drive belt pulley (2b).3. Loosen the timing belt tensioner nut.4. Remove the timing belt.

1. Completely undo the bolt (1a) loosened previously and remove the timing belt drive pulley (1b).2. Undo the bolts (2a) and remove the timing side rigid engine mount (2b).3. Disconnect the water outlet hose fitting from the water/oil heat exchanger.4. Disconnect the water inlet hose in the water-oil heat exchanger.

Rotate the engine through 180° on the overhaul stand.1. Unscrew the bolt connecting the crankcase sump to the intermediate driveshaft mount.2. Undo the front and rear bolts (2a) fixing the crankcase sump using the tool (2b).

	Description	Code
2b	Spanner	1.822.145.000

3. Undo the side bolts (3a) fixing the crankcase sump using the tool (3b).

	Description	Code
3b	Spanner	1.822.144.000

4. Remove the crankcase sump.

To release the crankcase sump, tap it gently using a wooden or resin hammer, then use a screwdriver for leverage in the projections at the sides of the sump.

1. Undo the bolts (1a) and remove the oil pump (1b) with with intake chamber (1c), water - oil heat exchanger (1d) and engine oil filter (1e).2. Remove the seal.Remove the crankshaft front oil seal.

Refitting ( Removing

) Fit the oil pump with intake chamber, water-oil heat exchanger, oil filter and a new gasket and secure by tightening the bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	-	-	-	-

1. Fit a new crankshaft front oil seal (1a) using the tool (1b).

	Description	Code
1b	Fitting tool	1.821.247.000

Apply silicon sealant to the entire perimeter of the crankcase sump.Fit the crankcase sump.ighten the front and rear bolts fixing the crankcase sump to the recommended torque using the tool.

	Fastening	Component	Ø	Value(daNm)
-	-	-	-	-

	Description	Code
-	Spanner	1.822.145.000

Tighten the side bolts fixing the crankcase sump to the recommended torque using the tool.

	Fastening	Component	Ø	Value(daNm)
-	-	-	-	-

	Description	Code
-	Spanner	1.822.144.000

Tignten the bolt connecting the crankcase sump to the intermediate driveshaft mount.Rotate the engine through 180° on the overhaul stand.Connect the water intake pipe in the water-oil heat exchanger and secure with the collar.Tighten the water outlet hose fitting from the water/oil heat exchanger.Fit the timing side power unit mount and secure it using the bolts.Fit the timing belt drive pulley and secure with the bolt without tightening.1. Disconnect the electrical connections from the ignition coils.

	Description	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 tool (3b).

	Description	Code
3b	Caliper	1.820.636.000

Undo the botls and remove the bracket complete with ignition coils and high tension leads.Undo the bolts and remove the cam cover (2b) complete with gasket.1. Loosen the bolt (1a) for the exhaust side driven timing pulley using tools (1b) for counter-torque.

	Description	Code
1b	Counter-torque	1.822.146.000

	Description	Code
1b	Counter-torque	1.822.156.000

2. Loosen the bolts (2a) for the inlet side camshaft pulley using tool (2a) for counter-torque.

	Description	Code
2b	Counter-torque	1.822.155.000

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

	Description	Code
1a	Extension	1.825.013.000

Rotate the crankshaft until the piston for cylinder no. 1 is at T.D.C. on the combustion stroke.Unscrew the bolts and remove the third cap on the intake and exhaust camshafts.2. Fit tool (2a) in place of the camshaft caps that have been removed and secure them tightening the bolts (2b) to the recommended torque.

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

	Description	Code
2a	Templates	1.870.734.000

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	TEMPLATES FOR ENGINE TIMING	M7	(Cylinder head side) 1.0

Fit the timing belt.1. Apply maximum tension to the timing belt using tool.

	Description	Code
1	Spanner	1.822.149.000

2. Tighten the belt tensioner nut to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	-	-	-	-

3. Tighten the bolts (3a) for the inlet side toothed timing drive pulley to the specified torque using tool (3b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
3a	-	-	-	-

	Description	Code
3b	Counter-torque	1.822.155.000

4. Tighten the bolt (4a) for the exhaust side toothed timing drive pulley to the specified torque using tools (4b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
4a	-	-	-	-

	Description	Code
4b	Counter-torque	1.822.146.000

	Description	Code
4b	Counter-torque	1.822.156.000

Undo the bolts and remove the tool.

	Description	Code
-	Templates	1.870.734.000

Fit the camshaft cams removed previously and tighten the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	-	-	-

Turn the crankshaft through two revolutions.Loosen the timing belt tensioner nut.5. Align the mobile pointer (5a) on the timing belt with reference hole (5b) using tool (5c).

	Description	Code
5c	Spanner	1.822.149.000

Tighten the belt tensioner nut to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	-	-	-

Remove the tool complete with dial gauge.

	Description	Code
-	Extension	1.825.013.000

Fit the spark plug for cylinder no. 1.Fit the cam cover complete with gasket and secure it using the bolts.Fit the bracket complete with ignition coils and high tension leads and secure using the bolts.Connect the spark plug high tension leads.Connect the earth lead to the cylinder head.Connect the electrical connections to the ignition coils.Fit the upper timing belt guard and secure it using the bolts.Fit the auxiliary drive belt drive pulley and secure it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	-	-	-

Fit the auxiliary drive belt fixed tensioner and secure it with the bolt.Fit the auxiliary drive belt by prising over the autumatic belt tensioner using a wrench.Fit the tool.

	Description	Code
-	Counter-torque	1.820.624.000

Tighten the timing belt pulley bolt to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	-	-	-	-

Remove the tool.

	Description	Code
-	Counter-torque	1.820.624.000