1088C20 WATER PUMP - R + R WITH ENGINE REMOVED (AUTOMATIC TRANSMISSION) - Alfa - 166 - eLearn

3315368 - 1088C20 water pump - r + r with engine removed (Automatic transmission)

) 1. Remove the "drip tray" for the power assisted steering fluid reservoir.2. Undo the bolts (2a) and remove the upper protective timing cover (2b).

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

1. Remove the engine oil filler cap.2. Undo the bolts (2a) and remove the left cylinder head spark plugs cover (2b).3. Disconnect the high tension leads (3a) from the left cylinder head spark plugs using the tool (3b).

	Name	Country
3b	Pliers	1.820.636.000

4. Undo the bolt (4a) and remove the engine oil dipstick mounting bracket (4b).

1. Undo the bolts (1a) and remove the left side tappet cover (1b) complete with gasket.

1. Loosen the bands fixing the inlet ducts to the air chamber.2. Disconnect the oil vapour recovery pipe from the right side tappet cover.3. Disconnect the condensation oil return pipe from the right cylinder head.4. Disconnect the high tension leads from the right cylinder head spark plugs.5. Undo the bolts (5a) for the high tension lead mounting bracket (5b) and move the leads aside.6. Disconnect the vacuum intake pipe for the fuel pressure regulator from the air chamber.

1. Undo the bolts (1a) and remove the air chamber (1b), complete with oil vapour separator and pipes.

Undo the bolts and remove the cylinder no. 3, 5 and 6 inlet ducts.1. Undo the bolt (1a) and remove the engine mounting bracket (1b) from the right cylinder head.2. Undo the bolts (2a) and remove the right side tappet cover (2b), complete with gasket.3. Remove the spark plug housing gaskets.

1. Rotate the crankshaft so that the references on the camshafts are aligned with those on the bearing caps (cylinder no. 1 at T.D.C.).

1. Undo the bolts (1a) and remove the moving timing belt tensioner (1b).2. Remove the timing belt from the drive pullies.

1. Undo the bolts (1a) and remove the water pump (1b) complete with gasket.

Refitting ( Removing

) Fit the water pump, complete with gasket, and fix it tightening the bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	COOLANT PUMP	M6	Engine crankcase side 0.7- 0.9

Remove the spark plug for cylinder no. 1.1. Fit the tool (1a), complete with dial gauge (1b), in the housing of the spark plug for cylinder no. 1.

	Name	Country
1a	Extension	1.825.013.000

Rotate the crankshaft, using small movements (in both directions), until the piston for cylinder no. 1 is at T.D.C. at the power stroke.

Make sure that the last crankshaft rotation is in the direction of operation.

Fit the timing belt moving tensioner and fix it using the bolts without tightening them.Fit the timing belt and check that the timing references on the camshafts are aligned.1. Fit the tool (1a) and fix it using the bolt (1b) for the alternator (having positioned a spacer previously) and the bolt (1c) to the water pump.

The tool tooth (1d) should produce a reaction with the moving part of the timing belt tensioner.

	Name	Country
1a	Belt tensioner	1.860.950.000

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

Rotate the crankshaft through two revolutions in its direction of rotation to allow the timing belt to bed in.1. Check that the moving reference on the timing belt tensioner is aligned with the fixed reference.2. If the references do not coincide, slightly discharge the tensioner acting on the tensioning tool nut and make sure that the references are aligned.3. Tighten the bolts for the timing belt tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	MOBILE TIMING TENSIONER	M8	Cylinder head side 1.7 - 2.1

Check once again that the timing references on the camshafts are aligned.Remove the belt tensioner tool.

	Name	Country
-	Belt tensioner	1.860.950.000

Remove the tool for checking top dead centre.

	Name	Country
-	Extension	1.825.013.000

1. Fit the spark plug housing gaskets.2. Fit the right side tappet cover (2a), complete with gasket, and fix it tightening the bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	CAM COVERS	M7	Cylinder head side 1.0 - 1.3

3. Fit the engine mounting bracket (3a) on the right cylinder head and fit is using the bolt (3b).

Fit the cylinder no. 3, 5 and 6 inlet ducts and fix them using the bolts.Fit the air chamber, complete with oil vapour separator and pipes, and fix it using the bolts.Connect the vacuum intake pipe for the fuel pressure regulator to the air chamber.Place the high tension leads back in their housings and fix them using the brackets.Connect the high tension leads to the right cylinder head spark plugs.Connect the condensation oil return pipe to the right cylinder head.Connect the oil vapour recovery pipe to the tappet cover, right side.Tighten the bands fixing the inlet ducts to the air chamber.1. Fit the left rocker cover (1a), complete with gasket, and fix it tightening the bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CAM COVERS	M7	Cylinder head side 1.0 - 1.3

Fit the engine oil dipstick mounting bracket and fix it using the bolt.Connect the high tension leads to the left cylinder head spark plugs.Fit left cylinder head spark plugs cover and fix it using the bolts.Fit the engine oil filler cap.Fit the lower protective timing covers and fix them using the bolts.Fit the upper protective timing gear cover and fix it using the bolts.Fit the power assisted steering fluid reservoir "drip tray".