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. Undo the bolts (1a) and remove the timing belt guards (1b).

1. Slacken the timing belt tensioner bolts.2. Remove the timing belt fromthe camshaft pulleys.

1. Undo the bolts (1a) and remove the water pump pulley (1b).2. Undo the bolts (2a) and remove the fixed timing belt tensioner (2b).3. Undo the bolts (3a) and remove the water pump (3b) complete with gasket (3c).

Refitting ( Removing

) Fit the water pump with a new gasket and fix it to the cylinder block, tightening the bolts to torque.

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

Fit the timing belt fixed tensioner and fix it with its bolt.Fit the water pump drive pulley and fix it using the bolts.1. Disconnect the earth lead from the left cylinder head rocker cover.2. Disconnect the electrical connection for the throttle body.

	Name	Connector
2	Integrated throttle body actuator	N75

1. Disconnect the oil vapour recovery pipe.2. Disconnect the condensation oil return pipe from the separator.

Slacken the bolts on the clips securing the air intake ducts to the intake chamber.1. Undo the bolts (1a) and remove the complete intake duct (1b).

1. Disconnect the electrical connection for the cam angle sensor (light blue).

	Name	Connector
1	Cam angle sensor	K47

2. Disconnect the electrical connection for the engine rpm and timng sensor (black).

	Name	Connector
2	Rpm sensor	K46

3. Disconnect the electrical connection for the rear knock sensor (black).

	Name	Connector
3	Detonation sensor	K50

4. Disconnect the electrical connection from the engine coolant temperature sensor.

	Name	Connector
4	Engine coolant temperature sensor-sender unit	K36

5. Disconnect the earth lead from the left cylinder head rocker cover.

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

1. Disconnect the electrical connection for the front knock sensor.

	Name	Connector
1	Knock sensor 2	K51

2. Undo the bolts (2a) and remove the electrical wiring securing brackets (2b).3. Disconnect the electrical connections from the injectors.

	Name	Connector
3	Injector	N70

4. Disconnect the electrical connections from the ignition coils.

	Name	Connector
4	Ignition coil	A30

5. Remove the electrical wiring after releasing it from the securing bands.

1. Undo the bolts (1a) and remove the bracket (1b) securing the timing belt guard.

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

	Name	Connector
1b	Ignition coil	A30

1. Undo the bolts (1a) and remove the rocker covers (1b) from the cylinder heads.

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

1. Fit the tool in place of the removed camshaft caps.

	Name	Country
1	Gauge	1.825.040.000

Slacken the camshaft pulley bolts using the tool for counter-torque.

	Name	Country
-	Counter-torque	1.822.146.000

Fit the tool (1a), complete with dial gauge (1b), in the housing in the spark plug for the 1st cylinder.

	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.

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

1. Fit the tool (1a) and secure it with the alternator bolt (1b) and the bolt (1c) to the water pump.

The bolt (1b) should be shimmed with a suitable spacer to recover the thickness of the alternator.The tool lug (1d) must press against the moving part of the timing belt tensioner.

	Name	Country
1a	Belt tensioner	1.860.950.000

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

1. Tighten the bolts (1a) for the camshaft pullies to torque using the tools (1b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	TIMING GEAR DRIVEN PULLEYS	M10	6.8 ÷ 8.4

	Name	Country
1b	Counter-torque	1.822.146.000

Remove the tool.

	Name	Country
-	Gauge	1.825.040.000

Fit the camshaft caps in place of the removed tool and tighten the bolts to torque.

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

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 line up, slightly decrease the tension of the tensioner acting on the tensioning tool nut and make sure that the references are aligned.3. Tighten the timing belt tensioner bolts to torque.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	MOBILE TIMING TENSIONER	M8	1.7 ÷ 2.1

Remove the tool.

	Name	Country
-	Belt tensioner	1.860.950.000

Fit the rocker covers and fix them using the bolts.Fit the ignition coils and fix them using the bolts.Fit the bracket securing the timing belt guard and fix it using the bolts.Fit the timing belt guards and fix them using the bolts.Place the electrical wiring back in its housing and fix it to the bands.Connect the electrical connections to the ignition coils.Connect the electrical connections to the injectors.Fit the electrical wiring securing brackets to the rocker covers and fix them using the bolts.Connect the electrical connection for the front knock sensor.Fit the left cylinder head ignition coils cover and fix it using the bolts.Connect the earth lead to the left cylinder head rocker cover.Connect the electrical connection to the engine coolant temperature sensor.Connect the electrical connection for the rear knock sensor (black).Connect the electrical connection for the engine rpm and timing sensor (black).Connect the electrical connection for the cam angle sensor (light blue).Fit the complete intake chamber and fix it using the bolts.Tighten the bands fixing the air intake ducts to the intake chamber.Connect the condensation oil return pipe to the separator.Connect the oil vapour recovery pipe.Connect the electrical connection to the motorized throttle body actuator.Connect the earth lead on the left cylinder head rocker cover.