1020D17 ENGIND FRONT COVER - R R - Alfa - 147 - eLearn

3025992 - 1020D17 engind front cover - r r

) 1. Fit the tool.

	Name	Country
1	Counter-torque	1.860.161.001

1. Loosen the bolt fixing the camshaft drive pulley.Remove the tool.

	Name	Country
-	Counter-torque	1.860.161.001

1. Undo the bolts (1a) and the nut (1b) and remove the auxiliary units drive belt protection (1c).2. Use a spanner on the moving tensioner (2a) and remove the single accessory drive belt (2b).3. Remove the cap, undo the bolt (3a) and remove the single engine component belt fixed tensioner (3b).

1. Undo the bolts (1a) and remove the upper timing gear covers (1b).2. Undo the bolts (2a) and remove the engine component drive pulley (2b).3. Undo the bolt (3a) and remove the lower cam cover (3b).4. Loosen the nut for the counter-balance shaft toothed drive belt tensioner.5. Prise off and remove the toothed counter-rotating shaft belt. 6. Slacken the nut on the timing belt moving tensioner.7. Prise off and remove the timing belt.

1. Undo the bolts (1a) and remove the counter-balance shaft drive belt drive pulley (1b).2. Fully undo the bolt (2a) previously slackened and remove the toothed timing belt drive pulley (2b).3. Undo the bolts (3a) and remove the timing side rigid power unit support (3b).4. Undo the connector (4a) for the coolant outlet pipe from the engine oil heat exchanger on the side of the water pump rigid inlet pipe.5. Disconnect the coolant inlet sleeve to the engine oil heat exchanger, exchanger side.

Rotate the engine through 180° on the overhauling stand.1. Undo the bolt fixing the crankcase sump to the support on the engine for the reaction rod.2. Undo the front and rear bolts (2a) for the crankcase sump using the tool (2b).

	Name	Country
2b	Key	1.822.145.000

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

	Name	Country
3b	Key	1.822.144.000

4. Cut the crankcase sump sealant using the tool.

	Name	Country
4	Blade	1.870.718.000

5. Remove the crankcase sump.

1. Undo the bolts (1a) and remove the crankshaft front cover (1b) complete with inlet (1c), engine oil heat exchanger (1d) and engine oil filter (1e). 2. Remove the seal.Prise up and remove the crankshaft front oil seal.

Take care not to damage the oil seal seat during removal.

Refitting ( Removing

) Place the crankshaft front cover, complete with intake, engine oil heat exchanger, oil filter and a new gasket, back in its housing, then secure it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CRANKSHAFT FRONT COVER	M6	(Engine crankcase side) 0.8 ÷ 1.0

1. Refit a new front crankshaft front cover oil seal (1a) using tool (1b).

	Name	Country
1b	Fitting tool	1.821.247.000

Clean the matching surfaces of crankcase sump and cylinder block.Apply silicone sealant around the edge of the crankcase sump.1. Place the crankcase sump back in its housing.2. Tighten the front and rear bolts (2a) fixing the crankcase sump to the recommended torque using the tool (2b).

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	OIL SUMP	M8	(Engine crankcase side) 2.3 ÷ 2.8

	Name	Country
2b	Key	1.822.145.000

3. Tighten the side bolts (3a) for the crankcase sump to the recommended torque using the tool (3b).

	Fastening	Component	Ø	Value(daNm)
3a	Bolt	OIL SUMP	M6	(Engine crankcase side) 0.8 ÷ 1.0

	Name	Country
3b	Key	1.822.144.000

4. Tighten the bolt securing the oil sump to the intermediate shaft support.

Rotate the engine through 180° on the overhauling stand.Connect the coolant inlet sleeve to the engine oil heat exchanger, exchanger side.Connect the engine oil heat exchanger coolant outlet pipe, rigid fluid inlet pipe side, to the water pump and tighten the connector.Fit the timing side power unit rigid rear support and fix it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ENGINE MOUNT TIMING SIDE	M10	(Crankcase side) 4.5 ÷ 5.5

Place the drive pulley back in its housing and secure it tightening the bolt to the recommended torque.Disconnect the electrical connection for the air conditioner compressor.

	Name	Connector
-	Air conditioning compressor engagement electro-magnet	L20

1. Disconnect the electrical connections from the ignition coils and release the wiring from the fixings.

	Name	Connector
1	Ignition coil	A30

2. Undo the bolt (2a) and disconnect the earth lead (2b) from the ignition coils single support plate.

	Name	Connector
2b	Earth on engine	C40B

3. Disconnect the caps for the high tension leads (3a) from the spark plugs using the tool (3b).

	Name	Country
3b	Pliers	1.820.636.000

4. Disconnect the oil vapour recovery pipe from the rocker cover.

Undo the bolts fixing the ignition coil support plate.Pull up the plate complete with ignition coils.Undo the bolts and remove the rocker cover complete with gasket.1. Loosen the bolt (1a) for the exhaust side timing driven pulley using tools (1b) and (1c) for counter-torque.

	Name	Country
1b	Counter-torque	1.822.146.000

	Name	Country
1c	Counter-torque	1.822.156.000

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

	Name	Country
2b	Counter-torque	1.822.155.000

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 until the piston for cylinder no. 1 is at T.D.C. at the combustion stroke.

If TDC is exceeded, do not turn backwards, but proceed by rotating the crankshaft through a further two revolutions in the same direction until the piston for cylinder no. 1 is at TDC.

Undo the bolts and remove the camshaft third cap.2. Fit the tool (2a) in place of the removed camshaft caps, and fix it tightening the bolts (2b) to the specified torque.

Check that the camshaft cam profile matches the tool correctly.

	Name	Country
2a	Gauge	1.825.041.000

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

1. Fit the toothed timing belt following the order shown in the diagram:toothed drive pulley (1a)fixed tensioner (1b)exhaust side toothed driven pulley (1c)

Before fitting the belt on the exhaust side driven pulley, rotate it in a clockwise direction (see diagram) until the end of travel position.

intake side toothed driven pulley (1d)

Before fitting the belt on the inlet side driven pulley, rotate it in a clockwise direction (see diagram) until the end of travel position.

mobile tensioner (1e)coolant pump pulley (1f).

When fitting, ensure that the arrow stamped on the belt is facing in the direction of engine rotation (clockwise - timing side).

1. Using the tool, rotate the timing moving tensioner until the maximum tension is applied to the timing belt.

	Name	Country
1	Key	1.822.149.000

2. Tighten the nut for the moving 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 camshaft driven pulley, inlet side, to the recommended torque using the tool (1b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	TIMING GEAR DRIVEN PULLEYS	M6	(Inlet camshaft side) 0.8 ÷ 1.0

	Name	Country
1b	Counter-torque	1.822.155.000

2. Tighten the bolt (2a) fixing the timing driven pulley to the recommended torque, using the tools (2b) and (2c) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	TIMING GEAR DRIVEN PULLEYS	M12	(Exhaust camshaft side) 10.8÷13.2

	Name	Country
2b	Counter-torque	1.822.156.000

	Name	Country
2c	Counter-torque	1.822.146.000

Remove the tool for timing the camshafts.

	Name	Country
-	Gauge	1.825.041.000

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

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAMSHAFT CAPS	M7	(Cylinder head side) 1.4 ÷ 1.7

Rotate the crankshaft through two revolutions in its direction of rotation (clockwise - timing side) and ensure that the piston for cylinder no. 1 is at TDC.1. Fit the tool (1a) for keeping the moving timing tensioner still and loosen the tensioner nut (1b).

	Name	Country
1a	Key	1.822.149.000

2. Rotate the tool (2a) in an anti-clockwise direction (timing side) until the tensioner moving reference (2b) coincides with the reference opening (2c).

	Name	Country
2a	Key	1.822.149.000

3. Tighten the nut for the moving tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3	Nut	MOBILE TIMING TENSIONER	M8	2.3 ÷ 2.8

Rotate the crankshaft through two revolutions in its direction of rotation (clockwise - timing side) until cyllinder no. 1 is at TDC in the combustion stroke and check that the engine timing is correct using the tool.

	Name	Country
-	Gauge	1.825.041.000

Remove the tool to check T.D.C. from the cylinder 1 spark plug socket.

	Name	Country
-	Extension	1.825.013.000

Place the spark plugs for cylinder no. 1 back in their housings and tighten them to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	SIDE SPARK PLUG	M10	(Cylinder head side) 1.0 ÷ 1.3

	Fastening	Component	Ø	Value(daNm)
-	-	CENTRE SPARK PLUG	M14	(Cylinder head side) 2.3 ÷ 2.8

Place the counter-balance shaft drive belt drive pulley back 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 drive. pulley. side) 0.8 - 1.0

1. Rotate the counter-balance shafts so that the references (1a) on the pullies are aligned with the ribs (1b).2. Temporarily fit the lower timing cover and the crankshaft pulley and check the alignment of the references.Fit the counter-balance shaft toothed drive belt.

1. Tension the counter-balance shaft drive belt using the tool (1a) so that the reference opening (1b) in the belt tensioner is at the centre of the rotation sector.

	Name	Country
1a	Key	1.822.154.000

2. Tighten the nut fixing the counter-balance shaft drive belt tensioner to the recommended torque.

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

Place the tapper cover, complete with gasket, back in its housing and fix it using the bolts.Place the plate and ignition coil back in its housing and secure it using the bolts.Connect the oil vapour recovery pipe to the rocker cover.Connect the high tension lead covers to the spark plugs.Connect the earth lead to the ignition coils support plate and secure it using the bolt.Connect the electrical connections to the ignition coils and secure the electrical wiring.Connect the electrical connection to the air conditioner compressorFit the lower protective timing cover and secure using the bolts.Fit the upper protective timing gear cover and fix it using the bolts.Fit the engine component drive pulley and fix it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CRANKSHAFT PULLEY	M8	2.3 ÷ 2.8

Place the engine components single drive belt fixed tensioner back in its housing and fix it tightening the bolt to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FIXED SINGLE SERVICE BELT TENSIONER	M8	2.3 ÷ 2.8

Place the plug back in its housing in the fixed tensioner.Use a spanner on the moving tensioner and fit the engine components single drive belt.Place the auxiliary units drive belt protection back in its housing and secure it using the bolts and the nut.Fit the tool.

	Name	Country
-	Counter-torque	1.860.161.001

Tighten the bolt (left-hand) on the drive pulley to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt with left hand thread	TOOTHED DRIVE PULLEY	M16	(Crankshaft side) 20.9 ÷ 23.1

Remove the tool.

	Name	Country
-	Counter-torque	1.860.161.001