1088C20 WATER PUMP - R + R WITH ENGINE REMOVED - Alfa - 147 - eLearn

3026003 - 1088C20 water pump - r + r with engine removed

) 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 drive belt (2b).3. Remove the cap (3a), undo the bolt and remove the single belt fixed tensioner (3b).

1. Undo the bolts (1a) and remove the upper timing gear cover (1b).2. Undo the bolts (2a) and remove the auxiliary shaft drive pulley (2b).3. Undo the bolts (3a) and remove the lower timing cover (3b).4. Loosen the nut for the counter-balance shaft toothed drive belt tensioner.5. Release and remove the counter-balance shaft drive 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 left side protective timing cover (1b).2. Undo the bolts (2a) of the inlet side drive pulley, using the tool (2b) for counter-torque.

	Name	Country
2b	Counter-torque	1.822.155.000

3. Remove the inlet side driven pulley.4. Undo bolts (4a) and remove water pump (4b) complete with O-ring (4c).

Refitting ( Removing

) 1. Place water pump (1a), complete with a new O-ring (1b), back in its housing and fix it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	COOLANT PUMP	M8	(Cylinder head side) 2.3 ÷ 2.8

2. Fit the inlet side driven pulley (2a) and fix it using the bolts (2b) without tightening them.3. Place the left side protective timing cover (3a) back in its housing and secure it using the bolts (3b).4. Loosen the bolt (4a) for the exhaust side driven pulley using the tools (4b) and (4c) for counter-torque.

	Name	Country
4b	Counter-torque	1.822.146.000

	Name	Country
4c	Counter-torque	1.822.156.000

1. Disconnect the electrical connections from the ignition coils.

	Name	Connector
1	Ignition coil	A30

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

	Name	Connector
2b	Earth on engine	C40B

3. Disconnect the covers 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 the plate, complete with ignition coils, upwards.Undo the bolts and remove the rocker cover complete with gasket.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 in a clockwise direction until the piston for cylinder no. 1 is at T.D.C. in the explosion 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 camshaft caps removed and fix it tightening the bolts (2b) to the recommended 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 explosion 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

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.Connect the oil vapour recovery pipe to the rocker cover.Fit the plate complete with ignition coils and high-tension cables and fix it using the bolts.Connect the high-tension leads to the spark plugs.Connect the earth lead to the ignition coils support plate.Connect the electrical connections to the ignition coils and position the electrical wiring in its housing.Fit the lower protective timing cover and secure using the bolts.Place the timing belt upper cover back in its housing and secure it using the bolts.Fit the engine components belt drive pulley and fix it tightening the bolts to 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	M10	4.5 ÷ 5.5

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.