3363573 - 1088C20 water pump - r + r with engine removed
Removing
(
Refitting
)
- 1004D40 engine - position on stand and remove
.
1. Fit the flywheel lock.
| Name | Country |
|---|
| 1 | Counter-torque | 1.860.846.000 |
1. Undo the bolts (1a) and remove the single engine component belt
drive pulley (1b).2. Loosen the mobile timing belt tensioner nut.3. Remove the timing belt.Remove the flywheel lock.
| Name | Country |
|---|
| - | Counter-torque | 1.860.846.000 |
1. Undo the bolt (1a) and remove the left side timing belt guard
(1b).2. Undo the bolts (2a) on the inlet side camshaft pulley, using
the tool (2b) for counter-torque.
| Name | Country |
|---|
| 2b | Counter-torque | 1.860.856.000 |
3. Remove the timing driven pulley, inlet side.4. Undo bolts (4a) and remove water pump (4b) complete with O-ring
(4c).
Refitting
(
Removing
)
1. Place water pump (1a), complete with 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) 2.1- 2.6 |
2. Fit the inlet side driven camshaft pulley (2a) and fix it using
the bolts (2b) without tightening them.3. Fit the left side timing belt guard (3a) and fix it using the
bolt (3b).
1. Disconnect the electrical connections from the ignition coils.
| Name | Connector |
|---|
| 1 | Ignition coil | A30 |
2. Undo the bolts (2a) and remove the ignition coils (2b).Disconnect the oil vapour recovery pipe
from the rocker cover.
Undo the bolts and remove the rocker cover
complete with gasket.1. Undo the bolt (1a) for the timing driven pulley, exhaust side
using the tools (1b) and (1c) for counter-torque.
| Name | Country |
|---|
| 1b | Support for counter-torque | 1.860.831.000 |
| Name | Country |
|---|
| 1c | Counter-torque | 1.860.848.000 |
Undo the bolts and remove the camshaft
third cap. | Mark the position of the camshaft
caps following removal so that they can be positioned correctly
upon refitting. |
1. Fit templates (1a) in place of the camshaft caps removed and
fix it tightening the bolts (1b) to the recommended torque. | Check that the camshaft cam profile
matches the tool correctly. |
| Name | Country |
|---|
| 1a | Gauge | 1.870.697.000 |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1b | Bolt | ENGINE TIMING ADJUSTMENT TEMPLATES | M7 | (Cylinder head side) 1.0 |
1. Remove the engine oil pump retaining bolt.2. Fit the timing belt.3. Fit the pin of the tool for setting the engine to TDC.4. Turn the crankshaft a little at a time to allow locating dowel
(4a) on the pulley to fit into the hole on tool (4b).5. Lock the tool in position using a nut (5a) and ordinary bolt
(5b).Complete the fitting of the toothed
timing belt following the order:
- toothed drive pulley
- fixed tensioner,
- exhaust side toothed driven pulley,
- intake side toothed driven pulley
- moving tensioner,
- coolant pump pulley
| When fitting, ensure that the
arrow stamped on the belt is facing in the direction of engine rotation.
Three notches on the belt must also line up with notches on the
toothed drive pulley and on the intake and exhaust toothed driven
pulleys |
1. Fit the tool into the hole on the timing belt mobile tensioner
and turn to apply maximum tension to the timing belt.
| Name | Country |
|---|
| 1 | Key | 1.860.845.000 |
2. Tighten the nut for the moving tensioner to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2 | Nut | MOBILE TIMING TENSIONER | M8 | 2.1 ÷ 2.6 |
3. Tighten the bolts (3a) for the camshaft toothed driven pulley,
inlet side, to the recommended torque using the tool (3b) for counter-torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 3a | Bolt | TIMING GEAR DRIVEN PULLEYS | M6 | (Inlet/camshaft side) 0.8 - 1.0 |
| Name | Country |
|---|
| 3b | Counter-torque | 1.860.856.000 |
4. Tighten the bolt (4a) for the exhaust side timing driven pulley
to the recommended torque using the tools (4b) and (4c) for counter-torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 4a | Bolt | TIMING GEAR DRIVEN PULLEYS | M12 | (Exhaust camshaft side) 10.2 - 12.6 |
| Name | Country |
|---|
| 4b | Support for counter-torque | 1.860.831.000 |
| Name | Country |
|---|
| 4c | Counter-torque | 1.860.848.000 |
Undo the bolts and remove the tool.
| Name | Country |
|---|
| - | Gauge | 1.870.697.000 |
Remove the engine positioning and TDC tool.
| Name | Country |
|---|
| - | Template | 1.860.905.000 |
Fit the camshaft caps removed previously
and tighten the bolts to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | CAMSHAFT SUPPORTS | M7 | Cylinder head side 1.3 ÷ 1.6 |
Rotate the crankshaft through two revolutions
in its normal direction of rotation.Loosen the moving tensioner nut.5. Fit tool (5a) in the hole on the mobile timing belt tensioner
mount and turn to align the tensioner moving pointer (5b) with fixed
reference (5c).
| Name | Country |
|---|
| 5a | Key | 1.860.845.000 |
Tighten the nut for the moving tensioner
to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Nut | MOBILE TIMING TENSIONER | M8 | 2.1 ÷ 2.6 |
Fit the rocker cover complete with gasket
and fix it using the bolts.Connect the oil vapour recovery pipe to
the rocker cover.Place the ignition coils back in their
housings and tighten them using the bolts.Connect the electrical connections to the
ignition coils.Fit the flywheel lock.
| Name | Country |
|---|
| - | Counter-torque | 1.860.846.000 |
Fit the single drive belt pulley and tighten
the bolts to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | CRANKSHAFT PULLEY | M8 | (Counter-balance shaft drive pulley2.1 - 2.6 |
Tighten the bolt fixing the timing belt
drive pulley to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | TOOTHED DRIVE PULLEY | M16 | (Crankshaft side) 20.9 - 23.1 |
Remove the flywheel lock.
| Name | Country |
|---|
| - | Counter-torque | 1.860.846.000 |
- 1004D40 engine - position on stand and remove
.
