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ALFA 159 2.2 JTS TIMING SYSTEM DRIVE CHAIN - R.R 1032A12

Removing ( Refitting )

- Position the vehicle on a lift.

- Make sure that the ignition key is in the OFF position, then disconnect the battery terminal
(-).

Description Connector

- Battery See A001 BATTERY

Op. 1048A28 VACUUM AIR CIRCUIT RESONATOR PIPE - R+R

- Using a suitable syringe, draw off the power assisted steering fluid from the reservoir.

1. Undo the connector (1a) and disconnect the supply pipe from the pump to the power
assisted steering box (1b), power assisted steering pump side.

2. Loosen the band and disconnect the supply pipe from the power assisted steering fluid
reservoir to the pump, power assisted steering pump side.

3. Loosen the band and disconnect the return pipe from the heat exchanger to the power
assisted steering fluid reservoir, reservoir side.

4. Undo the bolts (4a) and remove the power assisted steering fluid reservoir (4b) complete
with pipe (4c).

5. Loosen the band and disconnect the coolant return pipe.

1. Disconnect the electrical connections (1a) and (1b) from the phase transformer
electromagnets.

Description Connector

See N093 PHASE SHIFTER

Exhaust side phase
1a SOLENOID VALVE ON
transformer solenoid valve
EXHAUST SIDE

Description Connector

See N092 PHASE SHIFTER

Inlet side phase transformer
1b SOLENOID VALVE ON
solenoid valve
INTAKE SIDE

1. Disconnect the electrical connections (1a) and (1b) from the cam angle sensors.

Description Connector

See K107 EXHAUST SIDE

1a Exhaust side timing sensor
TIMING SENSOR

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Description Connector

See K106 INTAKE SIDE

1b Inlet side timing sensor
TIMING SENSOR

2. Disconnect the electrical connections from the electronic power module.

Description Connector

2 Ignition coil See A030 IGNITION COIL

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

Description Connector

See K036 ENGINE

Engine coolant temperature
1 COOLANT TEMPERATURE
sensor/sender unit
SENSOR/SENDER UNIT

- Release the engine electrical wiring from the securing bands and move it aside.

1. Undo the bolts (1a) and remove the electronic power module (1b).

1. Undo the bolts (1a) and remove the tappet cover (1b) complete with gaskets.

2. Unscrew the timing system hydraulic tensioner and remove.

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- Remove the spark plugs to facilitate the subsequent engine cranking operations.

1. Rotate the crankshaft until cylinder no. 4 is at T.D.C. in the explosion stroke; in this
condition the reference (1a) on the inner part of the crankshaft pulley should be in line with
the reference (1b) on the timing chain cover.

1. Undo the bolts (1a) and disconnect the intermediate exhaust pipe (1b), exhaust manifold
side with the catalytic converter.

1. Undo the bolts (1a) and remove the phase transformer electromagnets (1b).

1. Undo the bolts (1a) and remove the upper timing chain tensioner pad (1b).

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1. Support the engine using a hydraulic hoist fitted with suitable chains attached to the
brackets on the actual engine.

1. Undo the bolts (1a), (1b) and remove the flexible mounting for the power unit timing side
front support (1c) complete with power assisted steering fluid reservoir mounting bracket
(1d).

- Raise the engine as necessary using the hydraulic hoist.

1. Undo the access cap to the belt tensioner pad upper fixing bolt.

- Undo the upper fixed belt tensioner fixed pad fixing bolt.

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1. Undo the camshaft phase transformer fixing bolts.

Turn the hexagonal bolts on the camshafts using a fixed wrench to provide counter-
torque.

2. Remove the camshaft phase transformers.

Secure the timing chain to prevent it falling inside the sump.

Op. 4450B04 RIGHT FRONT WHEEL - R.R

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH -
R.R.

Op. 1092G10 SINGLE ENGINE BELT - R.R

Op. 1092A10 CRANKSHAFT PULLEY - R + R

Op. 1092G14 ENGINE COMPONENT SINGLE BELT MOVING TENSIONER - R + R

1. Undo the bolts (1a) and remove the crankshaft oil seal front cover (1b).

To remove the crankshaft front oil seal cover, move forward first to release the two
locating bushes.

The crankshaft front oil seal cover gasket does not need replacing whenever the cover
is removed but only if it is damaged.

1. Remove the crankshaft front oil seal cover (1a) destructively by cutting through points
(1b) shown in the figure.

The part of the gasket (1c) that remains attached to the rigid engine mount does not
affect the seal. Remove the same section from the new gasket to allow installation.

- Working at the bench, remove the oil seal from the timing chain cover.

Take care not to damage the sealing surfaces (of the timing chain cover) during the
"destructive" removal of the oil seal.

1. Undo the lower bolt (1a) and remove the timing fixed tensioner pad (1b).

1. Undo the belt tensioner mobile pad fixing bolt.

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- Release the timing chain from the toothed drive pulley.

1. Remove the mobile chain tensioner pad.

- Remove the timing chain.

Refitting ( Removing )

- Tighten the plug for access to the upper bolt securing the chain tensioner fixed pad.

Component Fastening dia Value (daNm) Validity

Cap for timing 1.9 JTS

fixed chain
- M22 6.5
tensioner pad
upper bolt 2.2 JTS

1. Place the inlet side camshaft phase transformer (1a) in its housing and secure it using a
new bolt (1b) without tightening it.

2. Turn the crankshaft until cylinder 4 is at TDC in the combustion phase, white notch
stamped on the timing chain toothed drive pulley turned down and key upward.

Rotate the crankshaft slowly and evenly (in the direction of rotation).

Ensure the timing chain is not stuck.

3. Fit the timing chain.

The pink link (3a) should be aligned with the white notch stamped on the timing chain
toothed drive pulley.
The light blue mesh (3b) should be in line with the reference (3c) on the inlet side

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camshaft phase transformer.

4. Place the exhaust side camshaft phase transformer (4a) in its housing and secure it using
a new bolt (4b) without tightening it.

Rotate the exhaust side camshaft using the hexagon until the pink mesh (4c) is in line
with the reference (4d) on the exhaust side camshaft phase transformer.

- The following drawing shows the fixed timing chain hydraulic tensioner disassembled.

Replace the seals.

- Before it is possible to refit the timing fixed hydraulic tensioner it must be pre-loaded as
described below.

1. Position the piston in a vice with protective jaws, holding it by the square end.

2. Insert the piston into the tensioner case by pressing and turning as shown in the figure
until the pin (2a) fits into the groove (2b).

3. Press and simultaneously turn the piston until the pin (3a) fits into the groove (3b).

- Insert the assembled piston into the tensioner body.

1. Refit the timing chain hydraulic tensioner into its seat and tighten to the specified torque.

Component Fastening dia Value (daNm) Validity

Timing fixed 1.9 JTS

hydraulic - M27 7.5
tensioner 2.2 JTS

1. Move the timing chain hydraulic tensioner to operating position by exercising overall
pressure by hand on the chain in the area shown in the figure. This puts the chain under
tension, which in turn acts on the mobile pad to release the mobile tensioner piston.

When the piston is activated the spring will make a noise.

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If the chain remains slack, the tensioner is not in the operating position.

- Rotate the crankshaft through 720°, then turn the crankshaft until cylinder 4 is at TDC in
the combustion phase, white notch stamped on the timing chain toothed drive pulley turned
down and key upward.

When the crankshaft is rotated the tensioner piston should follow the chain during the
rotation stage.

- Check the timing making sure that the timing references correspond.

1. Place the upper timing chain pad (1a) in its housing and fasten it tightening the bolts (1b)
to the recommended torque.

Component Fastening dia Value (daNm) Validity

Timing upper 1.9 JTS

(cylinder head
chain tensioner Bolt M6
side) 1.0
pad 2.2 JTS

1. Tighten the bolts fixing the camshaft phase transformers to the recommended torque
tightening the exhaust side phase transformer bolt first.

Turn the hexagonal bolts on the camshafts to provide countertorque.

Component Fastening dia Value (daNm) Validity

1.9 JTS
Camshaft phase (camshaft side)
Bolt M11
transformers 9.0 - 11.0
2.2 JTS

- Refit the timing chain provisionally in its seat.

Secure the timing chain to prevent it falling.

- Refit the chain tensioner mobile pad.

1. Tighten the bolt fixing the mobile belt tensioner pad to the recommended torque.

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- Fit the spark plugs and tighten them to the recommended torque.

Component Fastening dia Value (daNm) Validity

1.9 JTS
(cylinder head
Spark plugs - M14
side) 1.8 - 2.2
2.2 JTS

- Clean the contact surfaces.

1. If the crankshaft oil seal front cover gasket has been removed, cut the section that
remains attached to the rigid engine mount to allow installation.

1. Refit the chain tensioner fixed pad (1a) and secure by tightening the lower bolt (1b) and
upper bolt through the hole to the specified torque.

- Refit the crankshaft front oil seal cover gasket and arrange as shown above.

1. Place the crankshaft oil seal front cover (1a) in its housing and secure it tightening the
bolts to the recommended torque tightening the lower ones first and then the upper ones.

Component Fastening dia Value (daNm) Validity

1.9 JTS
Crankshaft oil (engine block
Bolt M8
seal front cover side) 2.1
2.2 JTS

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1. Fit a new oil seal (1a) on the timing chain cover using the tool (1b).

Before fitting, slightly moisten the lip of the new oil seal.

Tool Description Function Validity

1.9 JTS
Fitting timing chain
1860099000 Fitting tool
cover oil seal
2.2 JTS

Op. 1092G14 ENGINE COMPONENT SINGLE BELT MOVING TENSIONER - R + R

Op. 1092A10 CRANKSHAFT PULLEY - R + R

Op. 1092G10 SINGLE ENGINE BELT - R.R

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH -
R.R.

Op. 4450B04 RIGHT FRONT WHEEL - R.R

1. Place the timing side power unit front support flexible mounting (1a) in its housing
complete with power assisted steering fluid reservoir mounting bracket (1b) and secure it
tightening the bolts (1c) and (1d) to the recommended torque.

Component Fastening dia Value (daNm) Validity

Timing side
(rigid support
power unit rigid Bolt (to be
M12 side) 6.3 - 7.7 +
support flexible replaced)
90°
mounting

Component Fastening dia Value (daNm) Validity

Timing side
power unit rigid Bolt (to be (bodyshell side)
M12
support flexible replaced) 6.3 - 7.7 + 90°
mounting

- Remove the hydraulic hoist fitted with suitable chains for supporting the engine.

1. Place the phase transformer electromagnets (1a) in their housings and secure them
tightening the bolts (1b) to the recommended torque.

The white phase transformer electromagnet is the inlet side one and the black phase
transformer electromagnet is the exhaust side one.

Component Fastening dia Value (daNm) Validity

1.9 JTS
Phase
(cylinder head
transformer Bolt M6 2.2 JTS
side) 1.0
solenoids
3.2 JTS

1. Connect the intermediate exhaust pipe (1b), exhaust manifold side with the catalytic
converter and tighten the bolts (1b) to the recommended torque.

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Component Fastening dia Value (daNm) Validity

(exhaust
Intermediate
manifold side 1.9 JTS
exhaust pipe
Bolt M8 with catalytic
with flexible
converter) 2.2 - 2.2 JTS
section
2.6

1. Place the tappet cover (1a) complete with gaskets in its housing and secure it tightening
the bolts (1b) to the recommended torque.

Component Fastening dia Value (daNm) Validity

1.9 JTS
(cylinder head
Tappet cover Bolt M6
side) 0.7 - 0.9
2.2 JTS

1. Place the electronic power module (1a) in its housing and secure it tightening the bolts
(1b) to the recommended torque.

Component Fastening dia Value (daNm) Validity

1.9 JTS
Ignition coil (tappet cover
Bolt M6
module side) 2.2
2.2 JTS

- Place the engine electrical wiring in position and fasten it with the bands.

- Connect the electrical connection to the engine coolant temperature sensor.

- Connect the electrical connections to the electronic power module.

- Connect the electrical connections to the cam angle sensors.

- Connect the electrical connections to the phase transformer electromagnets.

- Connect the coolant return pipe and tighten the band.

- Place the power assisted steering fluid reservoir complete with pipe in its housing and
secure it using the bolts.

- Connect the return pipe from the heat exchanger to the power assisted steering fluid
reservoir, reservoir side and tighten the band.

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- Connect the supply pipe from the fluid reservoir to the power assisted steering pump, power
assisted steering pump side, and tighten the band.

- Connect the supply pipe from the pump to the power assisted steering box , power assisted
steering pump side, and tighten the connector to the recommended torque.

Component Fastening dia Value (daNm) Validity

Supply pipe from

(power assisted
pump to power
Connector M16 steering pump
assisted steering
side) 3.6 - 4.4
box

Op. 1048A28 VACUUM AIR CIRCUIT RESONATOR PIPE - R+R

- Connect the negative battery terminal (-).

Op. 0010T71 POWER STEERING FLUID CHECK LEVEL AND TOP UP IF NECESSARY

Op. 0010T75 HYDRAULIC POWER STEERING SYSTEM BLEED AIR

- Remove the vehicle from the lift.

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