Mirrored from:
Replacing The Cam Belt And Water Pump On The Alfa 4C Coupe (Part 1) (alfaworkshop.co.uk)
Replacing The Cam Belt And Water Pump On The Alfa 4C Coupe (Part 2) (alfaworkshop.co.uk)
Replacing The Cam Belt And Water Pump On
The Alfa 4C Coupe (Part 1)
Replacing the cam belt can be done with all the body panels still in place but
we've removed the rear, right side wing to make it easier to see.
WORKSHOP TIME 6hrs
Cam belt kit 6000629434,
water pump 60586222
Gaskets 55213959 and 71779194
If you would like to BOOK yourself
in for a cam belt replacement the price of this service in our workshop
is £668.40 (price
of water pump NOT included).
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Prop
up the boot and pull off the plastic engine cover.
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Undo
the x3 10mm bolts to the breather pipe fixings...
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...and
unclip the connector at each end.
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Unclip
the vacuum pump hose.
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Unplug
the thermostat temp sensor.
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Undo
the x4 5mm allen bolts to the vacuum pump and move the pump to one side.
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The
inlet camshaft blanking
plate has x3 10mm bolts.
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The
undertray is held by x14 T30 (Torx)
screws.
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The
rear diffuser has x2 T30, x3 Phillips screws and x4 4mm allen bolts.
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Unbolt
the rear RIGHT side wheel and remove.
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The
rear RIGHT side wheel arch liner has x3 allen and x3 Phillips screws.
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Where
the rear wing joins the bumper there are x5 10mm nuts, remove the first x4
(the last one is in a tight corner).
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The
wings alloy support frame has x4 10mm bolts.
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There's
a T30 screw at the front of the wheel arch joining the side skirt...
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....and
x4 more in the 'door shut'.
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In
the top LEFT corner of the 'door shut' behind the weather seal is a 5mm allen
bolt.
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There's
x2 T30 screws under the fuel filler flap to a plastic cover and one more
underneath the cover.
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Behind
the filler above the filler neck is a 10mm bolt.
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Lift
the rubber weather seal around the right side of the boot and undo the T25
screw...
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...and
the other x4 along the edge of the black infill panel.
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You
can now easily access the fifth 10mm nut joining the rear wing to the bumper.
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Carefully
lift the wing away from the car (noting the rear end is sitting on the x5
bumper studs). The drain pipe for the fuel overspill is still connected so
this will pull out with the wing.
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With
the wing out of the way you can now work on the engine.
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Undo
the x4 T45 bolts to the auxiliary bottom
pulley.
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The
auxiliary tensioner mounting bolt is a T47.
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Using
a T50 allen key with an extension bar undo the the auxiliary idler.
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At
the bottom of the engine support (large alloy side casting) are x3 13mm bolts
and x1 15mm.
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Take
out the oil pumps 10mm bolt and replace it with the timing tool locating pin.
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Turn
the crank clockwise with a 19mm spanner until it's aligned with the crank
locking tool then secure with a T45 bolt.
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Replacing The Cam Belt And Water Pump On
The Alfa 4C Coupe (Part 2)
The main objective now is
removing the cast alloy side support that covers the cam belt
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RETURN
TO PART 1 Jack
the engine up enough to take the weight off of the engine mounts.
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Undo
the 15mm nut and bolt to the right side engine mount stabiliser bar.
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Then
the x2 15mm bolts on top of the engine mount...
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...and
x3 18mm nuts.
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The
alternator has x2 10mm bolts to a plastic covering.
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The
last alternator bolt is 13mm, once unbolted just lay the alternator down.
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The
cam belt protective plastic covering has x5 5mm allen bolts. To the right of
the side cover unclip the pipe and electric trunking so that the cover can be
removed.
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The
last bolts to the alloy side support are a 13mm...
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....and
x3 15mm.
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You
can now remove the alloy support.
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If
the exhaust camshaft doesn't align with the cam locking tool, release the
crank shaft locking tool and rotate the crank clockwise 180° then lock it
back up. You should now be able to lock up the exhaust camshaft.
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Next
lock up the inlet camshaft.
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Undo
the 12mm bolt to the cam belt tensioner and remove. Take off the crank locking
tool so you can remove the cam
belt.
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The cam belt idler has a 15mm bolt.
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Undo
the 30mm caps on the camshaft pulleys.
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Loosen
the exhaust camshaft pulley so it can turn freely (T55
bolt) but take off the inlet pulley to gain access to the water pump.
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The
water pump has x2 6mm allen bolts.
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Put
a tray on the floor under the water pump to catch the coolant as you prise the pump off.
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Clean
any residue and dry around the contact area where the pump has been lifted.
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We
tend to apply a bead of gasket sealant around the 'O' ring of the new water
pump. Bolt on the new water pump.
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When
replacing the cam belt tensioner the lug on the support plate locates between
the fork on the tensioner, the fixing nut slides so just TACK the tensioner
on for now.
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Loop
on the new cam belt noting the 'DIRECTIONAL' markings.
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Using
a long handled FLAT head screwdriver rotate the base of the tensioner so that
the needle....
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....points
to the hole on the tensioner fork, then tighten the mounting bolt.
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Tighten
up both the cam shaft pulleys then take off all the locking tools.
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Bolt
back on the blanking plate and vacuum pump using new gaskets.
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Top
up the coolant tank to the MAXIMUM level.
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You
will need to bleed the system so undo the 8mm bleed screw...
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...until
no air but just coolant escapes.
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At
the Alfaworkshop we then pressure test the cooling system up to x1 BAR (14
psi) to check there's no leakage from the water pump.
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