V6 Tensioner Procedure

["Nick Sorensen" <nicksorensen@xxxxxxxxx>]

My apologies.  When I posted earlier, I did not realize the T-belt procedure
was not on the Centerline website.  Here it is.  Figure 'A' is the same
figure 'A' that was used with the factory service bulletin regarding the
tensioner.
Thanks, Nick
Centerline Products
888-750-ALFA


Installation/modification instructions for new style V-6 timing belt
tensioner

1) On Milano and GTV-6 models:
Access the old style timing belt tensioner by removing the radiator,
auxiliary drive belts, and timing belt covers.

On 164 models:
a) Remove the passenger's side front wheel.
b) Remove the strut assembly (four bolts on the bottom and three nuts on top
of the shock tower)
c) Remove the front inner fender panel.
d) Remove the water pump-a/c belt and the power steering pump belt.  Use
special tool 1822-104 to loosen the rear power steering pump-adjusting nut.
e) After draining the cooling system, remove the radiator hoses from the
thermostat housing/water pump
f) Remove the two lower timing belt covers.
g) Remove the top engine "dog bone brace" and the two top timing belt
covers.

2) Using a 1 5/8" socket on the crankshaft nut, turn the engine clockwise
until the engine is at Top Dead Center (TDC) for cylinder number one.  This
is achieved when the pointer is aligned with the "P" mark on the crankshaft
pulley AND the ignition rotor is aligned with the ignition wire for number
one cylinder from the distributor cap.

3) Very carefully and clearly mark the relative position of the camshaft
drive pulleys in relation to the cylinder heads.  On Milano and GTV-6
models, you will also need to mark the auxiliary drive pulley relative to
the head, as it drives the ignition distributor.  Be sure to mark the cam
pulleys or you will have to remove the valve covers in order to reference
the factory marks.  If you miss-time the cams, valves could bend when the
engine is rotated so be very careful!

4) Remove the old style timing belt tensioner.  Do not lose the large flat
washer as you will reuse it later to mount the new style tensioner.

5) Remove the old timing belt (you must remove the Motronic crank sensor if
the vehicle is a 164).

6) Remove the long hollow oil-feed stud.  The stud can be easily removed if
you "double nut" it and you shock it lose by striking it sharply two or
three times on the end with a brass hammer.  Be sure to wear eye protection
and do not use a steel hammer-brass only!

7) Clean the area around the hole for the stud and clean all traces of oil
from the threads in the block.  Then blow air directly into the hole to dry
the threads and to back flush the oil out of the oil passage.

8) Apply several drops of Wurth thread locker part number 8932423
(Centerline number SS164) to the 10mm end of the special conversion stud
(Alfa part number 608-97506, Centerline part number TB308).  Do not use any
other type of thread lock.  Use only Wurth part 8932423 no other sealant or
thread lock compound is recommended.

9) Double nut the 8mm end of the special conversion stud and thread it into
the block until the 10mm portion of the stud is flush with the surface.
Remove the double nuts.

10) Drill, tap, and plug the drain-back hole.  Start by drilling it out with
a <" drill bit.  Put tape on the bit =" from the end so that you can gauge
your drilling depth.  Next, enlarge the hole using a 17/64" bit.  Put tape
on the bit =" from the end so that you can gauge your drilling depth.  You
may notice that the passage you are drilling out goes into the block at
angle- and is not a straight passage.  This is normal.  Let your drill bit
follow the passage.  When the hole is plugged, the thread locker will
compensate for any irregularities and since the passage is not under any
pressure, it will provide a positive seal.  Use an 8 x 1.25 tap and thread
the hole = way, remove the tap, and clear away any shavings.  Then tap the
hole the rest of the way.  Again clear away any shavings.

11) Apply Wurth thread locker to plug (part number 608-97507) and thread it
into the hole until it is flush.  Clean away any excess thread locker.

12) Install the new style belt tensioner.  Use a wavy washer and a new nut
for the top-mounting stud.  For the lower hole install the large flat washer
from the oil-fed tensioner followed by either a flanged locking nut or a
lock washer and a new nut.   If you do not have the flat washer from the
original tensioner, you will need to find a thick, 8mm flat washer with an
outside diameter no greater than 19.6mm.  Be sure that the washer seats
properly around the lower mounting hole.  Lightly tighten the two mounting
nuts (approximately 3 ft.lbs), insert a 3/8" square drive into the lift
square, and gently rotate the tensioner clockwise until it stops.  This
positions the tensioner so that more room is allowed for timing belt
installation.

13) Install a new timing belt, paying close attention to the timing
reference marks made earlier by double checking the alignment of all marks.
Start by placing the timing belt over the crankshaft pulley. Next work the
belt onto the other pulleys in a counter clockwise order, allocating all the
slack in the belt for the length between the crank pulley and the auxiliary
pulley.  Double check that you did not disturb the top dead center position
of the crankshaft and that you engaged the appropriate teeth of the cam
drive pulleys.  Use great care so as to maintain proper cam timing.  On
Milano and GTV-6 models you must properly index the auxiliary drive pulley
to maintain the proper ignition timing.
Important note: new style tensioner has a temperature sensitive switching
device.  It is important that it is only adjusted on a cold engine and when
the workshop's ambient air temperature is between 59: & 96:F. (15:-35:C).
14) With engine cold and positioned at top dead center, loosen both
tensioner-retaining nuts.  Insert a 3/8 square drive inserted into the lift
square (see figure "a" attached) of the tensioner and rotate the assembly
counter-clockwise (into the drive belt) until the pointer aligns with the
reference mark.  Do not use excessive force!  Too much force may damage the
clutching mechanism!

15) Holding the tensioner in this position, lock down the tensioner by
tightening the adjustment nut to approximately 15ftlbs.
16) With the tensioner set in this way, rotate the engine clockwise at least
four crankshaft revolutions to seat the belt.  On the last revolution, line
up the TDC marks.  Do not back up the engine at any time.  If you
accidentally pass TDC, keep going and bring it around again.
Do not allow the tensioner to release tension on the belt, or you will have
to go back to step 13.  While rotating the engine, it is normal for the
pointer to oscillate slightly to either side of the mark.  What is important
is that the pointer is aligned with the reference mark at TDC.  .  If the
pointer backs off the mark, increase the tension until it is aligned with
the mark again.
17) Tighten the adjustment nut and the tensioner pivot nut to 20ft.lbs.
18) Rotate the engine several more times in a clockwise direction.  Line up
TDC just as in Step #4.  Verify that the position indicator pointer is still
aligned with the nominal reference mark.
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