All right, so looks like this will be a larger job than I originally hoped. Will be relying on your support guys :-) Anyway, this is what I assume I will need to do:
1. Take off auxiliary belt, aux belt fixed tensioner and aux belt crankshaft pulley
Will need: spanners, ribe bits for the crankshaft pulley (already ordered, but might take some time for them to arrive... bummer)
Found nice guide for removal of aux belt, so will use that: Board Message
(courtesy of Sir GialloEvo
2. Take off cam belt cover, cam belt and the crankshaft cam belt pulley
Will need: just regular spanners, I assume
These guides: The cam variator
Alfa Romeo Cam Belt Replacement on 1.6l and 1.8l TS engines
give some hints, as well as the repair manuals here: Board Message
3. Take off the oil filter, the oil/coolant heat exchanger and finally the oil pump itself
Will need: oil filter wrench. I assume a regular one such as one of these: E-Shop Auto Kelly, a.s. - náhradní díly
will do the trick; don't need any Alfa Romeo special, right?
4. Fix the pump/gasket/whatever it is
Might need: the tool for measuring clearances to check the pump
Details on this to be filled in later
5. Put the pump, the oil/coolant heat exchanger and the oil filter back on.
Will need: Loctite maybe?
I don't need to change any gaskets here and can just reuse the old ones, as long as they are not damaged, right?
Also, can I just reuse the oil filter, or would you recommend I buy a new one (and do oil change as well)?
The repair manual prescribes use of a tool 1.821.247.000 to fit the front oil seal properly. Is this tool really necessary? Does anyone have any experience with this?
6. Fit cam belt crankshaft pulley, cam belt and cam belt cover.
Will need: cam shaft locks, TDC gauge, flywheel lock tool, maybe other special tools?
The two guides I mentioned above (variator change and cam belt change) provide good instructions, but I'm thinking I might rather ask a garage to do this step for me. The tools might be rather expensive (haven't checked yet) and I'm not sure if I'd be able to do this properly and don't want my pistons to get acquainted with the valves too closely
Anyway to be decided yet.
7. Fit aux belt crankshaft pulley, fixed tensioner, and finally aux belt and hope the leak is really fixed
A few more questions:
Should I buy new belts and tensioners, or can I reuse them?
Both belts and all tensioners have been changed in Nov 2009, about 4500km before. I'm afraid both belts have already been off and on twice and as I know they don't like being re-tensioned, I assume it would be safer to buy new belts. What about the tensioners then? Will I need to buy new ones as well, or can I keep them?
The repair manuals prescribe specific torques for the various bolts. Should I use a torque wrench, or do you think this job can be safely done without it?