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Evening,

I’m stripping my engine bay to get to my timing chains, with the engine still in. Got down to the crankshaft pulley and finding it really hard to get off using a 3 arm puller after removing the crankshaft bolt. Has anyone got any ideas on how to get the pulley off?

Also, I removed all the bolts on the timing cover and it’s still sealed on super tight, has anyone got any techniques to cut the sealant and get the cover loose?

Many thanks

Tom
 

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Hey Tom I did my chains with engine in situ earlier this year. Attached Pic of the puller I used. It was tricky with the thing slipping off all the time. Tip: tighten the nuts to make the leg movement stiff. I also put a bolt in the crank shaft to push against. Also Pic of metal spatular I used to remove sealant around cover. Tip: the hardest part for me was removing and replacing that dam cover. It seemed to get stuck in the alternator bracket but it doesn't. Just needs a really good wiggle to get off and on. You'll see!
Good luck.
I posted about my chain fun on this forum.
Roop
 

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Thanks Roop!

Managed to get the pulley off today! Had to remove one of the arms off the puller so I could get it in the space then attach it whilst it was in position. Also used an 12mm socket on the end of the threaded bar to locate and to protect the thread where the bolt came from.

Ran out of time to start removing the cover but still, with all the bolts removed, it’s not shifting. Found a metal scraper I can use, but not sure where to start. How did you manage to get between the cover and block to cut the seal?

Thanks

Tom
 

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Thanks Roop!

Managed to get the pulley off today! Had to remove one of the arms off the puller so I could get it in the space then attach it whilst it was in position. Also used an 12mm socket on the end of the threaded bar to locate and to protect the thread where the bolt came from.

Ran out of time to start removing the cover but still, with all the bolts removed, it’s not shifting. Found a metal scraper I can use, but not sure where to start. How did you manage to get between the cover and block to cut the seal?

Thanks

Tom
Hi Tom,

Well done with the pulley!

To start getting the cover off, Standing at the front of the car - place the scraper in the gap at the top corner where the front cover meets the head. Hit it down with a rubber mallet / hammer. Repeat on the rear bank, Repeat at the two center points either side of the water pump if you see what I mean. Once you've hit the blade all the way down so the handle touches the head at those 4 points. Start at the front again and try and follow the edge of the cover around as much as you can. Then get under neath and hit the blade in to the seem at the very bottom - underneath the crank. Cut round the outside of the plate / cover as much as possible then wriggle a screw driver in to open gaps further, keep wriggling.
As I said the most difficult part of the whole job (doing it with the engine in situ) is removing the cover. I felt like giving up with frustration a few times but it does come off in the end, then all other parts of the job are easy and enjoyable. Keep us updated ...
Roop.
 

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Discussion Starter #5
Hi Tom,

Well done with the pulley!

To start getting the cover off, Standing at the front of the car - place the scraper in the gap at the top corner where the front cover meets the head. Hit it down with a rubber mallet / hammer. Repeat on the rear bank, Repeat at the two center points either side of the water pump if you see what I mean. Once you've hit the blade all the way down so the handle touches the head at those 4 points. Start at the front again and try and follow the edge of the cover around as much as you can. Then get under neath and hit the blade in to the seem at the very bottom - underneath the crank. Cut round the outside of the plate / cover as much as possible then wriggle a screw driver in to open gaps further, keep wriggling.
As I said the most difficult part of the whole job (doing it with the engine in situ) is removing the cover. I felt like giving up with frustration a few times but it does come off in the end, then all other parts of the job are easy and enjoyable. Keep us updated ...
Roop.
Good evening,

Looks like I’ve almost got this timing cover off. Used a wallpaper scraper to start it off, then bought a cheap 300mm steel rule and sharpened one end so I could reach down the seal as far as I could from the top and bottom. The cover is loose but seems to be hitting something. Did you have to take the alternator and it’s mounting bracket off?

Thanks

Tom
 

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Ics alfa 166

Bonjour a touse je vient achete une alfa 166 est lasse je n est pas eu le code ics si quel q un pouvait l avoire le code je vous remerci
 

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Good evening,

Looks like I’ve almost got this timing cover off. Used a wallpaper scraper to start it off, then bought a cheap 300mm steel rule and sharpened one end so I could reach down the seal as far as I could from the top and bottom. The cover is loose but seems to be hitting something. Did you have to take the alternator and it’s mounting bracket off?

Thanks

Tom
Hey Tom,

You should read through my thread I started when in the same positions as you: https://www.alfaowner.com/Forum/alfa-159-brera-andamp-946-spider/1174921-brera-3-2-p0340-how-to-replace-sensor.html

Yes, it seems that there's something stopping the cover coming off at the lower left hand corner. When you look it seems that it's the alternator bracket. I went as far as undoing the alternator and moving it as much as I could out the way to the left, but then discovered there's absolutely no way of removing the bracket. Read my post - I was at my wit's end. LEAVE THE ALTERNATOR ALONE.

The cover has a couple of round tubes that sink in to the block and it's one of those (the lower left one) that makes it appear that the cover is caught on the alternator bracket. Get a long pry bar or similar and just violently wriggle the f'ing cover backwards and forwards - suddenly it comes free.

and again as repeated, the hardest part of the whole job is getting that cover off, but it does come off.

Roop
 

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Hi Roop,

I appreciate your advice, such a relief to know I don’t have to take the alternator off. After reading your thread, my Brera has very similar symptoms before I got my specialist to read the codes.

I’ll have a go at the weekend with a bit more force and keep you updated.

Thanks

Tom
 

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I had another go yesterday, still can’t seem to get the timing cover off. Genuinely seems like it’s caught behind that alternator bracket. Starting to think I may have to remove the alternator after all. The photo shows the bracket over lapping the timing cover.
930188


Do you if I have to remove the position sensors from the timing cover?
930189


Might be able to wriggle the cover further to the right if these were out of the way. Or is it more hassle to remove them?

Thanks

Tom
 

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I had another go yesterday, still can’t seem to get the timing cover off. Genuinely seems like it’s caught behind that alternator bracket. Starting to think I may have to remove the alternator after all. The photo shows the bracket over lapping the timing cover. View attachment 930188

Do you if I have to remove the position sensors from the timing cover?
View attachment 930189

Might be able to wriggle the cover further to the right if these were out of the way. Or is it more hassle to remove them?

Thanks

Tom
No, you don't.! This engine requires more patience than normal. But it is very straight forward when one allows time - what is the hurry. If you want to take the position sensors out, fine. But it will not make a great deal of difference. The alternator bracket is a red herring. The cover will come off as Roop admirably demonstrated - record time for changing chains. Go and have a pint and relax. You are not going to screw anything up - that comes on re - assembly. Only joking as the chain kit is marked up so you would have to be an idiot to F --- that up.

Whoops, silly me. You own an Alfa, which means you qualify.

Persevere and you will be rewarded - you are saving yourself a fortune.
 

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I had another go yesterday, still can’t seem to get the timing cover off. Genuinely seems like it’s caught behind that alternator bracket. Starting to think I may have to remove the alternator after all. The photo shows the bracket over lapping the timing cover. View attachment 930188

Do you if I have to remove the position sensors from the timing cover?
View attachment 930189

Might be able to wriggle the cover further to the right if these were out of the way. Or is it more hassle to remove them?

Thanks

Tom
Hey Tom

I took all 4 sensors out. Undid each nut, turned them left and right a bit and they all pulled out.

This may help loosen things up a bit but won't let you turn / swivel the plate. Again again again and as Sizewell confirms leave the alternator alone. I'm guessing you've loosened and moved the pump on the top right out the way. You have to of have to remove all the bolts.
Have you got a rubber mallet? Smacking the edges and wriggling a bar or lever of some sort and swearing a lot seemed to do the trick for me.
Even though it SEEMS that its clanking and catching on the lower left corner against the alternator bracket. It's not. Even when you look at it with a torch it looks like it is. It's not!!!!
The cover doesn't have to wriggle left and right it just pulls out STRAIGHT FORWARDS. Yes I know there's only 2 inches or so before it hits the inner wing. There's a tube that is part of the casting on the back of the plate you can't see. That is what prevents it coming out.
Take the sensors out. Then rubber mallet the thing.
When it does come off and it will you'll all yourself why was that so hard?
I really feel for you and wish I was there to help. Don't give up it comes off.
 

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Here's a pic of the rear side of the plate. The shallow circular casts are kind of vacuum sucked to the block and what are preventing the plate from just pulling off.
Looking forward to hearing your sigh of relief when you get it off.
 
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