Alfa 164 Technical Service Bulletin 01.94.08

Information: Replacing the Poly-V Belt

Models: 24 Valve Engines

Date: 12/05/94

The PoIy-V Belt Tensioning procedure found in the current 1994 & 1995 Service Manuals Group "00, 0l and 23" has now been changed.

Please disregard any information pertaining to Poly-V Belt Tensioning on 24 Valve engines published prior to 10/31/94.

Within this Technical Service Bulletin you will have the new information needed to properly adjust the poly-v belt tension. The information should be followed precisely with no steps ignored.

REPLACING THE POLY-V BELT

  1. Remove the right front wheel and the front inner fender panel.
  2. Loosen the Poly-V eccentric pulley lock bolt. Rotate the eccentric pulley to the fully counter-clockwise (retracted) position. Tighten the lock bolt to hold eccentric in the retracted position.
  3. Assemble adapter (#1820-275) onto weight tool (#1820-273) and install tool onto the Poly-V tensioner eccentric. Lift up on the weight end of the tool to fully compress the "shock absorber". Slip the belt off of the water pump pulley. Remove the Poly-V belt.
  4. Install new Poly-V belt onto the motor by routing the belt around all the pulleys, except the water pump pulley (refer to the illustration below).
  5. Install weight tool (#1820-273) onto the Poly-V eccentric. Lift up on the weight end of the tool to fully the "shock absorber". Slip the belt onto the water pump
  6. Lift up or press down on the weight end of tool (#1820-273) as necessary, to cause the hole above the shock absorber to align. Insert locking pin (#1821-271).
  7. Loosen the Poly-V eccentric pulley lock bolt. Adjust the adapter (#1820-275) on weight tool (#1820-273) so that the shaft of the tool is inclined slightly above parallel to the ground (about 50 TO 100).
  8. Position the weight on the tool so that the inside edge of the weight is 100mm (3.93") from the point where the shaft changes from round to square. Do not remove locking pin (#1821-271) from the tensioner until the operation is completed and the Poly-V belt tension is properly set.
  9. Gently lift up and down on the weight end of the special tool to verify that the eccentric pulley moves freely.
  10. Using a thin wall 4lmm socket (see Technical Bulletin 01.93.07) rotate the engine two complete revolutions in a clockwise direction.
  11. Check once again that the weight tool is still horizontal or slightly inclined. If it is, proceed to the next step. If it is not, temporarily tighten the eccentric lock nut and re-position the weight tool (#1820-273) on adapter (#1820-275) 50 that it is horizontal. Then, loosen the lock nut for the tensioner eccentric and turn the engine two more revolutions. Proceed to the next step only when the weight is found to still be horizontal (or slightly inclined) after the engine has been turned two revolutions.
  12. Tighten the tensioner eccentric lock nut to a torque of 37 ft lb (50 Nm). It is very important that the weight does not move while you tighten the lock bolt. After tightening, the weight arm should be at the exact same angle as it was before tightening.
  13. Remove the weight tool (#1820-273) and the special locking pin (#1821-271) from the tensioner.
  14. Manually rotate the engine another two complete revolutions and return the engine to T.D.C..
  15. Test for proper belt tension by trying to insert the special locking pin (#1821-271). If the pin will not go in try to insert the butt end of a 3/16" drill bit. If either the special locking pin (#1821-271) or the 3/16" drill bit can be inserted, the belt is properly tensioned.
  16. Remove the special locking pin (#1821-271) from the tensioner. Reinstall the front inner fender panel and the right front wheel.

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