Alfa Romeo GTV6 Thermostat Element Installation

Alfa Romeo Milano and GTV6 Thermostat (IAP #350021)Originally, Alfa Romeo supplied this thermostat along with its housing, but that item is no longer available. We now supply a replacement internal element which you install into your existing thermostat housing. Here's the procedure:

1. (Photo 1). Using pliers, flatten the tabs (A) that retain the old element to the housing's mounting ears.

2. (Photo 2). Now you can twist the old thermostat element free and lift it from the housing.

3. (Photo 3). Place the new element into the housing, making sure the actuating pin fits into the hole (B) in the top of the housing. 

4. (Photo 4). Depress the new element and twist it into the grooves in the mounting ears, similar to the way the old element was removed (it may take a little more effort). Make sure the element is centered and equally started into each "ear" before twisting, or it will be difficult to twist all the way around to the correct location. Keep rotating the element until it snaps into place.

Note: The new thermostat functions the same as the original; it opens at approximately 83 degrees C (181 degrees F), and opens 7-9 mm when hot.

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V-6 Tensioner Modification

Alfa 164 Technical Service Bulletin 01.93.03

Information: New Style V-6 Tensioner Modification

Models: All Models-1981 Thru 1993- with The Old Style Oil-Fed Tensioner

Date: 08/11/93

A NEW STYLE, NON OIL-FED, TIMING BELT TENSIONER IS NOW SUPPLIED AS A REPLACEMENT PART FOR ALL ALFA ROMEO V-6 ENGINES - MODEL YEARS 1981 THROUGH 1993. THIS NEW STYLE TENSIONER (PART NUMBER 605-88421) SUPERSEDES ALL OLD STYLE, OIL-FED TENSIONERS.

TO RETROFIT THIS NEW STYLE TENSIONER, YOU MUST PLUG OFF THE OLD STYLE TENSIONER'S DRAIN BACK HOLE IN THE BLOCK WITH A SPECIAL PLUG (PART NUMBER 608-97507) AND REPLACE THE HOLLOW STUD WHICH' PREVIOUSLY F~D OIL TO THE OLD STYLE TENSIONER WITH A SPECIAL ADAPTER STUD (PART NUMBER 608-97506).

ATTACHED PLEASE FIND THE INSTALLATION I MODIFICATIQN INSTRUCTIONS. INSTALLATION / MODIFICATION INSTRUCTIONS
NEW STYLE V-6 TIMING BELT TENSIONER
(REFERENCE VIDEO TAPE PART # 608-97518)

1. ON MILANO & GTV 6 MODELS:

   ACCESS THE OLD STYLE TIMING BELT TENSIONER BY REMOVING THE RADIATOR, AUXILIARY DRIVE BELTS AND THE TIMING BELT COVERS.

   ON 164 MODELS:

   1. REMOVE THE PASSENGER'S SIDE FRONT WHEEL.
   2. REMOVE THE STRUT ASSEMBLY (FOUR BOLTS ON THE BOTTOM AND THREE NUTS ON TOP OF THE SHOCK TOWER).
   3. REMOVE THE FRONT INNER FENDER PANEL.
   4. 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.
   5. REMOVE THE RADIATOR HOSES FROM THE THERMOSTAT HOUSING/WATER PUMP.
   6. REMOVE THE TWO LOWER TIMING BELT COVERS.
   7. REMOVE THE TOP ENGINE "DOG BONE BRACE" AND THE TWO TOP TIMING BELT COVERS.
2. USING A SOCKET ON THE CRANKSHAFT NUT, TURN THE ENGINE CLOCKWISE AND LINE UP THE TOP DEAD CENTER MARKS AT THE CRANKSHAFT PULLEY.
3. VERY CAREFULLY AND CLEARLY MARK THE RELATIVE POSITION OF THE CAMSHAFT DRIVE PULLEYS IN RELATION TO THE CYLINDER HEADS. ON MILANO AND GTV6 MODELS, YOU WILL ALSO NEED TO MARK THE AUXILIARY DRIVE PULLEY, AS IT DRIVES THE IGNITION DISTRIBUTOR. BE SURE TO MAKE YOUR MARKS CLEAR AND ACCURATE. IF YOU DO NOT MARK THE CAM PULLEYS YOU WILL HAVE TO REMOVE THE VALVE COVERS IN ORDER TO REFERENCE THE FACTORY MARKS. IF YOU MIS-TIME THE CAMS YOU COULD BEND VALVES - SO BE VERY CAREFUL!
4. REMOVE THE OLD STYLE TIMING BELT TENSIONER. DO NOT LOSE THE RETAINING NUTS AND WASHERS AS YOU WILL REUSE THEM 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. 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 THREADLOCKER PART NUMBER 8932423- TO THE 10 MM END OF THE SPECIAL CONVERSION STUD (PART NUMBER 608-97506). DO NOT USE ANY OTHER TYPE OF THREAD LOCK. USE ONL Y WURTH PART #8932423. NO OTHER SEALER OR THREAD LOCK COMPOUND IS RECOMMENDED.
9. DOUBLE NUT THE 8 MM~END OF THE SPECIAL CONVERSION STUD AND THREAD IT INTO THE BLOCK UNTIL THE 10 MM 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 1/4" DRILL BIT. PUT TAPE ON THE BIT 1/2" FROM THE END SO THAT YOU CAN GAUGE YOUR DRILLING DEPTH.

    NEXT, ENLARGE THE HOLE USING A 17/64" BIT. ALSO PUT TAPE ON THIS BIT 1/2" FROM THE END TO GAUGE DRILLING DEPTH.

    YOU MAY NOTICE THAT THE PASSAGE YOU ARE DRILLING OUT GOES INTO THE BLOCK AT AN ANGLE AND IS NOT A STRAIGHT PASSAGE. THIS IS NORMAL, IN THAT THIS PASSAGE IS CAST AND NOT MACHINED. 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 A 8 X 1.25 TAP AND THREAD THE HOLE 1/2 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 THREADLOCKER TO PLUG (PART NUMBER 608- 97507) AND THREAD IT INTO THE HOLE UNTIL IT IS FLUSH. CLEAN AWAY ANY EXCESSIVE THREADLOCKER.
12. INSTALL THE NEW STYLE BELT TENSIONER. MOUNT IT USING THE SAME NUTS AND WASHERS WHICH RETAINED THE OLD TENSIONER.
13. INSTALL A NEW TIMING BELT. PAY CLOSE ATTENTION TO THE TIMING REFERENCE MARKS MADE EARLIER. USE SPECIAL TOOL (PART NUMBER 608-97517) TO RETRACT THE TENSIONER PULLEY AND SLIP THE BELT OVER THE TENSIONER PULLEY. DOUBLE CHECK THAT YOU DID NOT DISTURB THE TOP DEAD CENTER POSITION OF THE CRANK SHAFT 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 SO AS TO MAINTAIN THE PROPER IGNITION TIMING.

    NOTE: FOR ADJUSTMENT / SET-UP PROCEDURES - SEE TECHNICAL BULLETIN 01.93.04

    SINCERELY, 
    ALFA ROMEO DISTRIBUTORS OF NORTH AMERICA