1020A20 CRANK CASE OIL SUMP - R + R CLEAN SEALS FOR SEALANT APPLICATION - Alfa - 156 - eLearn

3237469 - 1020A20 crank case oil sump - r + r clean seals for sealant application

- 1092G10 single engine belt r r - 1092A12 crankshaft pulley - r+r for versions with air conditioner - 1092G20 engine component single belt fixed tensioner - one - r + r - 1032D12 timing system protective cover(s) - r + r - 1032D12 timing system protective cover(s) - r + r - 1092G20 engine component single belt fixed tensioner - one - r + r - 1092A12 crankshaft pulley - r+r for versions with air conditioner - 1092G10 single engine belt r r

Removing ( Refitting

) Position the vehicle on the ramp.Ensure that the ignition key is in the OFF position, then disconnect the negative battery terminal (-).

	Name	Connector
-	Battery	A1B

Drain the air conditioner coolant circuit - 5040A10 Air conditioning refrigerant CIRCUIT - Draining and Refilling . Proceed with removal - 4450B04 right front wheel r r . Proceed with removal - 7055B54 under-engine guard - r r . Proceed with removal - 1016A40 ignition coil cover on cylinder head- r+r . Proceed with removal - 5040A20 air conditioner compressor - r+r - includes fluid level check and top up if necessary . Proceed with removal - 5040A26 compressor mount - r r . Proceed with removal - 1076A48 catalytic converter heat shield - r r . Proceed with removal - 1080B62 catalytic converter - r + r . 1. Undo the bolt securing the collar supporting the rigid exhaust pipe section between the catalytic converter and silencer to the relevant bracket.2. Undo the bolts (2a) and remove the rigid pipe for the exhaust pipe between the catalytic converter and the silencer (2b). 3. Remove the gasket.

1. Undo the bolt (1a) and the nut (1b) and remove the exhaust pipe (1c) support.

Position a hydraulic jack under the motor.1. Undo the bolt (1a) and nut (1b) and remove the reinforcing link (1c).

1. Undo the bolts (1a) and remove the power unit rigid rear support (1b).

1. Undo bolts (1a) and remove protection (1b).2. Fit the flywheel lock.

	Name	Country
2	Counter-torque	1.860.898.000

1. Undo the bolts (1a) and remove the crankshaft pulley (1b).

1. Remove the cap (1a), undo the bolt (1b) and remove the single belt fixed tensioner (1c).

1. Undo the bolts (1a) and remove the upper protective timing cover (1b).

1. Undo the bolts (1a) and remove the lower protective timing cover (1b).

1. Undo the bolt connecting the oil sump to the intermediate shaft support.2. Undo the drain plug and drain the engine oil.

Collect the engine oil in a suitable container.

1. Undo the bolts fixing the manual gearbox and differential to the cylinder block/crankcase.

1. Undo the front and rear bolts (1a) securing the crankcase sump using tool (1b).

	Name	Country
1b	Spanner	1.860.833.001

2. Undo the side bolts (2a) securing the crankcase sump using tool (2b).

	Name	Country
2b	Spanner	1.860.834.001

3. Use the tool to cut the crankcase sump sealant.

	Name	Country
3	Blade	1.870.718.000

4. Remove the crankcase sump.

Refitting ( Removing

) Apply silicon sealant around the edge of the crankcase sump.1. Position the sump on the crankcase.2. Tighten the front and rear bolts (2a) fixing the crankcase sump to the recommended torque using the tool (2b).

	Fastening	Component	Ø	Value(daNm)
2a	Front and rear bolts	OIL SUMP	M6	(Engine crankcase side) 0.8 ÷ 1.0

	Name	Country
2b	Spanner	1.860.833.001

3. Tighten the side bolts (3a) fixing the crankcase sump to the recommended torque using the tool (3b).

	Fastening	Component	Ø	Value(daNm)
3a	Side bolts	OIL SUMP	M8	(Engine crankcase side) 2.3 ÷ 2.8

	Name	Country
3b	Spanner	1.860.834.001

1. Tighten the bolts securing the manual gearbox with differential to the crankcase to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	MANUAL GEARBOX	M10	(Crankcase sump side) 5.0 ÷ 6.1

1. Tighten the engine oil drain plug to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	-	ENGINE OIL DRAIN PLUG	M18	(Crankcase sump side) 1.8 ÷ 2.2

2. Tighten the bolt securing the oil sump to the intermediate shaft support to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	ENGINE LINK AND VARIOUS COMPT.MOUNTS	M8	(Crankcase sump side) 2.3 ÷ 2.8

Fit the lower protective timing cover and secure using the bolts.Fit the upper protective timing gear cover and fix it using the bolts.1. Place the engine components single drive belt fixed tensioner (1a) back in its housing and fix it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FIXED SINGLE SERVICE BELT TENSIONER	M8	2.2 ÷ 2.8

2. Place the engine components single drive belt fixed tensioner plug back in its seating.

1. Place the crankshaft pulley (1a) back in its seating and secure it tightening the bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CRANKSHAFT PULLEY	M8	2.3 ÷ 2.8

Remove the flywheel lock.

	Name	Country
-	Counter-torque	1.860.898.000

1. Refit the gearbox side power unit rear rigid support reinforcement (1a) in its seating and secure by tightening the bolts (1b), (1c) and (1d) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT RIGID REAR MOUNT	M12	(Gearbox side) 6.8 ÷ 8.3

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	POWER UNIT RIGID REAR MOUNT	M12	(Engine oil sump side) 6.8 ÷ 8.3

	Fastening	Component	Ø	Value(daNm)
1d	-	-	-	-

1. Place the reinforcement rod (1a) back in its housing and secure it by tightening the bolt (1b) and the nut (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT REAR RIGID SUPPORT REINFORCEMENT ROD....	M12	6.8 ÷ 8.3

	Fastening	Component	Ø	Value(daNm)
1c	Nut	POWER UNIT REAR RIGID SUPPORT REINFORCEMENT ROD....	M12	5.0 ÷ 6.1

Remove the hydraulic jack from beneath the engine1. Fit the support for the exhaust pipe (1a) and secure by tightening bolt (1b) and nut (1c) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	EXHAUST PIPE RIGID MOUNT	M8	2.3 ÷ 2.8

	Fastening	Component	Ø	Value(daNm)
1c	Nut	EXHAUST PIPE RIGID MOUNT	M12	6.8 ÷ 8.3

1. Place the rigid pipe for the exhaust pipe between the catalytic converter and the silencer (1a) complete with gasket (1b) back in its housing and secure it to the front exhaust silencer by tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	RIGID EXHAUST PIPE	M10	(Front silencer side) 5.9 ÷ 7.2

2. Tighten the bolt securing the collar supporting the rigid exhaust pipe section between catalytic converter and silencer to the relevant bracket.

Proceed with refitting - 1080B62 catalytic converter - r + r . Proceed with refitting - 1076A48 catalytic converter heat shield - r r . Proceed with refitting - 5040A26 compressor mount - r r . Proceed with refitting - 5040A20 air conditioner compressor - r+r - includes fluid level check and top up if necessary . Proceed with refitting - 1016A40 ignition coil cover on cylinder head- r+r . Proceed with refitting - 7055B54 under-engine guard - r r . Proceed with refitting - 4450B04 right front wheel r r . Refill the engine lubrication circuit - 1084A10 ENGINE OIL - Check level and top up, if necessary . Fill the air conditioner coolant circuit - 5040A10 Air conditioning refrigerant CIRCUIT - Draining and Refilling . Connect the negative (-) battery terminal.Remove the car from the ramps.