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

125000917 - 1020A20 CRANK CASE OIL SUMP - R + R CLEAN SEALS FOR SEALANT APPLICATION

) Position the vehicle on a lift.Make sure that the ignition key is in the OFF position, then disconnect the negative battery terminal (-)

	Description	Connector
-	Battery	See A1B BATTERY ( BATTERY NEGATIVE )

Drain the air conditioning refrigerant circuit Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE.Proceed with the removal Op. 4450B04 RIGHT FRONT WHEEL R R.Proceed with the removal Op. 7055B54 UNDER-ENGINE GUARD - R R.Proceed with the removal Op. 1016A40 IGNITION COIL COVER ON CYLINDER HEAD- R+R.Proceed with the removal Op. 5040A20 AIR CONDITIONER COMPRESSOR - R+R - INCLUDES FLUID LEVEL CHECK AND TOP UP IF NECESSARY.Proceed with the removal Op. 5040A26 COMPRESSOR MOUNT - R R.Proceed with the removal Op. 1076A48 CATALYTIC CONVERTER HEAT SHIELD - R R.Proceed with the removal Op. 1080B62 CATALYTIC CONVERTER - R + R.1. Undo the bolt fixing the rigid pipe mounting collar for the exhaust pipe between the catalytic converter and the silencer to the bracket.2. Loosen the collar (2a) and remove the rigid pipe for the exhaust pipe between the catalytic converter and the silencer (2b).3. Remove the seal.

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

Position a hydraulic jack beneath the engine.1. Undo the bolts (1a) and remove the heat shield (1b).

1. Undo the bolt (1a) and the nut (1b) and remove the reinforcement rod (1c).

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

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

	Description	Code
2	Counter-torque	1.860.898.000

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

1. Remove plug (1a), unscrew bolt (1b) and remove the fixed auxiliary drivebelt tensioner (1c).

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

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

1. Unscrew the bolt connecting the crankcase sump to the intermediate driveshaft mount.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-differential unit to the crankcase sump.

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

	Description	Code
1b	Spanner	1.860.833.001

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

	Description	Code
2b	Spanner	1.860.834.001

3. Cut the crankcase sump sealant using the tool.

	Description	Code
3	Blade	1.870.718.000

4. Remove the crankcase sump.

Refitting ( Removing

) Apply silicon sealant to the entire perimeter 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

	Description	Code
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

	Description	Code
3b	Spanner	1.860.834.001

1. Tighten the bolts fixing the manual gearbox-differential unit to the crankcase sump to the specified torque.

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

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

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

2. Tighten the bolt connecting the crankcase sump to the intermediate driveshaft mount to the specified torque.

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

Refit the lower timing belt covers and secure them using the bolts.Refit the upper timing belt covers and secure them using the bolts.1. Position the engine components single belt fixed tensioner (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

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

2. Refit the plug on the auxiliary drivebelt fixed tensioner.

1. Position the crankshaft pulley (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

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

Remove the flywheel lock.

	Description	Code
-	Counter-torque	1.860.898.000

1. Place the power unit rigid rear support (1a) in its housing and secure it tightening the bolts (1b, (1c) and (1d) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	RIGID REAR SUPPORT POWER UNIT	M12	(Gearbox side) 7.2 - 8.8

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

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

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

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	SEATBELT HEIGHT ADJUSTER FRONT	M8	2.5

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

Place the heat shield back in its housing and secure it using the bolts.Remove the hydraulic jack from beneath the engine.1. Place the exhaust pipe mounting (1a) in its housing and fasten it tightening the bolt (1b) and the nut (1c) to the recommended 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	M8

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 tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	RIGID EXHAUST PIPE	M8

2. Tighten the bolt fixing the rigid pipe mounting collar for the exhaust pipe between the catalytic converter and the silencer to the bracket.

Proceed with the refitting Op. 1080B62 CATALYTIC CONVERTER - R + R.Proceed with the refitting Op. 1076A48 CATALYTIC CONVERTER HEAT SHIELD - R R.Proceed with the refitting Op. 5040A26 COMPRESSOR MOUNT - R R.Proceed with the refitting Op. 5040A20 AIR CONDITIONER COMPRESSOR - R+R - INCLUDES FLUID LEVEL CHECK AND TOP UP IF NECESSARY.Proceed with the refitting Op. 1016A40 IGNITION COIL COVER ON CYLINDER HEAD- R+R.Proceed with the refitting Op. 7055B54 UNDER-ENGINE GUARD - R R.Proceed with the refitting Op. 4450B04 RIGHT FRONT WHEEL R R.Refill the engine oil lubrication system Op. 0010T11 ENGINE OIL CHECK LEVEL AND TOP UP.Refill the air conditioning refrigerant circuit Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE.Connect the negative battery terminal (-).Remove the vehicle from the lift.