1020D10 FRONT CRANK SHAFT OIL SEAL COVER - R + R AND REPLACE SEALS WITH TIMING BELT REMOVED - Alfa - GT - eLearn

125000921 - 1020D10 FRONT CRANK SHAFT OIL SEAL COVER - R + R AND REPLACE SEALS WITH TIMING BELT REMOVED

) Proceed with the removal Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD ON BULKHEAD - R+R.1. Fit the tool (1a) complete with mountings (1b).

	Description	Code
1a	Crossmember	1.820.581.000

	Description	Code
1b	Support mountings	1.870.650.000

2. Fit the tools (2a) and (2b), then connect them to the exhaust manifold using the rod (2c) as shown in the figure.

	Description	Code
2a	Crossmember	1.860.851.003

	Description	Code
2b	Vertical support	1.870.748.000

Proceed with the removal Op. 1080B40 CATALYTIC PRE-CONVERTER - R R.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 bolt (1a) (left hand thread) and remove the toothed drive pulley (1b).

1. Undo the nut fixing the reinforcement link to the cylinder block/crankcase.2. Undo the bolt securing the power unit rigid rear mount to the crankcase sump.3. Undo bolt (3a) and nut (3b) securing the power unit rear rigid mount to the gearbox.4. Loosen the bolt securing the reinforcement link to the power unit rear rigid mount.5. Undo bolt (5a) and remove the power unit rear rigid mount (5b) complete with reinforcement link (5c).6. Undo the 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.

Undo the bolt connecting the intermediate bearing mount o the crankcase sump.1. Undo the front and rear bolts (1a) fixing the crankcase sump using the tool (1b).

	Description	Code
1b	Spanner	1.822.145.000

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

	Description	Code
2b	Spanner	1.822.144.000

3. Cut the crankcase sump sealant using the tool.

	Description	Code
3	Blade	1.870.718.000

4. Remove the crankcase sump.

1. Unscrew the bolt securing the power unit rigid mount to the flexible block.2. Undo the bolts (2a) and remove the power unit gearbox side rigid mount (2b).3. Undo the bolt (3a) and remove the auxiliary driveshaft mobile tensioner (3b).

1. Undo and remove the engine oil filter using a suitable tool.2. Unscrew pin (2a) and release engine oil heat exchanger (2b) from the crankshaft oil seal front cover.

1. Undo bolts (1a) and remove the crankshaft oil seal front cover (1b) complete with oil seal (1c), gasket (1d) and intake duct (1e).

Prise up and release the oil seal from the crankshaft oil seal front cover.

Take care not to damage the oil seal seat during its removal.

Refitting ( Removing

) 1. Refit the crankshaft oil seal front cover (1a) complete with engine oil intake duct (1b), new gasket (1c) and secure by tightening bolts (1d) to the specified torque.

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

1. Fit a new crankshaft front oil seal (1a) using the tool (1b).

	Description	Code
1b	Fitting tool	1.821.247.000

Refit the engine oil heat exchanger and secure it to the crankshaft oil seal front cover using the pin.Refit the engine oil filter in its seat and tighten fully by hand.1. Position the engine components single belt moving 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 MOVING TENSIONER VARIOUS	M8	2.3 ÷ 2.8

2. Place the power unit gearbox side rigid support (2a) in its housing and secure it by tightening the bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
2b	Bolt	RIGID ENGINE MOUNT, TIMING SIDE	M10	(Engine crankcase side) 4.5 - 5.5

3. Tighten the bolt securing the power unit gearbox side rigid support to the flexible block to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
3	Bolt	RIGID ENGINE MOUNT, TIMING SIDE	M12	(Flexible block side) 7.9 - 9.7

Clean the mating surfaces between the crankcase sump and the cylinder block/crankcase.Apply silicon sealant to the entire perimeter of the crankcase sump.1. Place the crankcase sump in its housing.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	Bolt	OIL SUMP	M8	(Engine crankcase side) 2.3 - 2.8

	Description	Code
2b	Spanner	1.822.145.000

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

	Fastening	Component	Ø	Value (daNm)
3a	Bolt	OIL SUMP	M6	(Engine crankcase side) 0.8 - 1.0

	Description	Code
3b	Spanner	1.822.144.000

Undo the bolt connecting the intermediate shaft bearing mount o the crankcase sump.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	(Engine crankcase sump side) 5.0 - 6.0

1. Tighten the engine sump 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. Refit the power unit rear rigid mount (2a) complete with reinforcement link and secure to the flexible block by tightening bolt (2b) to the specified torque.

	Fastening	Component	Ø	Value (daNm)
2b	Bolt	POWER UNIT REAR RIGID MOUNT	M12	(Flexible block side) 7.5 - 9.2

3. Tighten bolt (3a) and nut (3b) securing the power unit rear rigid mount to the gearbox to the specified torque.

	Fastening	Component	Ø	Value(daNm)
3a	Bolt	RIGID REAR SUPPORT POWER UNIT	M12	(Gearbox side) 6.8 - 8.3

	Fastening	Component	Ø	Value(daNm)
3b	Nut	RIGID REAR SUPPORT POWER UNIT	M12	(Gearbox side) 7.2 - 8.3

4. Tighten the bolt securing the power unit rigid rear mount to the crankcase sump to the specified torque.

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

5. Tighten bolt (5a) and nut (5b) securing the reinforcement link to the engine crankcase to the specified torque.

	Fastening	Component	Ø	Value(daNm)
5a	Bolt	POWER UNIT REAR RIGID UPPER REINFORCEMENT LINK	M12	(Power unit rear rigid mount side) 6.8 ÷ 8.3

	Fastening	Component	Ø	Value(daNm)
5b	Nut	POWER UNIT REAR RIGID UPPER REINFORCEMENT LINK	M8	(Engine crankcase side) 2.4

1. Position the toothed timing drive pulley (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
1b	Left hand bolt	DRIVE PULLEY(PULLIES) TIMING	M16	(Crankshaft side) 20.9 - 23.1

Remove the flywheel lock.

	Description	Code
-	Counter-torque	1.860.898.000

Place the protection in its housing and secure it using the bolts.?Proceed with the refitting Op. 1080B40 CATALYTIC PRE-CONVERTER - R R.Remove the tools used for supporting the power unit safely.

	Description	Code
-	Crossmember	1.860.851.003

	Description	Code
-	Vertical support	1.870.748.000

	Description	Code
-	Crossmember	1.820.581.000

	Description	Code
-	Support mountings	1.870.650.000

Proceed with the refitting Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD ON BULKHEAD - R+R.Refill the engine oil lubrication system Op. 0010T11 ENGINE OIL CHECK LEVEL AND TOP UP.