1020D10 FRONT CRANK SHAFT OIL SEAL COVER - R + R AND REPLACE SEALS WITH TIMING BELT REMOVED - Alfa - 147 - eLearn

3024774 - 1020D10 front crank shaft oil seal cover - r + r and replace seals with timing belt removed

) Proceed with removal - 7055B54 under-engine guard - r r .Proceed with removal - 1072C44 exhaust manifold heat shield on bulkhead - r+r .1. Fit the tool (1a), complete with support mountings (1b).

	Name	Country
1a	Crossmember	1.820.581.000

	Name	Country
1b	Support mountings	1.870.650.000

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

	Name	Country
2a	Crossmember	1.860.851.003

	Name	Country
2b	Vertical support	1.870.748.000

Proceed with removal - 1080B40 catalytic pre-converter - r r .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 counter-balance shaft drive belt drive pulley (1b).2. Undo the (left hand thread) bolt (2a) and remove the drive pulley (2b).

1. Undo the plug and drain the engine oil.

Collect the engine oil in a suitable container.

2. Undo the bolt fixing the crankcase sump to the support on the engine for the reaction rod.

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

1. Undo the bolt (1a) and the nut (1b) and remove the reinforcement rod (1c).2. Undo the bolt (2a) and the nut (2b) fixing the rigid rear support for the power unit to the gearbox.3. Undo the bolt fixing the power unit rigid rear support to the cylinder block/crankcase.4. Undo the bolt (4a) and remove the rigid rear support for the power unit (4b).

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

	Name	Country
1b	Key	1.822.145.000

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

	Name	Country
2b	Key	1.822.144.000

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

	Name	Country
3	Blade	1.870.718.000

4. Remove the crankcase sump.

1. Undo the bolts fixing the power unit timing side rigid support to the flexible mounting.2. Undo the bolt (2a) and remove the power unit timing side rigid engine mount (2b).

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

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

Release the oil seal from the crankshaft front cover and remove it.

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

Refitting ( Removing

) 1. Place the crankshaft front cover (1a) complete with engine oil intake (1b) and a new gasket (1c) back in its housing and secure it tightening the bolts (1d) to the recommended torque.

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

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

	Name	Country
1b	Fitting tool	1.821.247.000

Fix the engine oil heat exchanger to the crankshaft oil seal front cover using the pin.Lubricate the gasket with engine oil and fit the engine oil filter, tightening fully by hand.1. Refit the timing side power unit rigid support (1a) in its seating and tighten the bolts (1b) to the specified torque.

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

2. Tighten the bolt securing timing side rigid support to the flexible mounting to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	ENGINE MOUNT TIMING SIDE	M12	(Flexible mounting side) 7.9 ÷ 9.7

Clean the matching surfaces of crankcase sump and cylinder block.Apply silicon sealant around the edge of the crankcase sump.1. Refit the crankcase sump2. 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	-	-	-	-

	Name	Country
2b	Key	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	-	-	-	-

	Name	Country
3b	Key	1.822.144.000

1. Place the power unit rigid rear support (1a) back in its housing and secure it to the flexible mounting by tightening the bolt (1b) to the recommended torque.

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

2. Tighten the bolt fixing the power unit rigid rear support to the cylinder block/crankcase to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	POWER UNIT RIGID REAR MOUNT	M12	(Crankcase sump side) 6.8 ÷ 8.3

3. Tighten the bolt (3a) and the nut (3b) fixing the power unit rigid rear support to the gearbox to the recommended torque.

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

	Fastening	Component	Ø	Value(daNm)
3b	Nut	POWER UNIT RIGID REAR MOUNT	M12	(Gearbox side) 7.2 ÷ 8.8

4. Place the reinforcement rod (4a) back in its housing and secure it tightening the bolt (4b) and the nut (4c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
4b	Bolt	POWER UNIT RIGID REAR SUPPORT REINFORCEMENT ROD....	M12	(Power unit rear rigid mounting side) 6.8 ÷ 8.3

	Fastening	Component	Ø	Value(daNm)
4c	Nut	POWER UNIT RIGID REAR SUPPORT REINFORCEMENT ROD....	M8	(Engine crankcase side) 2.4

1. Tighten the bolts fixing the manual gearbox and differential to the crankcase sump to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	MANUAL GEARBOX	M10	(Crankcase sump side) 5.0 ÷ 6.0

1. Tighten the bolt fixing the crankcase sump to the support on the engine for the reaction rod.2. Tighten the engine oil drain plug to the crankcase sump to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	-	-	-	-

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

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

2. Place the counter-balance shaft drive belt drive pulley (2a) back in its housing and secure it tightening the bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	-	-	-	-

Remove the flywheel lock.

	Name	Country
-	Counter-torque	1.860.898.000

Place the protection back in its housing and secure it using the bolt.Proceed with refitting - 1080B40 catalytic pre-converter - r r .Remove the safety tools used for supporting the power unit.

	Name	Country
-	Crossmember	1.820.581.000

	Name	Country
-	Support mountings	1.870.650.000

	Name	Country
-	Crossmember	1.860.851.003

	Name	Country
-	Vertical support	1.870.748.000

Proceed with refitting - 1072C44 exhaust manifold heat shield on bulkhead - r+r .Proceed with refitting - 7055B54 under-engine guard - r r .Refill the engine oil lubrication system - 1084A10 ENGINE OIL - Check level and top up, if necessary .