Regular Servicing

April 26, 2020 49

This article describes the regular maintenance plan including oil (engine & transmission), filters (oil, air, fuel) and spark plugs replacement.

Parts needed

4 liters engine oil (recommended SELENIA 20K 10W/40 or Star 5W/40 for northern climates)
2 liters manual transmission oil (TUTELA EPYX 80W/90)
2 copper washers for oil drain plugs (engine and transmission)
Air filter element (OEM AR part No. 60570436)
Oil filter - be sure that it features two non-return valves (OEM AR part No. 46805828)
Spark plugs (recommended SPICA Golden Lodge 25HL AR part No. 60504563)
Fuel filter (OEM AR part No.60801638 or BOSCH part No. 0 450 905 005 )
Plastic container for oil draining
Plastic bottle to be used as funnel

Engine oil and oil filter are replaced every 5.000 km and air filter along with spark plugs every 10.000 km. It is a good practice for the engine longevity to have regular oil changes as city driving and driving habits affect the quality and lubrication characteristics of the oil. A note here regarding air filter; driving in dusty areas require the periodic cleaning of the filter with the help of compressed air.

In addition, fuel filter is replaced every 20.000 km and transmission oil every 40.000 km; these intervals are narrowed down compared to the official maintenance schedule by Alfa. It is really not worth having a clogged fuel filter which struggle the fuel pump; replacing fuel filter in the prescribed intervals plays a significant role in emissions control and fresh transmission oil will preserve as much as possible the notorious 2nd gear synchro mesh.

An important piece of advise. Do replace engine oil once a year even regardless of the predetermined number of Km or miles. Never let oil more than a year in the engine as it oxidizes and certain characteristics are not effective any more resulting in engine lubrication.

Regular Servicing

SELENIA engine oil 10W/40.

Tutela EPYX transmission oil 80W/90

Spark plugs (SPICA Golden Lodge 25HL), Original oil filter and Original air filter.

BOSCH fuel filter. Check the packaging includes two pairs of copper rings as these should be renewed whenever the fuel filter is replaced.

Warm up the engine to normal running temperature and then drain.

This is the engine oil drain plug (12 mm Allen key).

Allow oil drain for about 15 minutes.

Undo the air filter box sleeve clamp.

Undo the four clamps holding the air filter box cover.

Air filter element demonstrated.

Note the discoloration of the air filter showing that it has properly done its job to filter out particulates.

Proceed removing the oil filter.

Just a notice. When removing the oil filter, a certain amount of oil drops in the stabilizer engine mount. Unfortunately, this engine mount sits exactly under the oil filter.
Since oil is the worst enemy of rubber parts, it is common for these engine mount to perish due to oil contamination.
In order to prevent such phenomenon, a plastic cover has been installed on the bush so that any oil drips away from the rubber bush.

Use an oil filter wrench to undo the filter. In case an oil filter wrench is not availalble, then the old trick of piercing the oil filter with a screwdrive can do the job.
Do place rags below the oil filter or newspaper sheets to prevent oil spilling.

Prior installing the new oil filter, apply some drops to the oil filter seal. Hand tight the oil filter according to the instructions on the oil filter body.

New copper seal for the oil drain plug.

Install the new air filter element.

Tighten the air filter box sleeve clamp.

Get hold of a plastic water bottle to use it as a funnel.
This is a more convenient trick rather than a real funnel as the plastic water bottle can simply be discarded.

Hold the oil container as lower as possible to avoid spilling.

Pour the oil slowly and carefully. The Boxer 8V engine oil capacity is about 3.8 liters including oil filter capacity.

New spark plugs. Spark plugs should be installed when engine is cold (NEVER on a hot engine). Prior installation apply a drop of engine oil on the threads.

The spark plug cavity should be cleaned from dust using compressed air prior removing the spark plug.

Drive the spark plug carefully by hand and apply torque of 25-34 Nm. In case a torque spanner is not available, the When-It-Feels -Right doctrine is also applicable.
Finally restore the spark plug leads.