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

This is the gearbox oil sump drain plug (12 mm Allen key)

Place a plastic container under the drain plug. Allow about 10 minutes for oil to drain and restore the drain plug (including a new copper washer).

This is the transmission oil filler plug located on the rear right side of the gearbox case.

Use a 12 mm Allen key to undo the filler plug.

A funnel attached to a transparent hose is required, so that gearbox oil is visible.

Place the hose end inside the transmission oil filler plug as far as it goes.

Pour gearbox oil slowly and carefully. Gear oil is thick and we rely on gravity to slowly drive it through the hose.
Gear oil smells awfully and can badly stain the surface it drops to; for this reason pour small quantities as an eye must always be kept to the hose.

Gearbox oil slowly finds its way to the gearbox. Oil will start seeping out of the filler plug when about 1.6 Lt are filled in.
Stop supplying oil and restore the drain plug.

Last but not least is the fuel filter. It is located in the left side of the engine bay just below the steering rack hidden by a black plastic cover.

This is the fuel filter cover. Shown are the two metal springs which affix the cover to the filter.

Fuel filter just below the steering rack.

Fuel filter inlet union.

Fuel filter outlet union. A 17 mm and 19mm wrench is needed to undo the union.

It is more convenient and practical to remove the fuel filter bracket complete with the fuel filter. Access to the locking screw is difficult so better remove the complete assembly.
Two nuts hold the bracket to the chassis.

Filter is out of the car along with the inlet fuel rubber hose.

Undo the fuel inlet union using 19 mm and 22 mm wrenches.

Transfer the rubber band to the new filter.

Slide in the new fuel filter to the bracket and the securing nut.

Install the new copper washers included with the new fuel filter.

It is important for the fuel inlet union to be parallel to the bracket mounting ears so that the fuel hose doesn't foul on the firewall and brake lines.

Install the fuel filter bracket to the chassis and tighten the securing nuts.

Attach the nylon fuel line to the fuel hose and tighten the respective clamp.

Install the outlet union using the second pair of copper washers included with the fuel filter packaging.

Restore the fuel filter plastic cover making sure the clips are properly seated on the fuel filter body.