2022-2024 Alfa Romeo Stelvio Timing Cover Oil Leak TSB

Symptoms of an Alfa Romeo Stelvio Oil Leak

Owners of 2022-2024 Alfa Romeo Stelvio vehicles may experience an Alfa Romeo Stelvio oil leak originating from the timing cover. This is the primary symptom identified in Technical Service Bulletin (TSB) 09-013-25 REV. B. Visible oil stains or drips under the vehicle, particularly near the front of the engine, are common indicators.

The Cause: Loose Timing Cover Fasteners

The root cause of the timing cover oil leak in affected vehicles is identified as loose timing cover fasteners. Over time, these fasteners can lose their specified torque, allowing engine oil to seep past the timing cover gasket or sealant.

Important Warnings for Diagnosis

Before proceeding with any repairs for an Alfa Romeo Stelvio oil leak, it is crucial to accurately identify the source of the leakage. Technicians are cautioned to ensure the oil leak is not originating from other areas such as the cylinder head, cylinder block, or the top of the crankcase. Proper diagnosis is essential to avoid unnecessary repairs and ensure the issue is resolved effectively.

Diagnosis and Inspection

If you suspect an Alfa Romeo Stelvio oil leak from the timing cover, a qualified technician will perform a thorough inspection. This involves carefully locating the source of the oil leak. If the leak is confirmed to be coming from the timing cover, the repair procedure outlined in TSB 09-013-25 REV. B will be followed. Detailed service procedures for engine diagnosis are available in the DealerCONNECT Service Library under "09 - Engine, 2.0L / Diagnosis and Testing."

Repair Procedure Summary

The repair for the timing cover oil leak, as described in TSB 09-013-25 REV. B, involves a multi-step process. Initially, the air cleaner assembly and serpentine belt are removed to access the timing cover. Technicians then mark each timing cover fastener's current rotational position using a paint pen. The fasteners are loosened and then re-torqued to their original position, aiming for a torque between 8.6 N·m (6.343 ft lb) and 11.0 N·m (8.113 ft. lb).

If the residual torque of the fasteners is found to be below 8.6 N·m, a more specific tightening sequence is followed. This involves loosening the fasteners, tightening them to 5 N·m (3.687 ft. lb), and then applying an additional 40° turn. The final torque in this scenario should be between 11.0 N·m (8.113 ft. lb) and 16.0 N·m (11.801 ft. lb). Alternatively, a direct torque of 10.0 N·m (7.376 ft. lb) can be applied. A specific tightening sequence, illustrated in the bulletin's Figure 1, must be followed to ensure even pressure.

After re-torquing, the affected area is cleaned, and the engine oil is topped off. The serpentine belt and air cleaner assembly are then reinstalled. The vehicle is subsequently idled for at least 10 minutes, or driven for approximately 6 miles, to check if the leak has been resolved. If the oil leak persists, the timing cover will need to be resealed, which involves removing and reinstalling the cover with new sealant. Finally, the engine oil and filter are changed.

Required Tools and Parts

Several specific tools and parts may be required to address the timing cover oil leak:

Special Tools

• Installer, Oil Seal: Ref. No. 9506
• Measuring container for Coolant Filling: (Tool number not listed in Service Manual)
• Retaining button removal tool: Ref. No. 1823015000
• Remover, Fuel Rail: Ref. No. 2044500140
• Guide, Fuel Rail Installer: Ref. No. 2044400140
• Holder, Front Damper MAIR: Ref. No. 2024700090

Replacement Parts

• Threebond RTV: Part No. 68082860AB
• Seal Kit: Part No. 68351878AA (Includes Four Fuel Injector To Valve Cover Seals and Four Fuel Injector Seals)
• Seal: Part No. 2142125000 (Crankshaft Oil)
• Bolt: Part No. 06513080AA (Crankshaft Damper Pulley)
• Filter: Part No. 04892339BE (Oil)
• Tube: Part No. 04893751AA (Fuel Rail Supply)
• Stud: Part No. 06512266AA (Timing Cover)
• Antifreeze: Part No. 68163849AB
• Gasket: Part No. 68217568AA (Cylinder Head Cover)
• Gasket: Part No. 68217569AA (Spark Plug Well)
• Oil: Part No. 68523988AA (0W30 - Quart)

Owner Action

If you own a 2022-2024 Alfa Romeo Stelvio and notice signs of an Alfa Romeo Stelvio oil leak from the timing cover, it is recommended to schedule an appointment with an authorized Alfa Romeo service center. This issue is reimbursable under warranty provisions. The service center will diagnose the exact source of the leak and perform the necessary repairs as outlined in TSB 09-013-25 REV. B. The labor operation for re-torquing bolts (09-10-10-98) is estimated at 1.1 hours, while resealing the front timing cover for a Stelvio (09-10-10-99) is estimated at 5.2 hours.

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Source: NHTSA ID: 11019431