1084C10 ENGINE OIL HEAT EXCHANGER - R + R - Alfa - 156 - eLearn

3237617 - 1084C10 engine oil heat exchanger - r + r

) Position the vehicle on the ramp.Ensure that the ignition key is in the OFF position, then disconnect the negative battery terminal.

	Name	Connector
-	Battery	A1B

Proceed with removal - 4450B12 front or rear wheels (two) - r+r . Proceed with the removal - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. (Right and left sides). Proceed with removal - 7055B54 under-engine guard - r r . Proceed with removal - 1076B52 exhaust pipe (one) leaving l/h or r/h exhaust manifold - r + r . 1. Press the rapid attachment springs, by hand, and disconnect the lower coolant outlet hose from the radiator.

Recover the engine cooling system coolant in a suitable container.

1. Remove the electrical connections top guard after disengaging it from the fuel vapour recirculation pipe.2. Undo the bolts (2a) and remove the electrical connections lower protection (2b).

1. Undo the bolts (1a) and move aside the oil vapour separator (1b).

1. Undo the nuts fixing the right cylinder head exhaust manifold.2. Undo the bolts securing the rigid coolant supply pipe to the engine oil heat exchanger.

1. Undo the nuts (1a) and the bolt (1b) and move the engine wiring (1c) away.

1. Fit a suitable bracket on the right cylinder head which can safely support the power unit.2. Fit the safety tools (2a) and (2b) for supporting the power unit and connect the rod to the bracket fitted previously.

	Name	Country
2a	Crossmember	1.820.581.000

	Name	Country
2b	Brackets	1.870.651.000

1. Undo the bolts (1a) and disconnect the right and left half shafts (1b).

The bolts securing the front half shafts, intermediate half shaft/differential inner half shaft side, have been treated with Eslok type locking compound; therefore every time they are removed they must be replaced.

Position a hydraulic jack under the gearbox.1. Undo the bolts (1a) and (1b), then remove the power unit rigid rear support (1c) complete with rubber block (1d).2. Recover the exhaust pipe mounting bracket.

1. Undo the nuts (1a) and remove the heat shield from the power steering box (1b).

1. Remove the clips securing the brake calipers to the mounting brackets.2. Disconnect the electrical connection for the right brake pad wear sensor.

	Name	Connector
2	Right brake pad wear sensor (switch)	K21

3. Undo the bolts securing the front brake calipers to their mounting brackets.4. Release the flexible pipes to the front brake calipers from the mounting brackets.5. Remove the front brake calipers and secure them to the front suspension springs so that they do not hinder future operations.

1. Undo the bolts (1a) and remove the front wheel rpm sensors (1b) from the housings in the steering knuckles.

1. Undo the nuts (1a) securing the front anti-roll bar joints (1b) to the forks securing the shock absorbers to the lower track control arms.2. Undo the bolts securing the shock absorber forks to the lower track control arms, shock absorber side.

1. Undo the nuts (1a) and disconnect the track rods (1b) from the steering knuckles using the tool (1c).

	Name	Country
1c	Extractor	1.821.169.000

1. Undo nuts (1a) and disconnect upper track control arms (1b) from the steering knuckles using tool (1c).

	Name	Country
1c	Extractor	1.821.169.000

1. Undo the front nuts securing the mounting for the gear control levers and handbrake.2. Recover the plates.3. Undo the rear bolts (3a) and undo the remaining bolts (3b) securing the gear control levers and handbrake mounting.

1. Support the front suspension crossmember using a hydraulic jack fitted with a suitable flange.2. Undo the bolts securing the power steering box to the front suspension crossmember.3. Undo the rear bolts (3a) and side bolts (3b) securing the front suspension crossmember to the bodyshell.

1. Lower the hydraulic jack and remove the complete front suspension crossmember.

1. Undo the drain plug and drain the manual gearbox and differential fluid, as necessary, to prevent it from escaping during the removal of the intermediate driveshaft, then tighten the drain plug.

1. Undo the bolts (1a) and remove the intermediate drive shaft (1b).

1. Remove the cartridge engine oil filter (1a) using a suitable tool (1b).

Recover the engine oil which comes out in a suitable container.

1. Remove the right cylinder head exhaust manifold whose fastenings were already loosened previously.

1. Release the electrical wiring for the alternator (1a) from the fastening band (1b).

1. Undo the bolt (1a) and remove the electrical wiring mounting bracket (1b).2. Loosen the band securing the coolant return hose to the engine oil heat exchanger, exchanger side.

1. Undo the nut fixing the engine oil heat exchanger.Remove the engine oil heat exchanger from its housing, releasing it from the hose.2. Disconnect the coolant supply pipe (2a) to the engine oil heat exchanger (2b), then remove the latter, complete with O-ring.

Refitting ( Removing

) Connect the coolant supply pipe to the engine oil heat exchanger.Place the engine oil heat exchanger, complete with O-ring, back in its housing and connect it to the hose.Tighten the nut fixing the engine oil heat exchanger.Tighten the band securing the coolant return hose to the engine oil heat exchanger, exchanger side.Place the electrical wiring mounting bracket back in its housing and secure it using the bolt.Fasten the electrical wiring for the alternator to the retaining band.Place the right cylinder head exhaust manifold in its housing.Place the cartridge engine oil filter in its housing, tightening it fully by hand.1. Refit the intermediate half shaft (1a) in its seating and tighten its bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	INTERMEDIATE DRIVE SHAFT	M8	(Support side) 2.5 ÷ 2.8

Place the complete front suspension crossmember back in its housing using the hydraulic jack.1. Tighten the rear bolts (1a) and the side bolts (1b) fixing the front suspension crossmember to the bodyshell.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	ENGINE OR ROD ANCHORAGE BEAM	M10	(Bodyshell side) 8.1 ÷ 9.9

	Fastening	Component	Ø	Value(daNm)
1a	Rear bolts	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 ÷ 13.2

	Fastening	Component	Ø	Value(daNm)
1b	Side bolt	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 ÷ 13.2

2. Tighten the bolts securing the power steering box to the front suspension crossmember to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	POWER STEERING BOX	M14	(Front suspension crossmember side) 11.0 - 13.6

3. Remove the hydraulic jack, complete with flange for supporting the front suspension crossmember.

Tighten the nuts and bolts fixing the handbrake and gear lever mounting.1. Connect the upper track control arms (1a) to the steering knuckles and tighten the nuts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	FRONT DAMPER BOTTOM ATTACHMENT	M12 x 1.25	(on pillar) 12

1. Connect the tie-rods (1a) to the steering knuckles and tighten the nuts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	POWER STEERNG BOX LINKS	M14	(Wheel damper side) 2.9 ÷ 3.6

1. Tighten the bolts securing the forks connecting the shock absorbers to the lower track control arms, shock absorber side, to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	FRONT DAMPER FORK ON WISHBONE	M12	(Shock absorber side) 8.1 - 8.9

2. Tighten the nuts (2a) securing the front anti-roll bar joints (2b) to the forks connecting the shock absorbers to the lower track control arms to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2a	Nut	FRONT ANTI-ROLL BAR JOINTS	M10	3.8 ÷ 4.7

Place the front wheel rpm sensors back in their housings and fasten them using the bolts.1. Place the front brake calipers (1a) back in their housings and fasten them to the mounting brackets by tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FRONT BRAKE CALIPER ASSEMBLY	M10	(Bracket side) 4.8 - 5.2

2. Fix the flexible pipes to the front brake calipers to their mounting brackets.3. Connect the electrical connection for the right brake pad wear sensor.4. Refit in their seats the clips securing the brake calipers to their mounting brackets.

Refit the power steering box heat shield in its seat and tighten its nuts.1. Place the power unit rigid rear support (1a), complete with flexible mounting (1b) and exhaust pipe mounting bracket (1c) back in its housing and fasten it by tightening the bolts (1d) and (1e) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1d	Bolt	POWER UNIT RIGID REAR MOUNT	M16	(Gearbox side) 10.2 ÷ 12.6

	Fastening	Component	Ø	Value(daNm)
1e	Bolt	INTERM RUBBER MOUNT	M8	(Front suspension crossmember side) 3.1 ÷ 3.8

Remove the hydraulic jack positioned under the gearbox.1. Connect the right and left half shafts (1a) and tighten the new bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M10	5.0 ÷ 6.1

Remove the safety tools used for supporting the power unit.

	Name	Country
-	Crossmember	1.820.581.000

	Name	Country
-	Brackets	1.870.651.000

Place the engine electrical wiring back in its housing and secure it using the nuts and the bolt.Tighten the bolts securing the rigid coolant supply pipe to the engine oil heat exchanger.Tighten the nuts fixing the right cylinder head exhaust manifold to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	EXHAUST MANIFOLD/S	M8	(Cylinder head side) 1.9 - 2.3

Place the oil vapour separator back in its housing and fix it using the bolts.Place the electrical connections lower protection back in its housing and secure it using the bolts.Place the electrical connections upper protection back in its housing, then secure the fuel vapour recirculation pipe to it.Connect the lower coolant outlet hose from the radiator. Proceed with removal - 1076B52 exhaust pipe (one) leaving l/h or r/h exhaust manifold - r + r . Proceed with removal - 7055B54 under-engine guard - r r . Proceed with the removal - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. (Right and left sides). Proceed with removal - 4450B12 front or rear wheels (two) - r+r . Connect the negative (-) battery terminal. Refill the engine oil lubrication system - 1084A10 ENGINE OIL - Check level and top up, if necessary . Refill the manual gearbox and differential - 2110A04 Manual gearbox and differential OIL - Check level and top up, if necessary . Supply the engine cooling system with the recommended fluid.

	Type	Component	Name	Qty.
-	Fluid [l]	ENGINE COOLING CIRCUIT	Mixture 50% Paraflu11 for Alfa Romeo/distilled water	9.2

Remove the car from the ramps.

Removing ( Refitting

) Position the vehicle on the ramp. Proceed with removal - 7055B54 under-engine guard - r r . 1. Disconnect the lower radiator hose from the water pump rigid inlet pipe.

Recover the engine coolant in a suitable container.

1. Release and remove the engine oil filter using a suitable tool.

1. Undo the bolts fixing the coolant supply pipe to the engine oil heat exchanger.2. Loosen the connector of the coolant outlet pipe from the engine oil heat exchanger on the water pump rigid inlet pipe side.

1. Undo the connector securing the engine oil heat exchanger.2. Loosen the bands (2a) and disconnect the engine coolant inlet and outlet pipes (2b) from the engine oil heat exchanger.3. Remove the engine oil heat exchanger.

Refitting ( Removing

) Connect the water inlet and outlet pipes to the heat exchanger and secure them using the bands.Place the engine oil heat exchanger back in its housing and secure it using the pin.Tighten the connector of the coolant outlet pipe from the engine oil heat exchanger on the water pump rigid inlet pipe side.Tighten the bolts fixing the coolant supply pipe to the engine oil heat exchanger.Refit the engine oil filter in its seating and tighten it fully by hand.Connect the lower radiator hose to the water pump rigid inlet pipe.Supply the engine cooling system with the recommended fluid.

	Type	Component	Name	Qty.
-	Fluid	ENGINE COOLING CIRCUIT	Mixture 50% Paraflu11 for Alfa Romeo/distilled water	6.9

Top up the engine oil lubrication circuit using the recommended oil.

	Type	Component	Name	Qty.
-	Oli [l]	ENGINE LUBRICATION CIRCUIT	SELENIA 20K	4.4

For a distinctly sporty performance, use the recommended oil for the lubrication circuit.

	Type	Component	Name	Qty.
-	Oli [l]	ENGINE LUBRICATION CIRCUIT	SELENIA RACING	4.4

For the optimum operation of the engine in particularly harsh climatic conditions (temperatures below -20 degrees C), use the recommended oil for the engine lubrication circuit.

	Type	Component	Name	Qty.
-	Oli [l]	ENGINE LUBRICATION CIRCUIT	SELENIA PERFORMER	4.4

Proceed with refitting - 7055B54 under-engine guard - r r . Remove the car from the ramps.