3237437 - 1004B12 power unit with manual gearbox - r+r for versions with a/c

Before any interventions on components of the fuel system, discharge the pressure in the system using tool N. 1.870.684.000 connected to the specific valve located on the fuel distribution manifold.

1. Disconnect the fuel supply pipe from the fuel distributor manifold.2. Disconnect the fuel vapour recirculation pipe coupling.3. Disconnect the electrical connection for the cam angle sensor.

	Name	Connector
3	Timing sensor	K47

 - 1048A28  vacuum air circuit resonator pipe - r+r - 1048A10  air cleaner filtering element - replace 1. Disconnect the oil vapour recirculation pipe from the tappet cover.2. Disconnect the accelerator cable from the throttle body3. Disconnect the corrugated hose from the butterfly casing.4. Disconnect the electrical connection from the air flow meter.

	Name	Connector
4	Air flow meter	K41

1. Disconnect the coolant supply pipe to the radiator from the thermostat.2. Disconnect the supply pipes (2a) and return pipes (2b) to the climate control system heater from the thermostat and release them from the fixings. Connect the electrical connection for the rpm and timing sensor.Connect the electrical connection for the detonation sensor.Connect the electrical connection for the Lambda sensor.Connect the electrical connection for the dashboard wiring to the injection/ignition single/separable wiring.Connect the electrical connection to the injection/ignition control unit.Place the corrugated hose, complete with air flow meter, back in its housing and connect it to the air filter and the butterfly casing.Connect the electrical connection to the air flow meter. Connect the accelerator cable to the throttle body integral with the M.D.S. and adjust it (refer to op.   1068A30  accelerator control cable - r + r ). Connect the oil vapour recirculation pipe to the tappet cover. - 1048A10  air cleaner filtering element - replace - 1048A28  vacuum air circuit resonator pipe - r+r Connect the electrical connection for the cam angle sensor.Connect the coupling for the fuel vapour recirculation pipe.Connect the fuel supply pipe to the fuel distribution manifold. Removing ( Refitting ) Position the vehicle on the ramp. - 5530B10  battery - r+r - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. - 4450B12  front or rear wheels (two) - r+r - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R. - 7055A43  central front grille - r r - 7055B10  Front BUMPER - R.R. - 5040A10  Air conditioning refrigerant CIRCUIT - Draining and RefillingDrain the power steering fluid from the reservoir using a suitable syringe.Raise the car.1. Disconnect the lower coolant outlet hose from the radiator and drain the engine coolant.

Recover the coolant using a suitable container.

1. Remove the lower coolant outlet hose from the radiator.Lower the vehicle.2. Disconnect the system supply pipe from the water pump rigid inlet pipe.3. Disconnect the intermediate coupling for the engine coolant reservoir return pipe. - 1048A50  air inlet pipe to turbo charger - r + r4. Disconnect the upper coolant inlet hose to the radiator from the thermostat. 1. Disconnect the electrical connection from the air flow meter.

	Name	Connector
1	Air flow meter	K41

2. Undo the bolt (2a) and remove the air filter (2b) and air flow meter (2c) assembly.3. Disconnect the air supply hose from the heat exchanger to the inlet manifold side inlet manifold.4. Disconnect the brake servo vacuum pipe from the vacuum pump. 1. Disconnect the fuel inlet pipe from the pressure pump.2. Disconnect the fuel return pipe to the reservoir from the fuel return manifold pipe.3. Disconnect the fuel return pipe from the filter to the fuel filter side fuel return manifold pipe. 1. Undo the bolts (1a) and remove the power unit reaction rod (1b). 1. Undo the nuts (1a) and move the oil vapour separator (1b) aside complete with pipes.Disconnect the engine oil vapour pipe from the intake side separator.Disconnect the crankcase side engine oil recovery pipe.2. Disconnect the engine compartment wiring main electrical connections.3. Disconnect the electrical connection from the combined sender unit for the engine coolant temperature gauge and warning light.

	Name	Connector
3	Coolant temperature sender unit	k35

4. Disconnect the electrical connection from the engine coolant temperature sensor.

	Name	Connector
4	Engine temperature sensor	k45

1. Disconnect the electrical connections from the injectors.

	Name	Connector
1	Injector	N70

1. Disconnect the electrical connection from the E.G.R. valve.

	Name	Connector
1	EGR solenoid	L30

2. Disconnect the electrical connections from the pre-heating control unit.

	Name	Connector
2	Plug preheating control unit	M15

3. Disconnect the electrical connection from the fuel pressure sensor.

	Name	Connector
3	Fuel pressure sensor	K83

4. Disconnect the electrical connection from the excess pressure sensor.

	Name	Connector
4	Turbocharging sensor	K82

5. Disconnect the electrical connection from the thermal switch for the fuel heater.

	Name	Connector
5	Diesel heater resistance	O20

6. Disconnect the electrical connection from the fuel heater.

	Name	Connector
6	Diesel heater resistance	O20

7. Disconnect the E.G.R. system vacuum pipe coupling. 1. Disconnect the electrical connection from the fuel temperature sensor.

	Name	Connector
1	Fuel temperature sensor	K81

2. Disconnect the electrical connection from the pressure regulator.

	Name	Connector
2	Fuel pressure regulator	N77

3. Disconnect the electrical connection for the timing sensor.

	Name	Connector
3	Timing sensor	K47

1. Disconnect the electrical connection for the air conditioning compressor electro-magnet coupling.

	Name	Connector
1	Air conditioning compressor "on" electromagnet	L20

Move the engine compartment right side wiring aside. 1. Disconnect the electrical connection from the reversing lights switch.

	Name	Connector
1	Reversing lights switch	I20

2. Disconnect the starter motor and alternator electrical connection. 1. Disconnect the water supply pipe to the heater from the thermostat.2. Disconnect the water return pipe from the heater from the water pump rigid inlet pipe. 1. Disconnect the gear selector and engagement cables.2. Undo the nuts (2a) and move the bracket (2b), complete with cables, aside. 1. Remove the circlip (1a) and remove the operating cylinder (1b) from the support and move it sideways without disconnecting the pipe. 1. Disconnect the supply pipe from the power assisted steering fluid reservoir to the pump, pump side.2. Disconnect the supply pipe from the power assisted steering fluid pump to the box, pump side. 1. Disconnect the electrical connections from the radiator cooling fans.

	Name	Connector
1	Engine fan motor - 1	N11

	Name	Connector
-	Engine fan motor - 2	N12

2. Disconnect the electrical connections from the engine cooling fan resistor.

	Name	Connector
2	Engine fan adjustment resistor - 1	O10

	Name	Connector
-	Engine fan adjustment resistor - 2	O12

1. Undo the bolt (1a) and disconnect the coolant supply pipe (1b) from the air conditioning compressor. 1. Undo the nuts (1a) and disconnect the intermediate coupling for the air conditioning system pipes (1b). 1. Undo the bolt (1a) and disconnect the coolant supply pipe (1b) from the air conditioning compressor.2. Remove the coolant supply pipe to the air conditioning compressor. 1. Disconnect the electrical connection from the four stage pressure switch.

	Name	Connector
-	4 stage pressure switch	K10

2. Undo the bolt (2a) and disconnect the coolant supply pipe (2b) from the condenser.3. Undo the bolts fixing the drier filter mounting bracket to the bodyshell. 1. Remove the drier filter (1a) complete with bracket (1b) and pipes (1c). Raise the car.1. Release the power assisted steering fluid coil from the bands. 1. Position a hydraulic jack under the radiator lower crossmember.2. Undo the bolts (2a) and remove the radiator lower crossmember (2b) complete with radiator (2c) and fans (2d). 1. Remove the air supply hose between the turbocharger and the heat exchanger.2. Undo the nut (2a) and disconnect the battery earth lead (2b) from the gearbox. 1. Disconnect the front brake caliper flexible pipes (1a) and the electrical cables for the front wheel rpm sensors (1b) from the brackets.2. Undo the bolts fixing the left and right driveshafts.

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.

3. Undo the nut (3a) and disconnect the front steering knuckles (3b) from the upper track control arms (3c) using the tool (3d).

	Name	Country
3d	Extractor	1.821.169.000

Move the right and left driveshafts away from the intermediate shaft and the differential, respectively.  - 1076B50  exhaust pipe attachment to engine - r + r1. Position the tools for removing the power unit (1b), (1c) and (1d) on a hydraulic jack (1a) as illustrated in the diagram.

	Name	Country
1b	Crossmember	1.820.225.000

	Name	Country
1c	Supports	1.820.623.000

	Name	Country
1d	Adaptor	1.870.682.000

1. Fix the tool assembled in this way to the power unit as illustrated in the diagram. 1. Undo the bolts (1a) and remove the gearbox side power unit rigid rear support (1b). 1. Undo the bolts (1a) and remove the power unit rigid rear support (1b). 1. Undo the bolt securing the timing side power unit rigid support to the flexible mounting.2. Lower the hydraulic jack and remove the power unit from the engine compartment. Secure and support the power unit using a hydraulic hoist, then release it from the tools used for the removal. Refitting ( Removing ) Using a hydraulic hoist, position and fix the power unit to the tools to be used for refitting. 1. Position the power unit in the engine compartment using the hydraulic jack.2. Tighten the bolt fixing the power unit rigid support to the mounting to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	ENGINE MOUNT TIMING SIDE	M12	(Flexible mounting side) 4.2 ÷ 5.1

1. Fit the rigid rear support for the power unit (1a) and fix it tightening the bolts (1b) and (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT RIGID REAR MOUNT	M12	7.5 ÷ 9.2

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT RIGID REAR MOUNT	M16	10.2 - 12.6

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	INTERM RUBBER MOUNT	M8	2.7 - 3.4

1. Fit the gearbox side power unit rigid support (1a) and and fix it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10	4.2 - 5.1

Undo the fixings and separate the tools used for refitting the power unit, then place it back in position after having separated it from the hydraulic jack.Place the left and right driveshafts back in their housings.Tighten the nuts fixing the front steering knuckles to the upper track control arms to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	FRONT SUSPENSION TOP LEVER	M10	(Front steering knuckle side) 4.3 ÷ 4.7

For the old solution, tighten the new bolts fixing the right driveshaft to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M8	(Int. diff./ intermediate. driveshaft. side.) 3.6 ÷ 4.4

For the new solution, tighten the new bolts fixing the right driveshaft to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M10	(Diff. internal./ intermediate. shaft. driveshaft.) side 5.0 ÷ 6.1

For the old solution, tighten the new bolts fixing the left driveshaft to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M8	(Int. diff./ intermediate. driveshaft. side.) 3.6 ÷ 4.4

Connect the battery earth lead to the gearbox and fix it using the nut.Fit the air supply hose between the turbocharger and the heat exchanger.Place the radiator lower crossmember, complete with radiator and fans, back in its housing using a hydraulic jack.Tighten the bolts securing the radiator lower crossmember to the bodyshell.Fix the power assisted steering fluid coil to the bands.Lower the vehicle.Place the drier filter, complete with bracket and pipes, back in its housing.1. Tighten the bolts fixing the drier filter mounting bracket to the bodyshell.2. Conect the coolant supply pipe (2a) to the condenser and fix it tightening the bolt (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	CLIMATE CONTROL HYDRAULIC CIRCUIT CONNECTOR.	M6	0.9 - 1.2

3. Connect the electrical connection to the four stage pressure switch. 1. Place the coolant supply pipe to the air conditioning compressor back in its housing.2. Connect the coolant supply pipe (2a) to the air conditioning compressor and fix it tightening the bolt (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	CLIMATE CONTROL HYDRAULIC CIRCUIT CONNECTOR.	M6	0.9 - 1.2

1. Connect the intermediate coupling for the air conditioning system pipes (1a) and tighten the nuts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	CLIMATE CONTROL HYDRAULIC CIRCUIT CONNECTOR.	M6	0.9 - 1.2

1. Connect the coolant supply pipe (1a) to the air conditioning compressor and tighten the nuts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CLIMATE CONTROL HYDRAULIC CIRCUIT CONNECTOR.	M6	0.9 - 1.2

Connect the electrical connections to the resistor for the engine cooling fan.Connect the electrical connections to the radiator cooling fans.1. Connect the supply pipe from the power assisted steering pump to the box, pump side and tighten the connector to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Connector	PIPE BTWN PUMP + POWER STEERING BOX	M16	3.8 - 4.2

2. Connect the supply pipe from the fluid reservoir to the power assisted steering pump, pump side. Place the operating cylinder back in its housing and secure it using a circlip.Place the bracket, complete with gear selector and engagement cables, back in its housing and fix it using the bolts.Connect the gear selector and engagement cables.Connect the water return pipe from the heater to the rigid inlet pipe to the water pump.Connect the water supply pipe to the heater to the thermostat.Disconnect the starter motor and alternator electrical connection.Connect the electrical connection to the reversing lights switch.Place the right side wiring in position in the engine compartment.Connect the electrical connection for the air conditioning compressor electro-magnet coupling.Connect the timing sensor electrical connection.Conect the electrical connection to the pressure regulator.Connect the electrical connection to the fuel temperature sensor.Connect the E.G.R. system vacuum pipe coupling.Connect the electrical connection to the fuel heater.Connect the electrical connection to the thermal switch for the fuel heater.Connect the electrical connection to the excess pressure sensor.Connect the electrical connection to the fuel pressure senor.Connect the electrical connections for the fuel pre-heating control unit.Connect the electrical connection to the E.G.R. valve.Connect the electrical connections to the injectors.Connect the electrical connection to the engine coolant temperature sensor.Connect the electrical connection to the combined sender unit for the coolant temperature gauge and overheating warning light.Connect the main electrical connections for the engine compartment wiring.Connect the engine oil recovery pipe, crankcase side.Conect the oil vapour pipe from the intake to the separator, intake side.Place the oil vapour separator, complete with pipes, back in its housing and fix it using the nuts.1. Fit the power unit (1a) reaction rod and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	REACTION ROD	M10	4.2 ÷ 5.1

Connect the fuel return pipe from the filter to the fuel return manifold pipe, fuel filter side.Connect the fuel return pipe to the tank to the fuel return manifold pipe.Connect the fuel inlet pipe to the pressure pump.Connect the brake servo vacuum intake pipe to the vacuum unit.Conect the air supply hose from the heat exchanger to the inlet manifold, inlet manifold side.Fit the air filter, complete with air flow meter and fix it using the bolt.Connect the electrical connection to the air flow meter.Connect the upper radiator coolant inlet hose from the thermostat. - 1048A50  air inlet pipe to turbo charger - r + rConnect the intermediate coupling for the return pipe to the engine coolant reservoir.Connect the system supply pipe to the water pump rigid inlet pipe.Fit the lower coolant outlet hose from the radiator.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	6.1

 - 5040A10  Air conditioning refrigerant CIRCUIT - Draining and Refilling - 7055B10  Front BUMPER - R.R. - 7055A43  central front grille - r r - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R. - 4450B12  front or rear wheels (two) - r+r - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. - 5530B10  battery - r+rFill the power steering circuit with the recommended fluid.

	Type	Component	Name	Qty.
-	Fluid	POWER ASSISTED STEERING CIRCUIT	TUTELA GI/A	-

Bleed the power steering system as described belowWith the front wheels raised off the ground, with the engine switched off turn the steering wheel to full lock, left and right, 4-5 times.Check and, if necessary, top up the fluid level in the reservoir.Position the vehicle on the ground and start up the engine.Carry out 4 - 5 complete steering wheel rotation cycles (right and left).Top up the fluid level in the reservoir.