3314029 - 1004B18 power unit with manual gearbox, with support frame, front suspension r + r for versions with a/c

Removing ( Refitting ) Place the car on a ramp with the wheels perfectly straight. Make sure that the ignition is OFF (STOP position), then disconnect the negative battery terminal (refer to op.   5530B10  battery - r+r ).

	Name	Connector
-	Battery	A1B

1. Remove the rubber protector (1a) and the accelerator pedal travel stop (1b).  - 7040A65  passenger compartment box lock , one , r r . 1. Move aside the floor carpet, unscrew the nuts (1a) and remove the steering column universal joint guard (1b).2. Undo the bolt fixing the steering column to the power assisted steering box and release it.

The bolt is pretreated and cannot therefore be refitted.

 - 7040D12  engine front side cover (one) lh or rh - r r (right and left)  - 7040D30  engine bay front beam cover - r r .  - 7040D14  engine bay rear side cover (one) lh or rh - r r (right and left)  - 5040A10  Air conditioning refrigerant CIRCUIT - Draining and Refilling .  - 4450B12  front or rear wheels (two) - r+r .  - 7055B39  front additional wheel arch half (one), lh or rh, front element - r r (right and left)  - 7055A43  central front grille - r r .  - 7055A41  RIGHT FRONT GRILLE - R.R. .  - 7055B10  Front BUMPER - R.R. .  - 7055B54  under-engine guard - r r . Drain the engine coolant.

Collect the coolant in a suitable container.

 - 1076B70  exhaust pipe between pre-catalytic converter and catalytic converter - r r . 1. Remove the clips (1a) and release the front brake caliper flexible pipes (1b) from the brackets. 1. Undo the bolts (1a), move the front brake calipers (1b) and fix them to the bodyshell. 1. Undo the bolts (1a) and move the front wheel rpm sensors (1b) from the housings in the steering knuckles.2. Undo the bolts (2a) and remove the front wheel rpm sensor mounting brackets (2b). 1. Undo the nuts fixing the front anti-roll bar joints to the mounting brackets.2. Undo the bolts fixing the front shock absorber forks to the track control arms, track control arm side. Position a hydraulic jack under the hub steering knuckle.1. Undo the nut (1a) and disconnect the upper track control arm (1b) from the front hub steering knuckle using tool (1c).

	Name	Country
1c	Extractor	1.821.169.000

Remove the hydraulic jack from under the hub steering knuckle. 1. Undo the bolt (1a) and disconnect the earth lead (1b) from the gearbox side rigid power unit support. 1. Undo the bolts (1a) and move the clutch master cylinder (1b), complete with mounting bracket and pipes, aside and fix it to the bodyshell.2. Disconnect the gear engagement/selector cables.3. Disconnect the electrical connection from the reversing lights switch.

	Name	Connector
3	Reversing light control	I20

Release the electrical wiring from the bands.  - 1048A21  filter input sleeve - r r . 1. Disconnect the lower coolant inlet hose from the radiator, radiator side.  - 7025A34  bonnet lid lock (one) - r+r or repair . - 7090G06 HEADLAMP HOUSING CONNECTING CROSSMEMBER - Replace. .  - 5040A40  air conditioner condenser - r+r .  - 1048A28  vacuum air circuit resonator pipe - r+r . 1. Disconnect the electrical connection from the air conditioning system multi-stage presure switch.

	Name	Connector
1	4 stage pressure switch	K10

2. Undo the bolt (2a) and disconnect the pipe (2b) from the drier filter/accumulator to the evaporator, filter side.3. Disconnect the electrical connections from the engine cooling fans (3a) and (3b).

	Name	Connector
3a	Engine electric fan motor	N11

	Name	Connector
3b	Engine electric fan motor	N12

4. Disconnect the electrical connections from the engine radiator fan resistances (4a) and (4b).

	Name	Connector
4a	Engine fan adjustment resistor	O10

	Name	Connector
4b	Engine fan adjustment resistor	O12

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

	Name	Connector
-	Air conditioning compressor engagement electro-magnet	L20

2. Disconnect the electrical connection for the engine oil level sensor.

	Name	Connector
2	Engine oil level sensor	K32

Release the electrical wiring from the drier filter/accumulator mounting bracket and move it.3. Undo the bolt (3a) and disconnect the coolant inlet and outlet pipes (3b) from the air conditioning compressor. 1. Disconnect the electrical connections from the injectors and move the wiring after having released it from the fixings.

	Name	Connector
1	Injector	N70

 - 1008C10  power unit upper reaction link r r .  - 1008C16  body link bracket - r r . 1. Disconnect the electrical connection for the Lambda sensor.

	Name	Connector
1	Lambda sensor	K40

2. Disconnect the electrical connection for the cam angle sensor.

	Name	Connector
2	Cam angle sensor	K47

3. Disconnect the electrical connection for the detonation sensor.

	Name	Connector
3	Detonation sensor	K50

1. Disconnect the fuel inlet and outlet pipes from the distribution manifold.2. Disconnect the vacuum socket pipe from the air chamber. 1. Disconnect the coolant return pipe to the engine coolant reservoir.2. Undo the bolt (2a) for the engine coolant reservoir and disconnect the system supply pipe (2b) from the latter.3. Remove the engine coolant reservoir. 1. Disconnect the water supply pipe to the heater from the connector on the right cylinder head.2. Disconnect the water return pipe from the heater from the water pump rigid inlet pipe. Undo the bolt fixing the air filter mounting bracket to the A.B.S. control unit support.1. Disconnect the electrical connection from the air flow meter.

	Name	Connector
1	Air flow meter	K41

2. Disconnect the electrical connection from the ignition coil.

	Name	Connector
2	Ignition coil	A30

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

	Name	Connector
3	Engine coolant temperature sensor-sender unit	K36

4. Disconnect the electrical connection for the engine rpm and timing sensor.

	Name	Connector
4	Rpm sensor	K46

5. Disconnect the electrical connection from the intake air temperature sensor.

	Name	Connector
5	Air temperature sensor	K42

6. Disconnect the electrical connection for the detonation sensor.

	Name	Connector
6	Knock sensor 2	K51

7. Disconnect the electrical connection from the throttle casing integrated with the D.V.L.

	Name	Connector
7	Integrated throttle body actuator	N75

8. Disconnect the electrical connection from the supercharging pressure solenoid valve.

	Name	Connector
8	Overboost solenoid	L35

Release the electrical wiring from the fixings and move it. 1. Undo the nuts (1a) and move the gear engagment/selector cables mounting brackets (1b). 1. Open the junction unit cover.2. Disconnect the starterm motor supply cable and release it from the fixing band.

	Name	Connector
2	Terminal board	A5

1. Remove the protective cover (1a) and disconnect the engine front coupling (1b) and release the wiring from the band.

	Name	Connector
1b	Engine front connection	D4

1. Disconnect the fuel /oil vapour recirculation pipe. 1. Undo the nuts (1a) and release the heat exchanger pipe (1b) from the underbody. 1. Position the tools (1a) and (1b) for removing the power unit under the vehicle.

	Name	Country
1a	Pulley	1.860.823.000

	Name	Country
1b	Adaptors	1.860.823.001

Lower the vehicle until the front suspension frame is positioned on the tool. 1. Undo the bolts (1a) and remove the brackets (1b) complete with spacers (1c) fixing the front suspension frame to the bodyshell. 1. Undo the bolts fixing the front suspension frame to the bodyshell. 1. Raise the vehicle until the power unit is completely separated from the manual gearbox, complete with support frame and front suspension. Refitting ( Removing ) Position the power unit with the manual gearbox, complete with support frame and front suspension, under the vehicle.Lower the vehicle until the power unit is correctly positioned in its housing.1. Tighten the bolts securing the front suspension frame to the bodyshell to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Front bolts	FRONT SUSPENSION SUBFRAME	M12	(Bodyshell side) 10.5 -11.6

1. Fit the brackets (1a), complete with spacers (1b), and tighten the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Rear bolts	FRONT SUSPENSION SUBFRAME	M12	(Bodyshell side) 12.4 - 13.7

Raise the vehicle and remove the tools used for refitting the power unit.

	Name	Country
-	Pulley	1.860.823.000

	Name	Country
-	Adaptors	1.860.823.001

Fix the heat exchanger pipe to the underbody using the nuts.Connect the fuel/oil vapour recirculation pipe.Connect the electrical connection of the engine front coupling, fix the wiring to the band and fit the protective cover.Connect the starter motor supply cable, fix the wiring to the band and close the junction box cover.Place the gear engagement/selector cables mounting brackets back in their housings and fix them using the nuts.Place the electrical wiring back in its housing and connect the electrical connection to the supercharging pressure solenoid valve.Connect the electrical connection to the throttle body integrated with the D.V.L.Connect the electrical connection for the detonation sensor.Connect the electrical connection to the intake air temperature sensor.Connect the electrical connection for the engine rpm and timing sensor.Connect the electrical connection to the engine coolant temperature sensor.Connect the electrical connection to the ignition coil.Connect the electrical connection to the air flow meter.Tighten the bolts fixing the air filter mounting to the A.B.S. control unit support.Connect the water return pipe from the heater to the water pump rigid inlet pipe.Connect the water supply pipe to the heater to the connector on the right cylinder head.Place the engine coolant reservoir back in its housing and connect the system supply pipe.Connect the coolant return pipe to the engine coolant reservoir.Connect the electrical connection for the detonation sensor.Connect the electrical connection for the cam angle sensor.Connect the electrical connection for the Lambda sensor. - 1008C16  body link bracket - r r .  - 1008C10  power unit upper reaction link r r . Place the electrical wiring back in its housing and connect the electrical connections to the injectors.Connect the coolant inlet and outlet pipes to the air conditioning compressor and fix them using the bolt.Connect the electrical connection to the engine oil level sensor.Connect the electrical connection for the air conditioning compressor electro-magnet coupling.Fix the electrical wiring to the drier filter/accumulator mounting bracket.1. Connect the electrical connections to the engine radiator fan resistances.2. Connect the electrical connections to the engine cooling fans.3. Connect the pipe (3a) from the drier filter/accumulator to the evaporator, filter side and fix it using the bolt (3b).

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	Pipe from drier filter to expansion valve.	M6	Drier filter/accumulator side 0.8 - 1.0

4. Connect the electrical connection to the air conditioning system multi-stage pressure switch.  - 1048A28  vacuum air circuit resonator pipe - r+r .  - 5040A40  air conditioner condenser - r+r . - 7090G06 HEADLAMP HOUSING CONNECTING CROSSMEMBER - Replace. .  - 7025A34  bonnet lid lock (one) - r+r or repair . Connect the lower coolant outlet hose from the radiator, radiator side. - 1048A21  filter input sleeve - r r . Connect the electrical wiring to the reversing lights switch and fix the electrical wiring to the bands.Connect the gear engagement/selector cables.Place the clutch master cylinder, complete with bracket and pipes, back in its housing and fix it using the bolts.Connect the earth lead to the gearbox side rigid power unit support and fix it using the bolt.Position a hydraulic jack under the hub steering knuckles.Connect the upper track control arms to the front steering knuckles and fix them tightening the nuts to the recommended torque.

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

Remove the hydraulic jack from under the hub steering knuckle.1. Tighten the bolts fixing the front shock absorber forks to the track control arms to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	FRONT DAMPER FORK ON WISHBONE	M12	Lower track control arm side 8.6 - 9.5

2. Tighten the nuts fixing the front anti-roll bar joints to the mounting brackets to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Nut	FRONT ANTI-ROLL BAR JOINTS	M10	(Shock absorber fork side) 3.8 ÷ 4.7

Fit the front wheel rpm sensor cable mounting brackets and fix them using the bolts.Place the front wheel rpm sensors back in their housings on the steering knuckle and fix them using the bolts.1. Place the front brake calipers (1a) back in their housings and fix them tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FRONT BRAKE CALIPER ASSEMBLY	M14	15.2 - 16.8

Position the front brake caliper flexible pipes on the brackets and fix them using the clips. - 7055B54  under-engine guard - r r .  - 7055B10  Front BUMPER - R.R. .  - 7055A41  RIGHT FRONT GRILLE - R.R. .  - 7055A43  central front grille - r r .  - 7055B39  front additional wheel arch half (one), lh or rh, front element - r r (right and left)  - 4450B12  front or rear wheels (two) - r+r .  - 5040A10  Air conditioning refrigerant CIRCUIT - Draining and Refilling .  - 7040D14  engine bay rear side cover (one) lh or rh - r r (right and left)  - 7040D30  engine bay front beam cover - r r .  - 7040D12  engine front side cover (one) lh or rh - r r (right and left) 1. Tighten the new bolt securing the steering column to the power steering box pinion to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	STEERING SHAFTS	M8	(Power steering box pinion side) 2.8 - 3.2

2. Fit the steering column universal joint guard (2a) and secure it with its nuts (2b).Put the floor carpet back in place.  - 7040A65  passenger compartment box lock , one , r r . Fit the accelerator pedal travel stop complete with rubber protector. Adjust the potentiometer (Refer to Op.   1068A50  accelerator potentiometer - r+rSupply the engine cooling system with the recommended fluid.

	Type	Component	Name	Qty.
-	Fluid [l]	ENGINE COOLING CIRCUIT	Alfa Romeo Climafluid Super Permanent -40°C	10.5

Connect the battery terminal (-).Remove the car from the ramp.