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

Removing ( Refitting ) Position the vehicle on the ramp. 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

 - 7040D12  engine front side cover (one) lh or rh - r r (left and right).  - 7040D30  engine bay front beam cover - r r .  - 7040D14  engine bay rear side cover (one) lh or rh - r r (left and right).  - 4450B12  front or rear wheels (two) - r+r .  - 5040A10  Air conditioning refrigerant CIRCUIT - Draining and Refilling .  - 7055B54  under-engine guard - r r . 1. Disconnect the upper engine radiator hose from the thermostat.2. Disconnect the lower engine radiator hose from the thermostat.

Collect the coolant in a suitable container.

 - 1048A48  throttle heater sleeve - r r .  - 1048A10  air cleaner filtering element - replace . 1. Remove the cover from the junction unit.2. Disconnect the starter motor supply cable from the junction unit.

	Name	Connector
2	Junction unit	B1

3. Disconnect the brake servo vacuum pipe from the intake air chamber. 1. Disconnect the electrical connection for the detonation sensor.

	Name	Connector
1	Detonation sensor	K50

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

	Name	Connector
2	Cam angle sensor	K47

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

	Name	Connector
3	Rpm sensor	K46

4. Disconnect the engine/i.e. connection.

	Name	Connector
4	Engine-i.e coupling.	D24

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

	Name	Connector
5	Integrated throttle body actuator	N75

6. Remove the protection (6a) and disconnect the electrical connection (6b). 1. Disconnect the electrical connection from the engine coolant temperature sensor.

	Name	Connector
1	Data not available yet	K45

1. Disconnect, from the thermostat, the coolant supply and return pipes to the climate control system radiator. 1. Disconnect the electrical connection from the reversing lights switch.

	Name	Connector
1	Reversing light control	I20

Release the engine wiring from the retaining bands and move it.2. Disconnect the gear engagement/selector cables. 1. Undo the nuts (1a) and move the two mounting brackets (1b), complete with gear selector/engagement cables. 1. Undo the bolts (1a) and move the dehumidifier filter/accumulator (1b) complete with mounting bracket and pipes. 1. Undo the bolt (1a) and disconnect the coolant inlet and outlet pipes (1b) from the air conditioner compressor.2. Disconnect the electrical connection for the air conditioning compressor electro-magnet.

	Name	Connector
2	Air conditioning compressor engagement electro-magnet	L20

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

	Name	Connector
3	Engine oil level sensor	K32

Drain the power steering fluid from the reservoir using a suitable syringe.1. Disconnect the power steering fluid return pipe (1a) from the power steering fluid reservoir (1b). 1. Disconnect the reservoir/pump pipe from the power steering pump.2. Disconnect the pump/power steering box pipe from the power steering pump. 1. Undo the bolts (1a) and remove the power unit reaction rod (1b).2. Disconnect the electrical connection for the detonation sensor.

	Name	Connector
2	Detonation sensor	K50

3. Disconnect the electrical connection for the Lambda sensor.

	Name	Connector
3	Lambda sensor	K40

Discharge the fuel supply pressure.4. Disconnect the fuel supply pipe from the injector fuel manifold.5. Disconnect the evaporation control system/supply unit pipe from the intake air chamber. Temporarily fix the engine radiator to the upper crossmember.1. Undo the bolts fixing the engine radiator to the lower crossmember.2. Undo the bolt fixing the air filter mounting to the lower crossmember. 1. Undo the bolt (1a) and remove the bulkhead side guards (1b).2. Undo the nuts securing the front upper track control arm supports to the bodyshell. Raise the vehicle. - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R. (right and left) Disconnect the brake pad wear cable from the mounting bracket.Disconnect the A.B.S. front wheel rpm sensor cable from the mounting bracket.1. Disconnect the left front brake caliper flexible pipe from the mounting bracket.2. Undo the bolts (2a) and move aside the front left brake caliper (2b).

Suitably fix the left front disc brake caliper so that it does not hinder future operations.

1. Undo the bolt (1a) and remove the A.B.S. front wheel rpm sensor (1b) from the front left steering knuckle.2. Undo the nut (2a) and disconnect the left power steering box rod (2b) from the front steering knuckle using the tool (2c).

	Name	Country
2c	Extractor	1.821.169.000

1. Disconnect the battery earth lead from the power unit rigid mounting, gearbox side.

	Name	Connector
1	Battery earth	C1

1. Undo the bolts (1a) and move the clutch operating cylinder (1b), complete with bracket and pipe, aside.

Suitably fix the clutch operating cylinder to the bodyshell so that it does not hinder future operations.

1. Undo the nut (1a) and disconnect the right power steering box rod (1b) from the front vertical link using the tool (1c).

	Name	Country
1c	Extractor	1.821.169.000

Disconnect the right brake pad wear cable from the mounting bracket.Disconnect the A.B.S. front right wheel rpm sensor cable from the mounting bracket.Undo the bolt and disconnect the A.B.S. front wheel rpm sensor from the right front steering knuckle.1. Disconnect the front right brake caliper flexible pipe from the mounting bracket.2. Undo the bolts (2a) and move aside the front right brake caliper (2b).

Suitably fix the front right brake caliper so that it does not hinder future operations.

3. Disconnect the pump/power steering box pipe (3a) from the clip (3b). 1. Undo the bolt (1a) and remove the bracket (1b) connecting the engine oil supply and return pipes to the cooling radiator. 1. Remove the plastic tacks (1a) and lower the guard (1b).2. Disconnect, from the engine cooling radiator, the engine oil pipe to the cooling radiator.3. Disconnect, from the engine cooling radiator, the engine oil pipe from the cooling radiator.  - 1076B52  exhaust pipe (one) leaving l/h or r/h exhaust manifold - r + r . 1. Undo the nuts fixing the engine radiator to the front suspension frame.2. Undo the nuts fixing the power assisted steering box to the front suspension frame. Position the tools for removing the power unit under the vehicle.

	Name	Country
-	Pulley	1.860.823.000

	Name	Country
-	Adaptors	1.860.823.001

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

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

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

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

1. Tighten the nuts securing the power steering box to the front suspension frame to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Nut	POWER STEERING BOX	M12	Front suspension frame side 10.5 - 11.5

2. Screw the engine radiator nuts on the front suspension frame.  - 1076B52  exhaust pipe (one) leaving l/h or r/h exhaust manifold - r + rConnect the oil inlet and outlet pipes to the engine oil cooling radiator and fix them with their bolts.Fit the plastic tacks on the guard under the bumper.Fit the bracket connecting the engine oil supply and return pipes to the cooling radiator and fix it using the bolt.1. Connect the pump/power steering box pipe (1a) to the band (1b).2. Refit the front right brake caliper (2a) in its housing and fix it tightening the bolts (2b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	FRONT BRAKE CALIPER ASSEMBLY	M14	Bracket side 15.2 - 16.8

3. Fit the front right brake caliper flexible pipe to the mounting bracket. Fit the A.B.S. front wheel rpm sensor to the front right steering knuckle and fix it using the bolt.Connect the right A.B.S. front right rpm sensor to the mounting bracket.Connect the right brake pad wear cable to the retaining bracket.1. Connect the right power steering box rod (1a) to the front steering knuckle and tighten the nut (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	ADJUSTABLE STEERING LINKS	M10	(Front wheel hub steering knuckle side) 4.3 ÷ 4.7

Fit the clutch operating cylinder, complete with pipe and bracket, then fix it using the bolts.Connect the battery earth lead to the gearbox side power unit rigid support.1. Connect the left power steering box rod (1a) to the front steering knuckle and tighten the nut (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	ADJUSTABLE STEERING LINKS	M10	(Front wheel hub steering knuckle side) 4.3 ÷ 4.7

2. Fit the A.B.S. front wheel rpm sensor (2a) to the front left steering knuckle and fix it using the bolt. 1. Fit the front left brake caliper (1a) and tighten the bolts (1b) to the specified torque.

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

2. Connect the left front brake caliper flexible pipe to the mounting bracket. Connect the left brake pad wear cable to the retaining bracket.Connect the A.B.S. front left rpm sensor cable to the retaining bracket. - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R. (right and left) Lower the vehicle.1. Tighten the nuts securing the front upper track control arm supports to the bodyshell to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Nut	FRONT UPPER SWINGING ARM MOUNT	M8	Bodyshell side 1.8 - 2.0

2. Fit the bulkhead side guards (2a) and fix them using the bolt (2b). Tighten the bolt securing the air cleaner mounting to the lower crossmember.Tighten the bolts securing the engine radiator to the lower crossmember.1. Connect the evaporation control system/supply unit pipe to the intake air chamber.2. Connect the fuel delivery pipe to the fuel injector manifold.3. Connect the electrical connection for the detonation sensor.4. Connect the electrical connection for the Lambda sensor.5. Fit the power unit reaction rod (5a) and tighten the bolts (5b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
5b	Bolt	REACTION ROD	M10	(Bracke on bodyshell/bracket on engine side) 4.3 - 5.3

1. Connect the pump/power steering box pipe to the power steering pump (1a) and tighten the connector (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Connector	PIPE BTWN PUMP + POWER STEERING BOX	M16	(Power steering pump side) 3.8 ÷ 4.2

2. Connect the reservoir/power steering pump pipe (2a) to the power steering pump and tighten the connector (2b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2b	Connector	POWER STEERING PUMP SUPPLY PIPE	M18	Power assisted steering pump side 3.2 - 3.6

Connect the power steering reservoir return pipe to the power steering fluid reservoir.1. Connect the electrical connection to the engine oil level sensor.2. Connect the electical connection for the air conditioning compressor electromagnet.3. Connect the coolant inlet and outlet pipes (3a) to the air conditioning compressor and fix them using the bolt (3b). Place the dehumidifying filter/accumulator complete with mounting bracket and pipes back in its seating, then fix it using the bolts.Place the two mounting brackets, complete with gear selector/engagement cables, back in their housings and fix them using the bolts.Connect the engine wiring to the mounting brackets.Connect the electrical connection to the reversing lights switch.Connect the climate control water supply and return pipes to the engine thermostat.Connect the electrical connection to the engine temperature sensor.Connect the electrical connection to the throttle body integrated with the D.V.L.Connect the engine/i.e. connection.Connect the electrical connection for the engine rpm and timing sensor.Connect the electrical connection for the cam angle sensor.Connect the electrical connection for the detonation sensor.Connect the brake servo vacuum pipe to the intake air chamber.Connect the starter motor supply cable to the junction unit and fit the cover. - 1048A10  air cleaner filtering element - replace .  - 1048A48  throttle heater sleeve - r r . Connect the lower engine radiator hose to the thermostat.Connect the upper engine radiator hose to the thermostat. - 7055B54  under-engine guard - r r .  - 5040A10  Air conditioning refrigerant CIRCUIT - Draining and Refilling .  - 4450B12  front or rear wheels (two) - r+r .  - 7040D14  engine bay rear side cover (one) lh or rh - r r (left and right).  - 7040D30  engine bay front beam cover - r r .  - 7040D12  engine front side cover (one) lh or rh - r r (left and right). Connect the battery negative terminal.Supply the engine cooling system with the recommended fluid.

	Type	Component	Name	Qty.
-	Fluid [l]	ENGINE COOLING CIRCUIT	Alfa Romeo Climafluid Super Permanent -40	10.3

Fill the power steering circuit with the recommended fluid.

	Type	Component	Name	Qty.
-	Fluid [l]	POWER ASSISTED STEERING CIRCUIT	TUTELA GI/A	1.4

Bleed the power steerign system as described below.With the front wheels raised off the ground, with the engine switched off, carry out 4-5 complete steering wheel rotation cycles (left and right).Check and, if necessary, top up the fluid level in the reservoir.Remove the car from the ramp.Start the engine and carry out 4 - 5 full steering wheel turn cycles (right and left).Top up the fluid level in the reservoir.