1080B39 RIGHT CATALYTIC PRECONVERTER R R OR REPLACE CYLINDER HEAD GASKET (AUTOMATIC TRANSMISSION) - Alfa - 166 - eLearn

3314324 - 1080B39 right catalytic preconverter r r or replace cylinder head gasket (Automatic transmission)

) Place the vehicle on a ramp. Ensure that the ignition key is in OFF position, then disconnect the battery negative terminal ( - 5530B10 battery - r+r ).

	Name	Connector
-	Battery	A1B

Proceed with the removal - 7040D12 engine front side cover (one) lh or rh - r r (Right and left sides). Proceed with the removal - 7040D14 engine bay rear side cover (one) lh or rh - r r (Right side). Proceed with the removal - 7040D30 engine bay front beam cover - r r . 1. Loosen the band (1a) and disconnect the oil vapour recirculation pipe (1b) from the cylinder head.2. Loosen the bands (2a) and remove the hose from the flow meter to the air chamber (2b) complete with resonator (2c).

1. Open the electrical connection box cover.2. Disconnect the electrical connection for the right Lambda sensor.

	Name	Connector
2	Lambda sensor on pre-catalyzer-2	K16

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

	Name	Connector
3	Integrated throttle body actuator	N75

4. Loosen the band (4a) and disconnect the vacuum intake pipe (4b) from the air capacity chamber5. Disconnect the quick-release connection of the fuel vapour recovery pipe from the air chamber.

1. Undo the bolt (1a) and disconnect the earth lead (1b) from the air capacity chamber.

	Name	Connector
1b	Chassis earth for I.E system.	C40

1. Disconnect the electrical connections (1a) and (1b) from the injection/ignition system control unit.

	Name	Connector
1a	Engine management control unit	M10A

	Name	Connector
1b	Engine management control unit	M10B

1. Undo the bolt securing the fuel delivery pipe to the air chamber.

1. Open the electrical connection box cover2. Disconnect the engine junction.

	Name	Connector
2	Engine-i.e coupling.	D24

3. Disconnect the rear lambda sensor electrical connections (3a) and (3b) from the catalytic converter.

	Name	Connector
3a	Lambda sensor on post-catalyzer	K17

	Name	Connector
3b	Lambda sensor on post-catalyzer-2	K18

4. Disconnect the electrical connection for the knock sensor, timing side.

	Name	Connector
4	Detonation sensor	K50

1. Undo the bolts (1a) and remove the connection box (1b).

1. Undo the bolt (1a) and unscrew bolt (1b) and remove the power unit reaction rod.

Proceed with the removal - 4450B12 front or rear wheels (two) - r+r . Proceed with the removal - 7055B39 front additional wheel arch half (one), lh or rh, front element - r r (Right and left sides). Proceed with the removal - 7055B54 under-engine guard - r r . 1. Undo the lower bolt fixing the left catalytic preconverter heat shield.

1. Undo the bolt (1a) and remove collar (1b) connecting the exhaust pipes between preconverters and catalytic converter.2. Undo nuts (2a) and (2b) and remove the exhaust pipe between right preconverter and catalytic converter (2c). Remove the gaskets.

1. Undo nuts (1a) and (1b) and remove the exhaust pipe between left preconverter and catalytic converter (1c). Remove the gaskets.

1. Undo the nuts (1a) and remove the power unit rear mount flexible block heat shield (1b).

1. Undo the nuts (1a) and remove the intermediate drive shaft oil seal heat shield (1b).

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

1. Undo the bolts (1a) and nut (1b) and remove the engine flywheel lower protection (1c).

1. Disconnect the electrical connection from the engine oil pressure warning light switch.

	Name	Connector
1	Insufficient engine oil pressure (switch) sensor	K30

1. Unscrew the bolts (1a) securing the right drive shaft to the intermediate drive shaft and remove retaining plates (1b).

1. Undo the bolts securing the intermediate driveshaft.

1. Undo the bolt (1a) and move the right front wheel rpm sensors (1b) to one side.

1. Disconnect the electrical connection on the brake pad wear warning light cable.

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

Release the front brake caliper flexible pipe, the brake pad wear sensor wiring and the wheel rpm sensor from their fastenings.

1. Undo the bolt (1a) fixing the front shock absorber fork to the lower track control arm (1b).2. Undo the bolt fixing the front shock absorber fork to the track control arm, shock absorber side.3. Undo the bolt securing the front suspension anti-roll bar joint mounting bracket.

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

1. Undo the bolts (1a) and move the right front disc brake caliper (1b).

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

Move the right drive shaft back to release from the intermediate drive shaft.1. Remove the intermediate driveshaft.

1. Undo the bolts fixing the power assisted steering pipes mounting bracket to the front suspension subframe.

Position a hydraulic jack under the gearbox.1. Undo the bolts fixing the gearbox side support flexible mounting to the front suspension frame.2. Undo the bolts securing the gearbox side power unit rigid support to the flexible mounting to the gearbox.

The gearbox side power unit rigid support with flexible block remains attached to the earth braid.

Lower the power unit using the hydraulic jack, then remove the jack.1. Unscrew the right lambda sensor (1a) using tool (1b) and remove it.

To avoid damaging the lambda sensor, take care to keep the tool at right angles to the lambda sensor during unscrewing/retightening.

	Name	Country
1b	Spanner	1.854.050.001

1. Unscrew the nuts securing the right catalytic preconverter to the cylinder head.

1. Working from beneath the car, remove the catalytic converter (1a), complete internal bulkhead and gaskets (1b).

Refitting ( Removing

) Refit the right catalytic preconverter complete with internal bulkhead and gaskets.1. Tighten the nuts fixing the right catalytic pre-converter to the cylinder head to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	-	-	-	-

1. Refit the right lambda sensor (1a) and tighten it to the specified torque using tool (1b).

	Fastening	Component	Ø	Value(daNm)
1a	-	-	-	-

	Name	Country
1b	Spanner	1.854.050.001

Place the power unit back in its housing using the hydraulic jack.1. Tighten the bolts fixing the gearbox side power unit rigid support flexible mounting to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10	(Gearbox side) 4.3 - 5.3

2. Tighten the bolts fixing the gearbox side support flexible mounting to the front suspension frame to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	INTERM RUBBER MOUNT	M10	(Front suspension frame side) 4.9 - 6.1

Remove the hydraulic jack from under the gearbox.

Tighten the bolts securing the power steering system pipe mounting bracket to the front suspension frame.Place the intermediate driveshaft back in its housing.Place the right driveshaft back in its housing and move close to the intermediate drive shaft.1. Replace the right front disc brake caliper (1a) in its housing and fix it tightening the bolts (1b) to the recommended torque.

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

1. Connect the upper track control arm (1a) to the front steering knuckle and fix it tightening the nut (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	FRONT SUSPENSION TOP LEVER	M10	Front hub steering knuckle side 4.3 - 4.7

1. Tighten the bolt securing the front suspension anti-roll bar joint mounting bracket.2. Tighten the bolt fixing the front shock absorber fork to the track control arm, shock absorber side, to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	FRONT DAMPER FORK ON WISHBONE	M12	Shock absorber side 11.7 - 12.9

3. Tighten the bolt (3a) fixing the front shock absorber fork to the lower track control arm (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3a	Bolt	FRONT DAMPER FORK ON WISHBONE	M12	Lower track control arm side 8.6 - 9.6

Fix the front brake caliper flexible pipe, brake pad wear sensor wiring and wheel rpm sensor to their fastenings. Connect the electrical connection on the right front brake pad wear warning light cable.Replace the right front wheel rpm sensor in its housing and fix it using the bolt.1. Tighten the bolt fixing the intermediate driveshaft to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	INTERMEDIATE DRIVE SHAFT	M6	(Support side) 0.5 - 0.8

1. Tighten the bolts (1a) securing the right drive shaft to the intermediate drive shaft and fit retaining plates (1b).

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M10	(Intermediate driveshaft side) 5.2 - 5.8

Connect the electrical connection to the engine oil pressure warning light switch.Refit the lower engine flywheel protection in its seating and fix it using the bolts.Refit in its seating the power steering box heat shield and tighten its bolts.Refit the intermediate drive shaft oil seal heat shield and secure it with its nuts.Fit the heat shield for the power unit rear flexible block and fix it tightening the bolts to the recommended torque.1. Refit the exhaust pipe between left preconverter and catalytic converter (1a) complete with gasket and secure it by tightening nuts (1b) and (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	-	-	-	-

	Fastening	Component	Ø	Value(daNm)
1c	-	-	-	-

1. Refit the exhaust pipe between right preconverter and catalytic converter (1a) complete with gasket and secure it by tightening nuts (1b) and (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	-	-	-	-

	Fastening	Component	Ø	Value(daNm)
1c	-	-	-	-

2. Refit the collar connecting exhaust pipes between preconverters and catalytic converter and tighten it using the nut.

Tighten the lower bolt securing the left catalytic converter heat shield. Proceed with the refitting - 7055B54 under-engine guard - r r . Proceed with the removal - 7055B39 front additional wheel arch half (one), lh or rh, front element - r r (Right and left sides). Proceed with the refitting - 4450B12 front or rear wheels (two) - r+r . 1. Tighten the bolts securing the power unit reaction link to the specified torque.

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

Refit the connection box and secure with the bolts.Connect the electrical connection for the knock sensor timing side.Connect the electrical connection for the rear Lambda sensors to the catalytic converter.Connect the engine coupling.Close the electric connection box cover.Tighten the bolt securing the fuel delivery pipe to the air chamber.Connect the electrical connections to the fuel injection/ignition control unit.Connect the earth lead to the air chamber and secure it using the bolt.Connect the quick-release fitting on the fuel vapour recovery pipe to the air chamber.Connect the vacuum intake pipe to the air chamber and tighten the band.Connect the electrical connection to the throttle body integrated with the D.V.L.Connect the electrical connection for the right Lambda sensor.Close the electrical connection box cover.Refit the hose from the flow meter to the air chamber complete with resonator and tighten the bands.Connect the oil vapour recirculation pipe to the left cylinder head and tighten the band. Proceed with the refitting - 7040D30 engine bay front beam cover - r r . Proceed with the refitting - 7040D14 engine bay rear side cover (one) lh or rh - r r (Right side). Proceed with the removal - 7040D12 engine front side cover (one) lh or rh - r r (Right and left sides). Connect the battery terminal (-). Proceed with the refitting - 1056B81 run electronic ignition/injection control unit (single) self-learning procedure . Remove the car from the ramp.