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 (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 .  - 4450B10  Front WHEEL (one) - R.R. (right and left)  - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - 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 .  - 1076B50  exhaust pipe attachment to engine - r + r .  - 1048B22  air delivery sleeve from heat exchanger to intake manifold - r + r . 1. Undo the drain plug in the radiator and drain the engine coolant.

Collect the coolant in a suitable container.

1. Disconnect the remove the upper coolant inlet hose to the radiator.2. Disconnect the vacuum pipe from the E.G.R. valve. 1. Disconnect the connections from the engine radiator fan resistances (1a) and (1b).

	Name	Connector
1a	Engine fan adjustment resistor	O10

	Name	Connector
1b	Engine fan adjustment resistor	O12

2. Disconnect the electrical connections from the engine cooling fans (2a) and (2b).

	Name	Connector
2a	Engine electric fan motor	N11

	Name	Connector
2b	Engine electric fan motor	N12

3. Disconnect the electrical connection for the air conditioning system multi-stage pressure switch.

	Name	Connector
3	4 stage pressure switch	K10

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

	Name	Connector
4	Air conditioning compressor engagement electro-magnet	L20

5. Release the electrical wiring from the securing bands and move it. 1. Undo the bolts (1a) and remove the fans with the single cooling duct (1b).  - 7055A43  central front grille - r r . 1. Undo the nuts (1a) and move the bonnet lid lock (1b).2. Undo the bolts (2a) and remove the upper radiator crossmember (2b). 1. Disconnect the lower radiator hose from the water pump rigid inlet pipe. 1. Undo the bolts (1a) and remove the engine cooling radiator (1b) complete with lower hose (1c).2. Recover the bracket. 1. Disconnect the electrical connection from the air flow meter.

	Name	Connector
1	Air flow meter	K41

2. Undo the bolt fixing the air filter casing mounting bracket. 1. Disconnect the oil vapour recovery pipe from the turbocharger air inlet hose.2. Disconnect the air inlet hose from the turbocharger. 1. Remove the air filter complete with hoses and resonators. 1. Undo the bolt (1a) and disconnect the pipe from the compressor to the condenser for the air conditioner (1b), compressor side.2. Undo the bolt (2a) and disconnect the pipe from the drier filter to the compressor (2b), compressor side.3. Undo the bolt fixing the pipe from the compressor to the air conditioning condenser. 1. Undo the bolt (1a) and remove the heat exchanger air duct (1b). 1. Disconnect the supercharging hose from the turbocharger to the heat exchanger, turbocharger side.2. Remove the air/air heat exchanger complete with hose. 1. Undo the bolt (1a) and disconnect the pipe from the condenser to the drier filter (1b), filter side. 1. Remove the air conditioning condenser complete with pipes. 1. Disconnect the electrical connection from the engine coolant temperature sensor.

	Name	Connector
1	Data not available yet	K45

1. Disconnect the electrical connections from the injectors.

	Name	Connector
1	Injector	N70

2. Release the electrical wiring from the bands and move it. 1. Disconnect the electrical connections from the pre-heating control unit.

	Name	Connector
1	Heater plugs control unit	M15

1. Disconnect the electrical connection and release it from the clip.

	Name	Connector
1	Data not available yet	-

1. Remove the protective cover (1a) and disconnect the starter motor supply cable (1b) from the junction box.

	Name	Connector
1b	Data not available yet	-

1. Disconnect the vacuum pipe from the vacuum unit.2. Disconnect the engine coolant system supply pipe from the water pump rigid inlet pipe.3. Disconnect the water supply pipe to the heater from the thermostat. 1. Disconnect the coolant return pipe to the engine coolant reservoir. 1. Disconnect the gear engagement/selector cables.2. Undo the nuts (2a) and move the mounting brackets (2b), complete with gear selector/engagement cables. 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. Disconnect the electrical connection for the cam angle sensor.

	Name	Connector
1	Cam angle sensor	K47

2. Disconnect the electrical connection from the fuel temperature sensor.

	Name	Connector
2	Fuel temperature sensor	K81

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

	Name	Connector
3	Turbocharging sensor	K82

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

	Name	Connector
-	Rpm sensor	K46

4. Disconnect the electrical connection from the fuel pressure regulator.

	Name	Connector
4	Fuel pressure regulator	N77

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

	Name	Connector
5	Fuel pressure sensor	K83

1. Undo the bolts (1a) and remove the reaction rod (1b). 1. Disconnect the fuel supply pipe from the tank, filter side.2. Disconnect the fuel return pipe to the tank from the fuel return manifold pipe. 1. Undo the bolt (1a) and remove the bulkhead protection on the left side.2. remove the power steering fluid reservoir cap and drain the fluid using a suitable syringe. 1. Disconnect the inlet pipe from the power assisted steering pump.2. Disconnect the supply pipe from the power assisted steering pump. 1. Undo the nuts (1a) and disconnect the steering box track rods (1b) from the front hub vertical links using tool (1c).

	Name	Country
1c	Extractor	1.821.169.000

2. Undo the bolts (2a) and remove the front wheel rpm sensors (2b) from the front steering knuckles. 1. Undo the bolts (1a) and remove the front wheel rpm sensor cable mounting brackets (1b).2. Undo the nuts (2a) and release the anti-roll bar joints (2b) complete with brackets (2c) from the front shock absorber forks. 1. Release the front flexible brake pipes and the brake pad wear cables from the brackets.2. Remove the plugs (2a), undo the bolts (2b), remove the spring (2c) and move the front disc brake calipers (2d), complete with pads, aside.

Suitably fix the front disc brake calipers so that they do not hinder future operations.

1. Undo the bolts fixing the front shock absorber forks to the lower track control arms.2. Position a hydraulic jack under the front wheel steering knuckles.3. Undo the nuts (3a) and disconnect the upper front track control arms from the front steering knuckles using the tool (3b).

	Name	Country
3b	Extractor	1.821.169.000

Lower the hydraulic jack. 1. Disconnect the earth cable from the gearbox side rigid power unit mounting.

	Name	Connector
1	Battery earth	C1

1. Undo the nuts fixing the power assisted steering box to the front suspension frame. 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

2. Undo the front bolts fixing the front suspension frame to the bodyshell. 1. Undo the rear bolts fixing the front suspension frame to the bodyshell.2. Recover the bracket (2a) and the spacers (2b). 1. Raise the vehicle until the power unit is completely separated from the manual gearbox complete with front suspension frame. 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) and the spacers (1b), then tighten the rear bolts (1c) fixing the front suspension frame to the bodyshell to the recommended torque.

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

1. Tighten the front bolts fixing the front suspension frame to the bodyshell.

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

2. Raise the vehicle and remove the tools (2a) and (2b) used for removing-refitting the power unit.

	Name	Country
2a	Pulley	1.860.823.000

	Name	Country
2b	Adaptors	1.860.823.001

1. Tighten the nuts fixing the power assisted steering box to the front suspension frame to the recommended torque.

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

Connect the earth cable to the gearbox side rigid power unit mounting.1. Position a hydraulic jack under the front wheel steering knuckles.2. Connect the upper front track control arms to the front steering knuckles and fix them tightening the nuts to the recommended torque.

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

Remove the hydraulic jack.3. Tighten the bolts fixing the front shock absorber forks to the lower track control arms to the recommended torque.

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

1. Place the front disc brake calipers (1a), complete with pads, in their housings, fit the springs (1b) and fix them tightnening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	FRONT BRAKE CALIPER ASSEMBLY	M14	2.5 - 3.0

2. Fit the protective caps.3. Fix the front flexible brake pipes and the brake pad wear cables to the brackets. 1. Place the brackets (1a), complete with front anti-roll bar joints (1b), back in their housings and fix them tightening the nuts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	FRONT DAMPER FORK ON WISHBONE	M12	Shock absorber side 11.7 - 12.9

2. Fit the front wheel rpm sensor cables mounting brackets (2a) and fix them using the bolts (2b). Fit the front wheel rpm sensors and fix them using the bolts.Connect the power assisted steering rods to the front steering knuckles and fix them tightening the nuts to the recommended torque.

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

1. Connect the supply pipe to the power assisted steering pump and tighten the connector to the recommended torque.

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

2. Connect the inlet pipe to the power assisted steering pump. Fit the bulkhead protection on the left side and secure it with its bolt.Connect the fuel return pipe to the tank to the fuel return manifold pipe.Connect the pipe from the fuel filter to the fuel return manifold pipe to the filter.1. Fit the reaction rod (1a) and fix it tightening the bolts (1b) to the recommended torque.

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

Connect the electrical connection to the fuel pressure sensor.Connect the electrical connection to the fuel pressure regulator.Connect the electrical connection for the engine rpm and timing sensor.Connect the electrical connection to the excess pressure sensor.Connect the electrical connection to the fuel temperature sensor.Connect the electrical connection for the cam angle sensor.Replace the bracket complete with clutch operating cylinder and pipe in its housing, 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 gear selector/engagement cables.Connect the coupling for the coolant return pipe to the engine coolant reservoir.Connect the water supply pipe to the heater to the thermostat.Connect the engine cooling system supply pipe to the water pump rigid outlet pipe.Connect the vacuum pipe to the vacuum unit.Connect the starter motor supply cable to the junction unit and fit the protective cover.Connect the electrical connection and fix it using the band to the A.B.S. control unit mounting bracket.Connect the electrical connections to the pre-heating control unit.Place the electrical wiring back in its housing and connect the electrical connections to the injectors.Connect the electrical connection to the engine coolant temperature sensor.Place the air conditioning condenser, complete with pipes, back in its housing.1. Connect the pipe from the condenser to the drier filter (1a), filter side and fix it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	PIPE FROM CONDENSER TO FILTER/DEHYDRATOR	M6	Drier filter side 0.8 - 1.0

Fit the air/air heat exchanger, complete with supercharging hose from the turbocharger to the heat exchanger, and connect the latter to the turbocharger.Fit the heat exchanger air duct and fix it using the bolt.1. Tighten the bolt fixing the pipe from the compressor to the air conditioning condenser.2. Connect the pipe from the drier filter to the compressor (2a) to the compressor (2a) and fix it tightening the bolt (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	PIPE FRM DEHYDRAT FILTR/ACCUM TO COMPRES	M6	Compressor side 0.8 - 1.0

3. Connect the pipe from the compressor to the air conditoning condenser (3a) to the turbocharger and fix it tightening the bolt (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	PIPES FROM COMPRESSOR TO CONDENSOR	M6	Compressor side 0.8 - 1.0

Fit the air filter complete with hoses and resonators.Connect the air inlet hose to the turbocharger.Connect the oil vapour recovery pipe to the turbocharger air inlet hose.Tighten the bolt fixing the air filter casing mounting bracket.Connect the electrical connection to the air flow meter.Fit the engine cooling radiator, complete with lower hose and bracket, then fix it using the bolts.Connect the lower radiator hose to the water pump rigid inlet pipe.Fit the radiator upper crossmember and fix it using the bolts.Place the bonnet lid lack back in its housing and fix it using the nuts. - 7055A43  central front grille - r r . Fit the electric fans with the single cooling duct and fix them using the bolts.Place the electrical wiring back in its housing and fix it to the bands.Connect the electrical connection for the air conditioning compressor electro-magnet coupling.Connnect the electrical connection to the air conditioning system multi-stage pressure switch.Connect the electrical connections to the engine cooling fans.Connect the electrical connections to the engine radiator fan resistances.Connect the vacuum pipe to the E.G.R. valve.Fit the upper coolant inlet hose to the radiator.Fit the engine coolant drain plug in the radiator. - 1048B22  air delivery sleeve from heat exchanger to intake manifold - r + r .  - 1076B50  exhaust pipe attachment to engine - r + r .  - 7055B54  under-engine guard - r r .  - 7055A41  RIGHT FRONT GRILLE - R.R. .  - 7055A43  central front grille - r r .  - 7055B10  Front BUMPER - R.R. .  - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R. (right and left)  - 4450B10  Front WHEEL (one) - R.R. (right and left)  - 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) Connect the battery terminal (-).Supply the engine cooling system with the recommended fluid.

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

Top up the power assisted circuit with the recommended fluid.

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

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.