3025431 - 5040C10 air conditioner box - r+r

Follow the safety instructions ( See subassembly 5040   AIR CONDITIONING CASING AND COMPONENTS ).

Removing ( Refitting )  - 7055B54  under-engine guard - r r - 1048A34  sleeve(s) from flow meter to air supply capacity case - r + rDrain the coolant ( - 5040A10  Air conditioning refrigerant CIRCUIT - Draining and Refilling ).Position a suitable container for recovering the coolant fluid.Raise the vehicle.1. Working underneath the engine compartment, loosen the bands retaining the coolant supply and return pipes to the air conditioning. 2. Disconnect the pipes from the connectors and let the coolant drain into the container. Lower the vehicle.1. Undo the bolt fixing the pipes to the air conditioning evaporator.2. Disconnect the pipes from the connector to the evaporator.

Seal the disconnected connectors, using suitable plugs, to prevent humidity and impurities from entering the system.

 - 7040A65  passenger compartment box lock , one , r r (left and right sides) - 3380A44  handbrake/linkage protection - r+r - 7040L20  tunnel trim - r r - 7040A80  compartment unit on facia r r - 5570T80  car radio unit - r+r - 5040D18  air conditioner control unit - r r

Before working on the Air Bag system follow the safety instructions for working on the system carefully ( See assembly 5580C   air bag system ).

 - 5580C26  LOCK BARREL KEY/SWITCH for deactivating passenger 'AIR BAG - R.R. - 7040A37  fuse box cover - r r - 5580C18  air bag module - r+r - 4110A11  steering wheel - r+r for replacement or check for versions with air bag - 7040A26  steering column trim - r+r - 5550A12  complete stalk unit - r+r for versions with air bag - 5560B11  analogue control panel - r+r or replace - 5560B56  TRIM with SWITCHES/BUTTONS FOR MULTIFUNCTION DISPLAY AND HEADLAMP alignment ADJUSTMENT - R.R. - 5010D56  solar sensor - r r after checking electrical system - 5010C12  Windscreen demising VENT - R.R. - 7040A31  flap assembly - r r - 7040A09  passenger air bag compartment cover - r r - 5580C22  AIR BAG MODULE - Passenger side - R.R. - 7040A10  instrument facia trim - r+r - 5010B45  duct from climate control system - r r (left and right sides) - 5010B56  DUCT between climate control casing and air duct to rear seats - R.R. - 7040A95  (One), REINFORCEMENT BRACKET left or right, between DASHBOARD supporting crossmember and bodyshell - R.R. - 7040L40  front compartment scuff strip - r r (left side) - 5505A10  electrical junction unit - r+r1. Unscrew the bolts2. Remove the support bracket with air duct.3. Disconnect the electrical connections connected to the air conditioning (3a, 3b, 3c).

	Name	Connector
3a	Front coupling / air conditioner - with heating	D8A

	Name	Connector
3a	Front coupling / air conditioner - with heating	D8B

	Name	Connector
3c	Air conditioning earth	C16

4. Disconnect the electrical connection for the dashboard wiring with the Air Bag control unit.

	Name	Connector
4	Air bag control unit	M60A

5. Disconnect the electrical connection for the Air Bag control unit earth.

	Name	Connector
5	Air Bag earth	C50A

6. Undo the bolt fixing the air conditioning casing to the bodyshell. 1. Undo the bolts securing the bonnet release.2. Move the bonnet release. 1. Cut the wiring retaining band.2. Unscrew the bolt.3. Move the support with the electrical connection.4. Release the electrical connection from the crossmember.5. Disconnect the electrical connections from the ignition barrel (5a, 5b).

	Name	Connector
5a	Ignition switch	H1A

	Name	Connector
5b	Ignition switch	H1B

6. Undo the bolts fixing the steering column.7. Lower the steering column. 1. Release the retainers for the wiring.2. Undo the upper bolts for the crossmember.3. Undo the lower bolts for the crossmember.4. Move the air conditioning crossmember slightly.5. Undo the bolt and move the earth carrier electrical connection.6. Disconnect the electrical connections.7. Disconnect any other electrical connections and remove the crossmember/air conditioning assembly with the dashboard wiring. If necessary, separate the air conditioning casing from the crossmember, as follows.1. At the bench, cut the dashboard wiring bands.2. Undo the bolts fixing the air conditioning casing.3. Undo the bracket retaining nut4. Remove the air conditioner case with wiring. Refitting ( Removing ) Check that the air conditioning casing is not damaged.If the air conditioning casing has been separated from the crossmember, reposition it and tighten the bracket fixing nut. Tighten the bolts fixing the air conditioning casing. Position the dashboard wiring and secure it using the bands. Position the crossmember/air conditioning assembly with the dashboard wiring.Connect the electrical connection.Tighten the crossmember side and upper bolts.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FACIA TRIMMOUNT BEAM	M10 x 1.25	3.6

Engage the wiring retainers.Lift up the steering column and tighten the fixing bolts.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	STEERING SHAFT MOUNTING	M8	2.4

Connect the electrical connections for the ignition barrel.Attach the electrical connection to the crossmeber.Position the support with the electrical connection and tighten the bolt.Secure the wiring with a new retaining band.Position the bonnet release and secure it using the bolts.Tighten the bolt fixing the air conditioning casing to the bodyshell.Connect the electrical connection to the Air Bag control unit and earth.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	AIR BAG SYSTEM EARTH	M8	2.4

Connect the electrical connections to the air conditiioning casing.Position the mounting bracket with air duct and secure it with the bolts. - 5505A10  electrical junction unit - r+r - 7040L40  front compartment scuff strip - r r (left side) - 7040A95  (One), REINFORCEMENT BRACKET left or right, between DASHBOARD supporting crossmember and bodyshell - R.R. - 5010B56  DUCT between climate control casing and air duct to rear seats - R.R. - 5010B45  duct from climate control system - r r (left and right sides) - 7040A10  instrument facia trim - r+r - 5580C22  AIR BAG MODULE - Passenger side - R.R. - 7040A09  passenger air bag compartment cover - r r - 7040A31  flap assembly - r r - 5010C12  Windscreen demising VENT - R.R. - 5010D56  solar sensor - r r after checking electrical system - 5560B56  TRIM with SWITCHES/BUTTONS FOR MULTIFUNCTION DISPLAY AND HEADLAMP alignment ADJUSTMENT - R.R. - 5560B11  analogue control panel - r+r or replace - 5550A12  complete stalk unit - r+r for versions with air bag - 7040A26  steering column trim - r+r - 4110A11  steering wheel - r+r for replacement or check for versions with air bag - 5580C18  air bag module - r+r - 7040A37  fuse box cover - r r - 5580C26  LOCK BARREL KEY/SWITCH for deactivating passenger 'AIR BAG - R.R. - 5040D18  air conditioner control unit - r r - 5570T80  car radio unit - r+r - 7040A80  compartment unit on facia r r - 7040L20  tunnel trim - r r - 3380A44  handbrake/linkage protection - r+r - 7040A65  passenger compartment box lock , one , r r (left and right sides)Connect the pipe connectors to the evaporator and tighten the bolt.

Replace the O-rings for the connectors.

Use only green coloured seals, resistant to R134A coolant fluid.

Lubricate the threads of the connectors using anti-freeze.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	COOLANT SYSTEM FITTINGS	M6	0.9

Working underneath the engine compartment, connect the coolant supply and return pipes to the air conditiong and secure them using the retaining bands. Repressurize using coolant fluid ( - 5040A10  Air conditioning refrigerant CIRCUIT - Draining and Refilling ). - 1048A34  sleeve(s) from flow meter to air supply capacity case - r + r - 7055B54  under-engine guard - r rRefill the engine cooling circuit using the recommended fluid.

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

Follow the safety instructions (see 5040 - Precautions).