1080B39 RIGHT CATALYTIC PRECONVERTER R R OR REPLACE CYLINDER HEAD GASKET - Alfa - 147 - eLearn

3024986 - 1080B39 right catalytic preconverter r r or replace cylinder head gasket

) Position the vehicle on the ramp.Make sure that the ignition key is in the OFF position. then disconnect the battery negative (-) terminal.

	Name	Connector
-	Battery	A1B

Drain the air conditioner coolant circuit - 5040A10 Air conditioning refrigerant CIRCUIT - Draining and Refilling .Proceed with removal - 7055B54 under-engine guard - r r .Proceed with removal - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. .Proceed with removal - 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R. .Proceed with removal - 7210E10 R.R. FRONT BUMPER .Proceed with the removal - 5540B76 Front LIGHT CLUSTER with fog light (one), left or right - R.R. with interfering components removed (Right and left sides).Proceed with removal - 7025A34 bonnet lid lock (one) - r+r or repair .Proceed with removal - 7210A15 R.R. HEADLAMP HOUSING/FRONT WING CROSSMEMBER .1. Loosen the band (1a) and disconnect the oil vapour recirculation pipe (1b) from the corrugated hose.2. Loosen the bands (2a) and remove the corrugated hose (2b), complete with resonator (2c).

1. Disconnect the electrical connection from the throttle body integrated with the D.V.L.

	Name	Connector
1	Throttle body actuator	N75

2. Open the electrical connections box cover.3. Disconnect the electrical connection for the right Lambda sensor.

	Name	Connector
3	Lambda sensor on left pre-catalyzer	K16

4. Disconnect the rapid connector for the fuel vapour recirculation pipe from the air chamber.5. Loosen the band and disconnect the brake servo vacuum intake pipe from the air chamber.

1. Open the electrical connections box cover.2. Disconnect the engine coupling.3. Disconnect the electrical connections (3a) and (3b) for the rear Lambda sensors and the catalytic converter.

	Name	Connector
3a	Lambda sensor downstream of post-catalyzer	K17

	Name	Connector
3b	Lambda sensor on catalyzer -2	K18

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

	Name	Connector
4	Detonation sensor - 1	K50

5. Release the electrical wiring for the timing side detonation sensor (5a) and the fuel supply pipe (5b) from the cable duct (5c).

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

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

	Name	Connector
1a	Engine management ECU	M10A

	Name	Connector
1b	Engine management ECU	M10B

2. Undo the bolt (2a) and disconnect the earth lead (1b) from the air chamber.

1. Loosen the bands and disconnect the flexible pipes from the engine coolant reservoir rigid coolant return pipe.2. Undo the bolts (2a) and remove the engine coolant reservoir rigid coolant return pipe (2b).3. Loosen the band and disconnect the oil vapour recovery pipe from the air chamber.4. Loosen the bands fixing the inlet ducts to the air chamber.

1. Undo the bolts (1a) and remove the reinforcement (1b) between the air chamber and bracket on the engine for the reaction link.

1. Undo the bolts (1a) and remove the air chamber (1b) complete with injection/ignition system control unit (1c) and throttle body integrated with D.V.L. (1d).

Proceed with removal - 1008C10 power unit upper reaction link r r .Proceed with removal - 1076B82 left exhasust pipe between catalytic preconverter and converter r r .Proceed with removal - 1076B84 right exhaust pipe between caralytic preconverter and converter r r .1. Position a hydraulic jack under the power unit gearbox side front support.2. Undo the bolts fixing the power unit gearbox side rigid support to the flexible mounting.Slowly lower the power unit using the hydraulic jack until it is resting on the front suspension crossmember.

1. Undo the right upper Lambda sensor using a suitable spanner and remove it.

Undo the lower nut fixing the right catalytic preconverter heat shield to the bracket.1. Undo the upper nuts (1a) and remove the right catalytic preconverter heat shield (1b).

1. Release the electrical wiring from the fastening bands on the mounting bracket located on the engine compartment bulkhead.2. Release the fuel vapour recirculation pipe (2a) from the bands (2b).3. Undo the bolts (3a) and remove the bracket (3b) from the engine compartment bulkhead.

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

	Name	Connector
1	4 stage pressure switch	K10

2. Undo the nut (2a) and disconnect the intermediate coupling for the pipe from the evaporator to the air conditioning compressor (2b).

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

1. Undo the bolt (1a) and disconnect the pipe from the condenser to the evaporator (1b), condenser side.

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

1. Undo the bolt fixing the evaporator coolant inlet and outlet pipes flange.

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

2. Remove the pipe from the evaporator to the air conditioning compressor and the pipe from the condenser to the evaporator.

1. Undo the nuts (1a) and remove the right catalytic preconverter (1b).Remove the gaskets.

Refitting ( Removing

) 1. Place the right catalytic preconverter (1a), complete with gaskets, back in its housing and secure it tightening the nuts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	RIGHT LAMBDA SENSOR	M8	(Cylinder head side) 2.3 ÷ 2.8

1. Place the pipe from the evaporator to the air conditioning compressor and the pipe from the condenser to the evaporator back in their housings.2. Connect the flange for the evaporator coolant inlet and outlet pipes and tighten the bolt to the recommended torque.

Replace the O-rings for the connectors using green coloured seals only, resistant to R134a refrigerant fluid. Lubricate the thread of the connectors using anti-freeze.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	COOLANT SYSTEM FITTINGS	M6	0.7 ÷ 1.1

1. Connect the pipe from the condenser to the evaporator (1a), condenser side and tighten the bolt (1b) to the recommended torque.

Replace the O-rings for the connectors using green coloured seals only, resistant to R134a refrigerant fluid.Lubricate the thread of the connectors using anti-freeze.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	COOLANT SYSTEM FITTINGS	M6	0.7 ÷ 1.1

1. Connect the intermediate coupling for the pipe from the evaporator to the air conditioning compressor (1a) and tighten the nut (1b) to the recommended torque.

Replace the O-rings for the connectors using green coloured seals only, resistant to R134a refrigerant fluid.Lubricate the thread of the connectors using anti-freeze.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	COOLANT SYSTEM FITTINGS	M6	0.7 ÷ 1.1

2. Connnect the electrical connection to the air conditioning system multi-stage pressure switch.

Place the bracket on the engine compartment bulkhead and secure it using the bolts.Fasten the fuel vapour recirculation pipe to the bands.Fasten the electrical wiring to the bands ont he mounting bracket positioned on the engine compartment bulkhead.Place the right catalytic preconverter heat shield back in its housing and secure it using the nuts.1. Place the right upper Lambda sensor back in its housing and tighten it to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	-	RIGHT LAMBDA SENSOR	M18	(Right preconverter side) 4.1 ÷ 5.0

1. Place the power unit back in its housing using a hydraulic jack positioned under the gearbox side rigid power unit support.2. Undo the bolt fixing the gearbox side rigid power unit support to the flexbile block to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2	-	-	-	-

Remove the hydraulic jack.

Proceed with refitting - 1076B84 right exhaust pipe between caralytic preconverter and converter r r .Proceed with refitting - 1076B82 left exhasust pipe between catalytic preconverter and converter r r .Proceed with refitting - 1008C10 power unit upper reaction link r r .Place the air chamber complee with injection/ignition system control unit and throttle casing integrated with D.V.L back in its housing and fasten it using the bolts.Refit in its seating the reinforcement between the air chamber and bracket on the engine for the reaction link and secure it with its bolts.Tighten the bands fixing the inlet ducts to the air chamber.Connect the oil vapour recovery pipe to the air chamber and tighten the band.Place the coolant rigid return pipe to the engine cooling system reservoir back in its housing and fix it using the bolts.Connect the flexible pipe to the coolant return pipe to the engine coolant reservoir and tighten the band.Connect the earth lead to the air chamber and secure it using the bolts.Connect the electrical connections to the fuel injection/ignition control unit.Place the electrical connections box back in its housing and secure it using the bolts.Fasten the electrical wiring for the timing side detonation sensor and the fuel supply pipe to the cable duct.Connect the electrical connection for the detonation sensor, timing side.Connect the electrical connections for the rear Lambda sensors to the catalytic converter.Connect the engine junction.Close the electrical connections box cover.Connect the brake servo vacuum intake pipe to the air chamber and tighten the band.Connect the rapid connector for the fuel vapour recirculation pipe to the air chamber.Connect the electrical connection for the right Lambda sensor.Close the electrical connections box cover.Connect the electrical connection to the throttle body integrated with the D.V.L.Place the corrugated hose, complete with resonator, back in its housing and tighten the bands.Connect the oil vapour recirculation pipe to the corrugated hose and tighten the band.Proceed with refitting - 7210A15 R.R. HEADLAMP HOUSING/FRONT WING CROSSMEMBER .Proceed with refitting - 7025A34 bonnet lid lock (one) - r+r or repair .Proceed with the refitting - 5540B76 Front LIGHT CLUSTER with fog light (one), left or right - R.R. with interfering components removed (Right and left sides).Proceed with refitting - 7210E10 R.R. FRONT BUMPER .Proceed with refitting - 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R. .Proceed with refitting - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. .Proceed with refitting - 7055B54 under-engine guard - r r .Fill the air conditioner coolant circuit - 5040A10 Air conditioning refrigerant CIRCUIT - Draining and Refilling .Connect the negative (-) battery terminal.Remove the car from the ramps.