Introduction - ENGINE

1.6 TS

CAUTION

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage. Follow these precautions scrupulously when carrying out operations in the engine compartment:

• Switch off the engine and wait for it to cool down.
• do not smoke
• no naked flames
• make sure that there is a fire extinguisher in the vicinity.

For some procedures, the use of special tools is indicated. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give the user.

The electronic ignition system generates voltages of 20,000 V and higher which could be very dangerous to people, especially if they suffer from a heart condition. Great care should be taken when working on this system or near its components.

WARNINGS

All the operations must be carried out with the utmost attention and care to avoid damaging the components.

Before any interventions on electrical components, including battery disconnection, make sure that the ignition is off ('STOP position).

In order to release parts which are sticking, apply gentle blows using an aluminium or lead hammer if iron materials are involved: use a wooden or resin hammer for light alloy parts. use a wooden or resin hammer for light alloy parts.

During dismantling, check that parts which have to be marked carry reference marks.

When refitting, lubricate the parts, where necessary, to prevent sticking or seizing during the initial operating period. During refitting, it is essential to observe the tightening torques and adjustment data.

During each refitting, replace the gaskets, oil seals, spring washers, safety plates, self-locking nuts, pre-treated bolts and all components which have deteriorated.

Protect adequately with adhesive tape or clean rags those parts of the engine which, remaining uncovered following dismantling, offer entry passages to dust or foreign bodies.

The replacement of removed assemblies or components should be carried out using genuine spare parts only: this is the only way that the interchangeability and perfect operation of the various components can be guaranteed.

Before any interventions on components of the fuel system, discharge the pressure in the system using tool N. 1.870.684.000 connected to the specific valve located on the fuel distribution manifold.

2.0 TS

CAUTION

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage. Follow these precautions scrupulously when carrying out operations in the engine compartment:

• Switch off the engine and wait for it to cool down.
• do not smoke
• no naked flames
• make sure that there is a fire extinguisher in the vicinity.

For some procedures, the use of special tools is indicated. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give the user.

The electronic ignition system generates voltages of 20,000 V and higher which could be very dangerous to people, especially if they suffer from a heart condition. Great care should be taken when working on this system or near its components.

WARNINGS

All the operations must be carried out with the utmost attention and care to avoid damaging the components.

Before any interventions on electrical components, including battery disconnection, make sure that the ignition is off ('STOP position).

In order to release parts which are sticking, apply gentle blows using an aluminium or lead hammer if iron materials are involved: use a wooden or resin hammer for light alloy parts. use a wooden or resin hammer for light alloy parts.

During dismantling, check that parts which have to be marked carry reference marks.

When refitting, lubricate the parts, where necessary, to prevent sticking or seizing during the initial operating period. During refitting, it is essential to observe the tightening torques and adjustment data.

During each refitting, replace the gaskets, oil seals, spring washers, safety plates, self-locking nuts, pre-treated bolts and all components which have deteriorated.

Protect adequately with adhesive tape or clean rags those parts of the engine which, remaining uncovered following dismantling, offer entry passages to dust or foreign bodies.

The replacement of removed assemblies or components should be carried out using genuine spare parts only: this is the only way that the interchangeability and perfect operation of the various components can be guaranteed.

Before any interventions on components of the fuel system, discharge the pressure in the system using tool N. 1.870.684.000 connected to the specific valve located on the fuel distribution manifold.

All versions

ATTENTION

ATTENTION

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage. Follow these precautions scrupulously when carrying out operations in the engine compartment:

• Switch off the engine and wait for it to cool down.
• Do not smoke.
• No naked flames.
• Make sure that there is a fire extinguisher in the vicinity.

For certain procedures, the use of Alfa Romeo special tools is recommended. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

For the use of chemical products, stick to the warnings on the safety card which the supplier must give the consumer (in Italy in accordance with D.M. no. 47/1992).

The electronic ignition system generates voltages of 20,000 V and higher which could be very dangerous to people, especially if they suffer from a heart condition. Great care should be taken when working on this system or near its components.

WARNINGS

ATTENTION

ATTENTION

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage. Follow these precautions scrupulously when carrying out operations in the engine compartment:

• Switch off the engine and wait for it to cool down.
• Do not smoke.
• No naked flames.
• Make sure that there is a fire extinguisher in the vicinity.

For certain procedures, the use of Alfa Romeo special tools is recommended. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

For the use of chemical products, stick to the warnings on the safety card which the supplier must give the consumer (in Italy in accordance with D.M. no. 47/1992).

The electronic ignition system generates voltages of 20,000 V and higher which could be very dangerous to people, especially if they suffer from a heart condition. Great care should be taken when working on this system or near its components.

WARNINGS

All the operations should be carried out taking great care not to damage the components.

Before any operation on the electrical equipment components, including the battery, make sure that the ignition is in the OFF position.

In order to release parts which are sticking, tap gently with an aluminium or lead hammer if iron materials are involved: use a wooden or resin hammer for light alloy parts. use a wooden or resin hammer for light alloy parts.

When dismantling, check that the components have reference marks.

During refitting, lubricate the parts as necessary to prevent seizure during the initial period of operation.

When refitting, it is vital to follow the recommended tightening torques and adjustment data.

During each refitting, replace the gaskets, oil seals, spring washers, safety plates, self-locking nuts, pre-treated bolts and all components which have deteriorated.

Protect adequately with adhesive tape or clean rags those parts of the engine which, remaining uncovered following dismantling, offer entry passages to dust or foreign bodies.

The replacement of removed assemblies or components should be carried out using genuine spare parts only: this is the only way that the interchangeability and perfect operation of the various components can be guaranteed.

Before any interventions on components of the fuel system, discharge the pressure in the system using tool N. 1.870.684.000 connected to the specific valve located on the fuel distribution manifold.

WARNINGS WHEN REMOVING/REFITTING LAMBDA SENSOR:

• To prevent damage, when removing-refitting the exhaust pipe Lambda sensors, do not, under any circumstances, twist the wiring.
• Therefore always disconnect the electrical connection first and release the wiring from any fastenings or clips along the entire length.
• When the cable is completed released the Lambda sensor casing can be unscrewed from the bush on the exhaust pipe.
• Also avoid any impacts to the Lmbda sensor and do not drop it.

1.9 JTD 8V

ATTENTION

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage.

Closely observe the following precautions when carrying out operations in the engine compartment.

• Turn off the engine and wait for it to cool down.
• Do not smoke.
• Do not use naked flames.
• Make sure that there is an extinguisher at hand in the workplace.

For some procedures, the use of special Fiat tools is indicated. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give to the user (in Italy, in accordance with D.M. no. 47/1992).

WARNINGS

To connect SL quick-release fittings, push the fitting fully home and then pull to check the pipe is secure without touching the tabs on the outer case of the female quick-release fitting.

To connect GSL quick-release fittings, push the fitting fully home and check there is no clearance between the thrust washer on the male fitting and the outer case of the female quick release fitting.

Do not use solvents and/or materials incompatible with the pipes and fittings.

1.9 JTD 16V

ATTENTION

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage. Closely observe the following precautions when carrying out operations in the engine compartment.

• Turn off the engine and wait for it to cool down.
• Do not smoke.
• Do not use naked flames.
• Make sure that there is an extinguisher at hand in the workplace.

For some procedures, the use of special tools is indicated. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give to the user (in Italy, in accordance with M.D. no. 47/1992).

WARNINGS

All the operations should be carried out taking great care not to damage the components.

Before any operation on the electrical equipment components, including the battery, make sure that the ignition is in the OFF position.

In order to release parts which are sticking, tap gently with an aluminium or lead hammer if iron materials are involved: use a wooden or resin hammer for light alloy parts. use a wooden or resin hammer for light alloy parts.

When dismantling, check that the components have reference marks.

During refitting, lubricate the parts as necessary to prevent seizure during the initial period of operation.

When refitting, it is vital to follow the recommended tightening torques and adjustment data.

During each refitting, replace the gaskets, oil seals, spring washers, safety plates, self-locking nuts and all components which have deteriorated.

Protect adequately with adhesive tape or clean rags those parts of the engine which, remaining uncovered following dismantling, offer entry passages to dust or foreign bodies.

The replacement of removed assemblies or components should be carried out using genuine spare parts only: this is the only way that the interchangeability and perfect operation of the various components can be guaranteed.

Whenever you dismantle the high pressure pipes within the fuel system:

• fuel manifold/injector pipe
• pipe between high pressure pump/fuel manifold, replace by ordering new pipes from Parts.

1.6 TS

CAUTION

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage. Follow these precautions scrupulously when carrying out operations in the engine compartment:

• Switch off the engine and wait for it to cool down.
• do not smoke
• no naked flames
• make sure that there is a fire extinguisher in the vicinity.

For some procedures, the use of special tools is indicated. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give the user.

The electronic ignition system generates voltages of 20,000 V and higher which could be very dangerous to people, especially if they suffer from a heart condition. Great care should be taken when working on this system or near its components.

WARNINGS

All the operations must be carried out with the utmost attention and care to avoid damaging the components.

Before any interventions on electrical components, including battery disconnection, make sure that the ignition is off ('STOP position).

In order to release parts which are sticking, apply gentle blows using an aluminium or lead hammer if iron materials are involved: use a wooden or resin hammer for light alloy parts. use a wooden or resin hammer for light alloy parts.

During dismantling, check that parts which have to be marked carry reference marks.

When refitting, lubricate the parts, where necessary, to prevent sticking or seizing during the initial operating period. During refitting, it is essential to observe the tightening torques and adjustment data.

During each refitting, replace the gaskets, oil seals, spring washers, safety plates, self-locking nuts, pre-treated bolts and all components which have deteriorated.

Protect adequately with adhesive tape or clean rags those parts of the engine which, remaining uncovered following dismantling, offer entry passages to dust or foreign bodies.

The replacement of removed assemblies or components should be carried out using genuine spare parts only: this is the only way that the interchangeability and perfect operation of the various components can be guaranteed.

Before any interventions on components of the fuel system, discharge the pressure in the system using tool N. 1.870.684.000 connected to the specific valve located on the fuel distribution manifold.

2.0 TS

CAUTION

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage. Follow these precautions scrupulously when carrying out operations in the engine compartment:

• Switch off the engine and wait for it to cool down.
• do not smoke
• no naked flames
• make sure that there is a fire extinguisher in the vicinity.

For some procedures, the use of special tools is indicated. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give the user.

The electronic ignition system generates voltages of 20,000 V and higher which could be very dangerous to people, especially if they suffer from a heart condition. Great care should be taken when working on this system or near its components.

WARNINGS

All the operations must be carried out with the utmost attention and care to avoid damaging the components.

Before any interventions on electrical components, including battery disconnection, make sure that the ignition is off ('STOP position).

In order to release parts which are sticking, apply gentle blows using an aluminium or lead hammer if iron materials are involved: use a wooden or resin hammer for light alloy parts. use a wooden or resin hammer for light alloy parts.

During dismantling, check that parts which have to be marked carry reference marks.

When refitting, lubricate the parts, where necessary, to prevent sticking or seizing during the initial operating period. During refitting, it is essential to observe the tightening torques and adjustment data.

During each refitting, replace the gaskets, oil seals, spring washers, safety plates, self-locking nuts, pre-treated bolts and all components which have deteriorated.

Protect adequately with adhesive tape or clean rags those parts of the engine which, remaining uncovered following dismantling, offer entry passages to dust or foreign bodies.

The replacement of removed assemblies or components should be carried out using genuine spare parts only: this is the only way that the interchangeability and perfect operation of the various components can be guaranteed.

Before any interventions on components of the fuel system, discharge the pressure in the system using tool N. 1.870.684.000 connected to the specific valve located on the fuel distribution manifold.

All versions

ATTENTION

ATTENTION

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage. Follow these precautions scrupulously when carrying out operations in the engine compartment:

• Switch off the engine and wait for it to cool down.
• Do not smoke.
• No naked flames.
• Make sure that there is a fire extinguisher in the vicinity.

For certain procedures, the use of Alfa Romeo special tools is recommended. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

For the use of chemical products, stick to the warnings on the safety card which the supplier must give the consumer (in Italy in accordance with D.M. no. 47/1992).

The electronic ignition system generates voltages of 20,000 V and higher which could be very dangerous to people, especially if they suffer from a heart condition. Great care should be taken when working on this system or near its components.

WARNINGS

ATTENTION

ATTENTION

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage. Follow these precautions scrupulously when carrying out operations in the engine compartment:

• Switch off the engine and wait for it to cool down.
• Do not smoke.
• No naked flames.
• Make sure that there is a fire extinguisher in the vicinity.

For certain procedures, the use of Alfa Romeo special tools is recommended. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

For the use of chemical products, stick to the warnings on the safety card which the supplier must give the consumer (in Italy in accordance with D.M. no. 47/1992).

The electronic ignition system generates voltages of 20,000 V and higher which could be very dangerous to people, especially if they suffer from a heart condition. Great care should be taken when working on this system or near its components.

WARNINGS

All the operations should be carried out taking great care not to damage the components.

Before any operation on the electrical equipment components, including the battery, make sure that the ignition is in the OFF position.

In order to release parts which are sticking, tap gently with an aluminium or lead hammer if iron materials are involved: use a wooden or resin hammer for light alloy parts. use a wooden or resin hammer for light alloy parts.

When dismantling, check that the components have reference marks.

During refitting, lubricate the parts as necessary to prevent seizure during the initial period of operation.

When refitting, it is vital to follow the recommended tightening torques and adjustment data.

During each refitting, replace the gaskets, oil seals, spring washers, safety plates, self-locking nuts, pre-treated bolts and all components which have deteriorated.

Protect adequately with adhesive tape or clean rags those parts of the engine which, remaining uncovered following dismantling, offer entry passages to dust or foreign bodies.

The replacement of removed assemblies or components should be carried out using genuine spare parts only: this is the only way that the interchangeability and perfect operation of the various components can be guaranteed.

Before any interventions on components of the fuel system, discharge the pressure in the system using tool N. 1.870.684.000 connected to the specific valve located on the fuel distribution manifold.

WARNINGS WHEN REMOVING/REFITTING LAMBDA SENSOR:

• To prevent damage, when removing-refitting the exhaust pipe Lambda sensors, do not, under any circumstances, twist the wiring.
• Therefore always disconnect the electrical connection first and release the wiring from any fastenings or clips along the entire length.
• When the cable is completed released the Lambda sensor casing can be unscrewed from the bush on the exhaust pipe.
• Also avoid any impacts to the Lmbda sensor and do not drop it.

1.9 JTD 8V

ATTENTION

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage.

Closely observe the following precautions when carrying out operations in the engine compartment.

• Turn off the engine and wait for it to cool down.
• Do not smoke.
• Do not use naked flames.
• Make sure that there is an extinguisher at hand in the workplace.

For some procedures, the use of special Fiat tools is indicated. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give to the user (in Italy, in accordance with D.M. no. 47/1992).

WARNINGS

To connect SL quick-release fittings, push the fitting fully home and then pull to check the pipe is secure without touching the tabs on the outer case of the female quick-release fitting.

To connect GSL quick-release fittings, push the fitting fully home and check there is no clearance between the thrust washer on the male fitting and the outer case of the female quick release fitting.

Do not use solvents and/or materials incompatible with the pipes and fittings.

1.9 JTD 16V

ATTENTION

All operations should be carried out taking great care to avoid injury to persons.

The engine compartment contains numerous moving parts, components at high temperatures and electrical wiring with voltage. Closely observe the following precautions when carrying out operations in the engine compartment.

• Turn off the engine and wait for it to cool down.
• Do not smoke.
• Do not use naked flames.
• Make sure that there is an extinguisher at hand in the workplace.

For some procedures, the use of special tools is indicated. The use of these tools is vital in order to work safely.

Follow the safety instructions in force for workshop procedures. Where necessary, the Manual contains specific warnings to prevent the risk of dangerous situations.

When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give to the user (in Italy, in accordance with M.D. no. 47/1992).

WARNINGS

All the operations should be carried out taking great care not to damage the components.

Before any operation on the electrical equipment components, including the battery, make sure that the ignition is in the OFF position.

In order to release parts which are sticking, tap gently with an aluminium or lead hammer if iron materials are involved: use a wooden or resin hammer for light alloy parts. use a wooden or resin hammer for light alloy parts.

When dismantling, check that the components have reference marks.

During refitting, lubricate the parts as necessary to prevent seizure during the initial period of operation.

When refitting, it is vital to follow the recommended tightening torques and adjustment data.

During each refitting, replace the gaskets, oil seals, spring washers, safety plates, self-locking nuts and all components which have deteriorated.

Protect adequately with adhesive tape or clean rags those parts of the engine which, remaining uncovered following dismantling, offer entry passages to dust or foreign bodies.

The replacement of removed assemblies or components should be carried out using genuine spare parts only: this is the only way that the interchangeability and perfect operation of the various components can be guaranteed.

Whenever you dismantle the high pressure pipes within the fuel system:

• fuel manifold/injector pipe
• pipe between high pressure pump/fuel manifold, replace by ordering new pipes from Parts.