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Home >> Alfa Romeo >> 2019 >> Giulia Base, AWD >> Repair and Diagnosis >> Body & Frame >> Frames, Subframes & Crossmembers >> Frame And Bumpers >> Frame >> CROSSMEMBER, Front Suspension >> Removal And Installation >> Removal And Installation >> Removal - 2.0L

Removal - 2.0L

  1. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  2. Remove the front steering knuckles. Refer to KNUCKLE, STEERING, REMOVAL AND INSTALLATION .
  3. Remove the front catalytic converters. Refer to CONVERTER, CATALYTIC, REMOVAL AND INSTALLATION .
  4. Remove the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
    GC0194896Courtesy of CHRYSLER GROUP, LLC
  5. Open the retaining clip and release the fuel line.
  6. Open the retaining clip and release the fuel vapor line (2).
  7. Remove the bolts (3a) and remove the turbocharger air cooling system cover (3b), releasing the retaining pins (3c) from the flexible mounts.
  8. Remove the air filter housing. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION .
    GC0195076Courtesy of CHRYSLER GROUP, LLC
  9. Disconnect the quick couplings (1) from the unions of the turbocharger air intake line.
    GC0198543Courtesy of CHRYSLER GROUP, LLC
  10. Loosen the clamp (1) and disconnect the air line from the air flow meter.
  11. Loosen the clamp (2) and disconnect the engine oil vapor intake line from the air line.
  12. Loosen the clamp (3) attaching the air intake line to the turbocharger.
  13. Disconnect the engine oil vapor outlet line (4a) quick coupling and remove the turbocharger air intake line (4b).
    GC0195074Courtesy of CHRYSLER GROUP, LLC
  14. Remove the bolts (1a) and remove the intake air line to the turbocharger (1b) complete with gasket (1c).
  15. Remove the front fascia. Refer to FASCIA, FRONT, REMOVAL AND INSTALLATION .
    GC0197553Courtesy of CHRYSLER GROUP, LLC
  16. Disconnect the wire harness connector (1) of the low pressure EGR exhaust gas temperature sensor.
    GC0197804Courtesy of CHRYSLER GROUP, LLC
  17. Remove the nut (1a) fastening the air conditioning compressor and refit the bracket (1b) that supports the powertrain.
    GC0198173Courtesy of CHRYSLER GROUP, LLC
  18. Remove the bolts (1a) and remove the heat shield mounting bracket (1b).
    GC0198125Courtesy of CHRYSLER GROUP, LLC
  19. Disconnect the wire harness connector (1) for the oxygen sensor.
    GC0197918Courtesy of CHRYSLER GROUP, LLC
  20. Fit the bracket (1) for supporting the powertrain assembly.
    GC0198015Courtesy of CHRYSLER GROUP, LLC
  21. On both sides, remove the nut (1a) and disconnect the stabilizer bar (1b) joint from the shock absorber.
    GC0198247Courtesy of CHRYSLER GROUP, LLC
  22. On both sides, remove the bolt (1) fastening the shock absorber to the rear lower control arm.
    GC0198443Courtesy of CHRYSLER GROUP, LLC
  23. Remove the bolt (1) and release the automatic transmission fluid supply and return line.
    GC0197693Courtesy of CHRYSLER GROUP, LLC
  24. Remove the bolt (1) and release the automatic transmission fluid supply and return line.
    GC0198068Courtesy of CHRYSLER GROUP, LLC
  25. Disconnect the steering gear wire harness connectors (1).
    GC0197759Courtesy of CHRYSLER GROUP, LLC
  26. Remove the bolt (1a) and disconnect the column (1b) from the steering gear (1c).
    GC0197555Courtesy of CHRYSLER GROUP, LLC
  27. On both sides, remove the bolts (1a) and remove the radiator mounting brackets (1b).
    GC0198428Courtesy of CHRYSLER GROUP, LLC
  28. Install the Power Unit Support 2000040436 (1) or (special tool #8534C, Fixture, Driveline Support).
    GC0197715Courtesy of CHRYSLER GROUP, LLC
  29. Using the tool (1a), remove the nut (1b) attaching the engine mount bracket to the insulator on both sides.
  30. Place commercially available rubber spacer blocks, such as ROTFJ2427/J2440 or equivalent, on the (special tool #BX50-CHR, Table, Bishamon Lift) and position it under the crossmember assembly.
    GC0197964Courtesy of CHRYSLER GROUP, LLC
  31. On both sides, remove the front bolts (1) attaching the front suspension crossmember to the body.
    GC0198067Courtesy of CHRYSLER GROUP, LLC
  32. Operating on both sides, remove the bolts (1a) and (1b) and remove the suspension crossmember (1c).
    GC0197806Courtesy of CHRYSLER GROUP, LLC
  33. Working on both sides, remove the attaching bolts (1a) and remove the insulators (1b) from the crossmember.
    GC0198161Courtesy of CHRYSLER GROUP, LLC
  34. Remove bolts (1a) and remove steering gear (1b) from the crossmember.
    GC0198263Courtesy of CHRYSLER GROUP, LLC
  35. Remove the bolts (1a) and remove the stabilizer bar (1b) from the crossmember.
GC0197621Courtesy of CHRYSLER GROUP, LLC

INSTALLATION

  1. Position the stabilizer bar (1a) in its housing and tighten the bolts (1b) to the proper specification. Refer to FRONT, TECHNICAL SPECIFICATIONS .
    GC0197500Courtesy of CHRYSLER GROUP, LLC
  2. Install the steering gear (1a) and tighten the bolts (1b) to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0197852Courtesy of CHRYSLER GROUP, LLC
  3. On both sides, place the isolators in their seats (1a) and tighten the bolts (1b) to the proper specification. Refer to SPECIFICATIONS .
  4. Lift the suspension crossmember into place using the (special tool #BX50-CHR, Table, Bishamon Lift).
    GC0198254Courtesy of CHRYSLER GROUP, LLC
  5. On both sides, tighten to the proper the new middle bolts (1a) and rear bolts (1b) attaching the front suspension crossmember (1c) to the body. Refer to TECHNICAL SPECIFICATIONS .
    GC0198411Courtesy of CHRYSLER GROUP, LLC
  6. Working on both sides, tighten the front bolt attaching the front suspension crossmember to the body to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0198398Courtesy of CHRYSLER GROUP, LLC
  7. Using the tool (1a), tighten the nut (1b) attaching the engine mount bracket to the insulator on both sides to the proper specification. Refer to SPECIFICATIONS .
    GC0197848Courtesy of CHRYSLER GROUP, LLC
  8. Remove the tools used for supporting the engine.
  9. Place the radiator support brackets in their housings and install the respective attaching bolts.
  10. Connect the column (1a) to the steering gear (1b) and tighten the new bolt (1c) to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0197853Courtesy of CHRYSLER GROUP, LLC
  11. Connect the steering gear wire harness connectors.
  12. Tighten the attaching bolts and secure the automatic transmission fluid supply and return line.
  13. Install the new bolt attaching the shock absorber to the lower rear control arm without tightening it.
    NOTE:

    This bolt will be tightened to torque when checking the wheel positions.

  14. On both sides, connect the stabilizer bar (1a) joint to the shock absorber and tighten the new nuts (1b) to the proper specification. Refer to FRONT, TECHNICAL SPECIFICATIONS .
    GC0198389Courtesy of CHRYSLER GROUP, LLC
  15. Connect the wire harness connector of the oxygen sensor.
  16. Install the heat exchanger shield bracket in its position and tighten the relative attaching bolt.
  17. Tighten the new bolt attaching the A/C compressor to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
  18. Install the front fascia. Refer to FASCIA, FRONT, REMOVAL AND INSTALLATION .
  19. Install the air filter housing. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION .
  20. Install the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
  21. Install the front catalytic converters. Refer to CONVERTER, CATALYTIC, REMOVAL AND INSTALLATION .
  22. Install the front steering knuckles. Refer to KNUCKLE, STEERING, REMOVAL AND INSTALLATION .
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