147 1.9 JTD 16V C530.6 gearbox — ALFA ROMEO

🧭 Before you start

Disconnect and remove the battery and tray, the air intake and the air filter with airflow meter, and release the clutch hydraulics via the reservoir. Remove the slave cylinder, starter and selector cables, then support the engine and take the upper bell-housing bolts out. From below, remove the wheels, arch liners, exhaust section, drive shafts, lower arms and stabiliser links, lower the subframe, drain the gearbox and lower it on a jack. Refitting is the reverse, with the clutch system bled at the end.

Fits: platform codes 1.9, JTD, 16V, (126), |, (136), (140), JTDM, (150), (170)

• Opens: brake fluid, gearbox oil, fuel

Don't miss

• Leave the clutch slave cylinder hydraulic line connected if possible; just move the cylinder aside.
• Support the engine from above before releasing the left gearbox support and the upper attaching bolts.
• Lower the subframe on a jack only after the power steering hose brackets are released.
• Bleed the hydraulic clutch through the bleed valve after refitting, catching fluid in a container.
• General practice: mark the subframe position before lowering so wheel alignment is not disturbed.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

📐 20 workshop diagrams for 192A5000

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Installation is in the reverse order of removal
2. Remove the engine upper cover
3. Engine hoist:
4. Remove the brake fluid reservoir cap
5. Connect the special tool to the reservoir

6. Disconnect the battery
7. Remove the battery and tray
8. Remove the air filter air inlet
9. Disconnect the mass airflow meter hose and connection
10. Position the container lower than the clutch slave cylinder
11. Open the clutch master cylinder bleed valve
12. Bleed the hydraulic clutch system
13. Remove the air filter together with the mass airflow meter
14. Remove the front left wheel
15. Remove the left wheel arch liner
16. Remove the special tool
17. Collect the escaping fluid in a container
18. Remove the pre-catalytic outlet pipe
19. Disconnect the catalytic converter
20. Open the cover
21. Disconnect the camshaft position sensor(s)
22. Disconnect the knock sensor
23. Disconnect the earth cable from the engine
24. Disconnect the coolant temperature sensor electrical connector
25. Disconnect the heater hose at the thermostat housing
26. Disconnect the thermostat
27. Move aside
28. Remove the clutch slave cylinder
29. Note: Do not disconnect the hydraulic lines
30. Secure to the vehicle
31. Remove the support
32. Remove the pendulum support
33. Disconnect the left-hand drive shaft from the gearbox
34. Support the gearbox with a trolley jack
35. Disconnect the gearbox support
36. Lower the gearbox slightly
37. Remove the coolant pipe
38. Remove the air hose between the turbo and the intercooler
39. Disconnect the earth cable from the gearbox
40. Remove the exhaust manifold heat shield
41. Disconnect the fuel lines
42. Collect the escaping fluid in a container
43. Disconnect the fuel temperature sensor
44. Renew the fuel filter water sensor
45. Remove the fuel filter
46. Remove the starter motor
47. Drain the hydraulic clutch
48. Disconnect the clutch slave cylinder hose
49. Remove the clutch slave cylinder
50. Disconnect the reversing light switch from the gearbox
51. Disconnect the gear selector cables from the gearbox
52. Remove the bonnet lock
53. Without disconnecting the cable, move the bonnet catch aside
54. Support the engine
55. Use the special tools
56. Remove the engine/gearbox upper attaching bolts
57. Remove the front wheels
58. Remove both front wheel arch liners
59. Disconnect the drive shafts from the gearbox
60. Remove the drive shaft centre bearing bracket
61. Remove the lower suspension arms
62. Use a special tool:
63. Disconnect the anti-roll bar ball joints
64. Remove the engine support bracket
65. Remove the bolts
66. Remove the gearbox lower cover
67. Fit a lifting jack
68. Remove the power steering mounting bolts
69. Remove the subframe bolts
70. Remove the power steering hose brackets
71. Lower the subframe
72. Drain the gearbox oil
73. Collect the escaping fluid in a container
74. Remove the flywheel inspection cover
75. Remove the engine/gearbox attaching bolts
76. Loosen the bolt
77. Remove the gearbox support
78. Remove the remaining engine/gearbox attaching bolts
79. Remove the gearbox
80. Rear engine support:
81. Lower suspension arm:
82. Refit the battery
83. Reconnect the battery

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