Alfa Romeo2004–2008Technical specifications

Crosswagon 1.9 JTD 16V 4x4: Technical specifications

Workshop data for the 1.9-litre diesel (engine code 937A5.000). Covers engine, fluids, brakes, service, torques and air conditioning: the figures to check before a job or a parts order.

Common faults & fixes

Summary

Match the engine code (937A5.000) to the vehicle before ordering parts or applying these figures.

Vehicle specifications

Overview

Make: Alfa Romeo
Model: Crosswagon
Years: 2004–2008
Fuel: Diesel
Engine code: 937A5.000

Performance & efficiency

Power: 110 kW (150 hp)
Engine size: 1,910 cc
Cylinders: 4 · DOHC
Compression ratio: 18.0:1
Fuel system: Bosch

Fluids & capacities

Engine oil (with the filter): 4.2 litres

All 93 specifications below

Engine & identification

Vehicle identification

No. of cylinders Type	4/DOHC
Capacity cc	1910
Compression ratio :1	18,0
Fuel system Make	Bosch
Fuel system Type	EDC 16C8

Injection system

Air metering Type	Mass
Fuel/injection pump assembly Make	Bosch
Pump type	Common rail
Injector nozzle Make	Bosch

Injection sequence

The injection sequence for the Alfa Romeo Crosswagon 1.9 JTD 16V 4x4 (2004–2008) is 1-3-4-2.

Injection sequence	1-3-4-2

Valve clearances

Valve clearances on the Alfa Romeo Crosswagon 1.9 JTD 16V 4x4 (2004–2008) are hydraulic — they self-adjust, so no manual clearance figure applies.

Valve clearance - INLET mm	Hydraulic
Valve clearance - EXHAUST mm	Hydraulic

Engine oil & fluids

Engine oil

The Alfa Romeo Crosswagon 1.9 JTD 16V 4x4 (2004–2008) takes 4.2 litres of engine oil with the filter.

See the reference table for the complete engine oil entries and their conditions.

Manual gearbox

See the reference table for the complete manual gearbox entries and their conditions.

Coolant

The listed total cooling-system capacity is 6.1 litres.

Grades, filling conditions and capacities

Lubricants and capacities — complete reference
Engine oil options
Ambient temperature range	All temperatures
Engine oil grade SAE	5W-40 Synthetic
Engine oil classification API/ACEA	CF/B3
Ambient temperature range	-15°C➞
Engine oil grade SAE	10W-40 Synthetic
Engine oil classification API/ACEA	CF/B3
Engine with filter(s) litres	4.2
Other lubricants and capacities
Manual transmission oil grade SAE	75W-85 Synthetic
Manual transmission oil classification	GL-4+
Manual transmission litres	2,0 4x4=3,2
Differential oil grade - rear SAE	80W-90
Differential oil classification - rear	GL-5
Differential rear litres	1.25
Cooling system - total capacity litres	6.1
Brake fluid Type	DOT 4
Brake fluid litres	0.52
Power steering fluid Type	Dexron II
Power steering fluid litres	1.3

Brakes & wear limits

Brake disc thickness

Brake discs on the Alfa Romeo Crosswagon 1.9 JTD 16V 4x4 (2004–2008) are replaced at a minimum thickness of 20,2 mm (ventilated) front and 9 mm rear.

Minimum disc thickness for replacement - ventilated Front	20,2 mm
Minimum disc thickness for replacement Rear	9 mm

Brake disc and drum dimensions

Minimum pad thickness Front	1,5 mm
Minimum pad thickness Rear	1,5 mm

Service & electrical

Battery

The Alfa Romeo Crosswagon 1.9 JTD 16V 4x4 (2004–2008) uses a 12 V, 60 Ah battery.

Battery V/RC(Ah)	12 (60)

Tuning and emissions

Idle speed rpm	850±20
Oil temperature °C	80
Maximum time at governed speed secs	1,0
Test mode A/B	B
Probe type 1/2	1
Smoke opacity - EU limit m-1 (%)	3,00 (73)
Smoke opacity - homologation value m-1 (%)	1,55 (49)

Service checks and adjustments

Oil pressure bar/rpm	4,0-4,5/4000
Radiator cap bar	0,98
Thermostat opens °C	78-82

Tightening torques

Cylinder head bolt torque

The cylinder head bolts on the Alfa Romeo Crosswagon 1.9 JTD 16V 4x4 (2004–2008) are tightened in 4 stages: 65 Nm, then 90°, then 90°, then a final 90°.

Cylinder head
Renew bolts	Yes
Tighten	65 Nm
Tighten	90°
Tighten	90°
Tighten	90°

Other engine tightening torques
Cylinder head instructions	—
Main bearings Renew bolts/nuts	No
Main bearings Stage 1	25 Nm
Main bearings Stage 2	100°
Big end bearings Renew bolts/nuts	No
Big end bearings Stage 1	25 Nm
Big end bearings Stage 2	60°
Sump bolts	—
Sump drain bolt	20 Nm
Flywheel/driveplate	160±16 Nm
Clutch pressure plate	28±3 Nm
Crankshaft pulley/damper centre bolt	340±17 Nm
Camshaft sprocket/gear	120±12 Nm
Camshaft carrier/cap	16 Nm
Camshaft/rocker cover	25±2 Nm
Inlet manifold to cylinder head	25±2 Nm
Exhaust manifold to cylinder head	25±2 Nm
Water pump	25±2 Nm
Injector/clamp	25±2 Nm
Injector pipe unions	22±2 Nm
Fuel/injection pump sprocket/gear	50±5 Nm
Fuel/injection pump mounting	25±2 Nm
Glow plugs	—
Camshaft position (CMP) sensor	9 Nm
Engine coolant temperature (ECT) sensor	20 Nm
Engine oil pressure switch	30 Nm
Chassis tightening torques
Front hub	70 Nm+62°
Rear hub	320 Nm
Steering wheel	50 Nm
Steering track rod end	30 Nm
Brake disc to hub Front	8-13 Nm
Brake disc to hub Rear	8-13 Nm
Brake caliper to carrier Rear	50 Nm
Brake caliper/carrier to hub Rear	52 Nm
ABS sensor Front	5 Nm
ABS sensor Rear	5 Nm
Road wheels	—

Air conditioning

No. of AC service connectors	2
Air conditioning restrictor type	Expansion valve
Compressor clutch/magnetic coupling	Yes
Compressor variable displacement solenoid	No
Air conditioning refrigerant Type	R134a
Air conditioning refrigerant quantity grams	500
Air conditioning oil group	PAG
Air conditioning oil Type	SP10
Air conditioning oil quantity cm³	130
Air conditioning oil viscosity ISO	46

Frequently asked questions

What is the injection sequence of the Alfa Romeo Crosswagon 1.9 JTD 16V 4x4?

The injection sequence for the Alfa Romeo Crosswagon 1.9 JTD 16V 4x4 (2004–2008) is 1-3-4-2.

How much oil does the Alfa Romeo Crosswagon 1.9 JTD 16V 4x4 take?

The Alfa Romeo Crosswagon 1.9 JTD 16V 4x4 (2004–2008) takes 4.2 litres of engine oil with the filter. See the reference table for the complete engine oil entries and their conditions.

What are the valve clearances for the Alfa Romeo Crosswagon 1.9 JTD 16V 4x4?

Valve clearances on the Alfa Romeo Crosswagon 1.9 JTD 16V 4x4 (2004–2008) are hydraulic — they self-adjust, so no manual clearance figure applies.

What is the cylinder head torque for the Alfa Romeo Crosswagon 1.9 JTD 16V 4x4?

The cylinder head bolts on the Alfa Romeo Crosswagon 1.9 JTD 16V 4x4 (2004–2008) are tightened in 4 stages: 65 Nm, then 90°, then 90°, then a final 90°.

What is the minimum brake disc thickness for the Alfa Romeo Crosswagon 1.9 JTD 16V 4x4?

Brake discs on the Alfa Romeo Crosswagon 1.9 JTD 16V 4x4 (2004–2008) are replaced at a minimum thickness of 20,2 mm (ventilated) front and 9 mm rear.

What battery does the Alfa Romeo Crosswagon 1.9 JTD 16V 4x4 use?

The Alfa Romeo Crosswagon 1.9 JTD 16V 4x4 (2004–2008) uses a 12 V, 60 Ah battery.