1004B10 POWER UNIT WITH MANUAL GEARBOX - R + R - Alfa - 156 - eLearn

3237722 - 1004B10 power unit with manual gearbox - r + r

) Position the vehicle on the ramp.DRAIN THE FUEL HIGH-PRESSURE SYSTEM AS DESCRIBED BELOW. Start up the engine.Maintain idle for 2 minutes.Remove the fuel pump relay.Wait for the engine to stall.Try to start the engine: if the engine starts within 10 seconds, wait for it to stall, then try to start it again; if the engine does not start within 10 seconds, continue cranking for a further 5 seconds. Wait until the engine cools down. Proceed with removal - 4450B12 front or rear wheels (two) - r+r . Proceed with removal - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. . Proceed with removal - 7055B54 under-engine guard - r r . 1. Disconnect the lower coolant outlet hose from the radiator and drain the engine coolant.

Manually press the springs and remove the rapid attachment for the hose.

Reconnect the rapid attachment for the bottom coolant outlet hose from the radiator.

Proceed with removal - 1016A40 ignition coil cover on cylinder head- r+r . 1. Disconnect the rapid attachment for the fuel supply pipe and release it from the attachment on the module inlet manifold. 2. Disconnect the rapid attachment coupling for the fuel vapour recover pipe.

1. Loosen the band and disconnect the coolant return pipe from the engine coolant reservoir.

1. Loosen the band and disconnect the system supply pipe from the water pump rigid inlet pipe.

Proceed with removal - 1008C10 power unit upper reaction link r r . Proceed with removal - 5530B10 battery - r+r . Proceed with removal - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. . 1. Disconnect the gear selector/engagement cables.2. Undo the nuts (2a) and release the bracket (2b) complete with gear selector/engagement cables.

1. Move the protective cover away.2. Remove the cap on the bleed valve.3. Connect the collection system (pipe and reservoir) to the bleed valve on the hydraulic clutch actuator. 4. Lift retaining clip (4a) until the first click is heard and remove pipe (4b) sufficiently to uncover the bleed hole. Let the hydraulic clutch system drain completely.Lift up the clip completely and disconnect the pipe from the hydraulic clutch control actuator.

1. Disconnect the electrical connection from the air flow meter.

	Name	Connector
1	Air flow meter	K41

1. Loosen the band and disconnect the oil vapour recirculation pipe from the cam cover.2. Loosen the band and disconnect the vacuum pipe from the corrugated sleeve.

1. Loosen the bands (1a) and remove the rigid pipe (1b) with corrugated air intake sleeve (1c) from the air filter to the throttle body.

1. Undo the bolt fixing the air filter cold air intake to the bodyshell.

1. Remove the air filter assembly (1a) together with the cold air intake for the air filter (1b).

1. Disconnect the electrical connections (1a) and (1b) for the engine wiring.

	Name	Connector
1a	Front/engine connection	D4A

	Name	Connector
1b	Front/engine connection	D4B

2. Loosen the band and disconnect the vacuum pipe from the modular inlet manifold.

1. Loosen band and disconnect the upper coolant inlet hose to the radiator, thermostat side. 2. Loosen the band and disconnect the coolant return pipe to the climate control heater, thermostat side. 3. Loosen the band and disconnect the coolant outlet pipe from the climate control heater, water pump rigid inlet pipe side. 4. Loosen the band and disconnect the lower radiator coolant outlet hose from the radiator, water pump rigid inlet pipe end.

Drain the power assisted steering reservoir using a suitable syringe.1. Disconnect the electrical connection from the enablement solenoid of the changeover device actuator.

	Name	Connector
1	Variable geometry control solenoid	L15

2. Disconnect the vacuum intake pipe from the air flow switching device actuator and release it from the fastening. 3. Disconnect the linkage for the air flow switching control actuator. 4. Undo the bolts (4a) and remove the air flow switching control actuator (4b).

Release the power steering fluid delivery and return pipes from the connection clip. 1. Undo the bolts (1a) and move the power assisted steering fluid reservoir (1b) aside.

1. Loosen the band and disconnect the power assisted steering fluid return pipe, reservoir side.

1. Unscrew the connector and disconnect the delivery pipe from pump to power steering box, pump side.

Proceed with removal - 1088E10 radiator cooling fan - r + r . Drain the air conditioner coolant circuit - 5040A10 Air conditioning refrigerant CIRCUIT - Draining and Refilling . 1. Undo the bolt (1a) and disconnect the flange for the inlet/outlet pipes (1b) from the air conditioning compressor.

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

Proceed with removal - 1076B18 rigid section of exhaust pipe between catalytic converter and silencer - r + r . Disconnect the electrical connections from the starter motor.

	Name	Connector
-	Starter' motor	A20

1. Disconnect the electrical connection from the reversing switch.

	Name	Connector
1	Reversing lights switch	I20

2. Disconnect the battery earth lead from the gearbox.

	Name	Connector
2	Battery earth	C1

1. Undo the bolts (1a) and disconnect the flanges for the driveshaft constant velocity joints (1b).

The bolts securing the front half shafts, intermediate half shaft/differential inner half shaft side, have been treated with Eslok type locking compound; therefore every time they are removed they must be replaced.

Remove the safety plates.

1. Undo the nut (1a) and disconnect the steering knuckles (1b) from the upper track control arms using the tool (1c).

	Name	Country
1c	Extractor	1.821.169.000

Release the front brake caliper flexible pipes and the cables for the A.B.S. sensors from the mounting brackets. Move the left driveshaft as far away as possible from the differential and the right one away from the intermediate driveshaft.1. Position tools (1a) and (1b), to be used for removing the power unit, on a hydraulic jack.

	Name	Country
1a	Crossmember	1.820.225.000

	Name	Country
1b	Supports	1.820.623.000

Position the tool assembled in this way under the power unit and fix it appropriately.1. Undo the bolt fixing the power unit rigid rear support to the flexible mounting.

1. Undo the bolts (1a), (1b) and remove the gearbox side power unit rigid support (1c).

1. Undo the bolt fixing the timing side rigid support to the flexible mounting.

Move the power unit towards the front of the vehicle and lower it using the hydraulic jack.Secure and support the power unit using a hydraulic hoist, then release it from the tools used for the removal.

Refitting ( Removing

) Using a hydraulic hoist, position the power unit on a hydraulic jack, complete with tools for refitting.

	Name	Country
-	Crossmember	1.820.225.000

	Name	Country
-	Supports	1.820.623.000

Place the power unit back in the engine compartment using the hydraulic jack.1. Tighten the bolt ecuring the timing side rigid power unit support to the flexible mounting to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	ENGINE MOUNT TIMING SIDE	M12	(Flexible mounting side) 7.9 ÷ 9.7

1. Refit the gearbox side power unit rigid support (1a) in its seating and tighten the bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10	(Gearbox side) 4.5 ÷ 5.5

2. Undo the bolt fixing the gearbox side rigid power unit support to the flexible block to the specified torque.

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

1. Tighten the bolt fixing the power unit rigid rear support to the flexible mounting.

	Fastening	Component	Ø	Value(daNm)
1	-	-	-	-

Remove the tools used for the refitting from the power unit and return them to their place.Fix the front brake caliper flexible pipes and the A.B.S. sensor cables to the mounting brackets. 1. Connect the steering knuckles to the upper track control arms (1a) and fix them tightening the nut (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	FRONT HUB STEERING KNUCKLE.	M10	(Upper track control arm side) 4.3 - 4.7

1. Position the safety plates and tighten the new bolts (1a) for the driveshaft constant velocity joint flanges (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M8	(Diff. int./ intermediate. shaft.) driveshaft side 3.6 ÷ 4.4

Connect the electrical connection to the reversing switch.Connect the battery earth lead to the gearbox.Connect the electrical connections to the starter motor. Proceed with refitting - 1076B18 rigid section of exhaust pipe between catalytic converter and silencer - r + r . 1. Connect the flange for the inlet/outlet pipes (1a) to the air conditioning compressor and secure it by tightening the bolt (1b) to the recommended torque.

Replace the O-rings for the connectors. Only use green coloured seals, resistant to R134A refrigerant. Lubricate the thread of the connectors using anti-freeze.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	Air conditioning compressor inlet/outlet pipes.	M10	(Air conditioner compressor side) 3.2 ÷ 3.9

Proceed with refitting - 1088E10 radiator cooling fan - r + r . 1. Connect the supply pipe from the power assisted steering pump to the box, pump side and tighten the connector to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Connector	PIPE BTWN PUMP + POWER STEERING BOX	M16	(Power steering pump side) 3.8 ÷ 4.2

Connect the return pipe to the power steering fluid reservoir and tighten the band. Refit in its seating the power steering fluid reservoir and secure it with its bolts. Secure the delivery and return lines from the power steering reservoir using the connection band. Fit the air flow switching device actuator in its seating and secure it using the bolts. Connect the linkage for the air flow switching control actuator. Connect the air flow switching control actuator vacuum intake pipe and fasten it. Connect the electrical connection from the enablement solenoid of the changeover device actuator. Connect the lower radiator coolant outlet hose to the water pump rigid inlet pipe and tighten the band. Connect the coolant return hose from the climate control heater on the side of the rigid inlet pipe to the water pump and do up the band. Connect the engine coolant return pipe from the climate control system heater, thermostat side, and tighten the band. Connect the upper coolant inlet hose to the radiator, thermostat side, and tighten the band. Connect the vacuum pipe to the modular inlet manifold and tighten the band. Connect the engine wiring electrical connections.Place the air filter back assembly in its housing and connect it to the cold air intake for the air filter.Tighten the bolt securing the cold air intake for air filter to the bodywork.Place the rigid air supply pipe with corrugated air intake sleeve from the filter to the throttle body back in its housing and secure it using the bands.Connect the vacuum pipe to the corrugated hose and tighten the band.Connect the oil vapour recirculation pipe to the tappet cover and secure with a band.Connect the electrical connection to the air flow meter.Fit the pipe fully home in its seat on the hydraulic clutch control actuator and secure with the retaining clip. Place the cap in its housing on the bleed valve.Place the protective cover back in its housing.Refit the bracket complete with gear selector/engagement cables and secure it using the nuts.Connect the gear selector/engagement cables. Proceed with refitting - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. . Proceed with refitting - 5530B10 battery - r+r . Proceed with refitting - 1008C10 power unit upper reaction link r r . Connect the system supply pipe to the water pump rigid inlet pipe and tighten the band. Connect the coolant return pipe to the engine coolant reservoir and tighten the band. Connect the rapid attachment for the fuel vapour recovery pipe.Connect the rapid attachment connector for the fuel supply pipe and secure it to the fastening on the modular intake manifold. Proceed with refitting - 1016A40 ignition coil cover on cylinder head- r+r . Proceed with refitting - 7055B54 under-engine guard - r r . Proceed with refitting - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. . Proceed with refitting - 4450B12 front or rear wheels (two) - r+r . Proceed with refitting - 0010T20 coolant change . Proceed with refitting - 1820B08 Clutch release HYDRAULIC SYSTEM - Bleeding air and restoring level . Fill the power steering circuit with the recommended fluid.

	Type	Component	Name	Qty.
-	Fluid	HYDRAULIC POWER ASSISTED STEERING SYSTEM	TUTELA GI/A	1.3

Fluid for Northern European countries: TUTELA CAR GI/E - ATF DEXRON III.

Bleed the power steering system as described belowWith the front wheels raised off the ground, with the engine switched off turn the steering wheel to full lock, left and right, 4-5 times. Check and, if necessary, top up the fluid level in the reservoir. Position the vehicle on the ground and start up the engine.Carry out 4 - 5 complete steering wheel rotation cycles (right and left).Top up the fluid level in the reservoir. Fill the air conditioner coolant circuit - 5040A10 Air conditioning refrigerant CIRCUIT - Draining and Refilling .