1004B12 POWER UNIT WITH MANUAL GEARBOX - R+R FOR VERSIONS WITH A/C - Alfa - 156 - eLearn

3237437 - 1004B12 power unit with manual gearbox - r+r for versions with a/c

) Position the vehicle on the ramp.Disconnect the battery negative (-) terminal.

	Name	Connector
-	Battery	A1

- 4450B12 front or rear wheels (two) - r+r - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. - 7055B54 under-engine guard - r r - 1088D10 lower sleeve for coolant outlet from radiator - r + r - 1016A40 ignition coil cover on cylinder head- r+r 1. Disconnect the fuel inlet and outlet pipes from the distribution manifold.2. Disconnect the fuel vapour recirculation pipe from the inlet chamber.3. Disconnect the electrical connection for the rpm and timing sensor.

	Name	Connector
3	Rpm sensor	K46

4. Disconnect the electrical connection for the detonation sensor.

	Name	Connector
4	Detonation sensor - 1	K50

5. Disconnect the electrical connection for the cam angle sensor.

	Name	Connector
5	Timing sensor	K47

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.

1. Disconnect the fuel supply pipe from the fuel distributor manifold.2. Disconnect the fuel vapour recirculation pipe coupling.3. Disconnect the electrical connection for the cam angle sensor.

	Name	Connector
3	Timing sensor	K47

1. Disconnect the coolant return pipe from the coolant reservoir from the thermostat.2. Disconnect the fuel system pipe from the water pump rigid inlet pipe.

- 1008C10 power unit upper reaction link r r - 5530B10 battery - r+r - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. 1. Undo the bolt and disconnect the oil vapour recirculation duct from the tappet cover.2. Disconnect the corrugated hose from the butterfly casing.3. Disconnect the accelerator cable from the throttle body4. Disconnect the electrical connection from the intake air temperature sensor.

	Name	Connector
4	Air temperature sensor	K42

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

	Name	Connector
5	Air flow meter	K41

- 1048A28 vacuum air circuit resonator pipe - r+r - 1048A10 air cleaner filtering element - replace 1. Disconnect the oil vapour recirculation pipe from the tappet cover.2. Disconnect the accelerator cable from the throttle body3. Disconnect the corrugated hose from the butterfly casing.4. Disconnect the electrical connection from the air flow meter.

	Name	Connector
4	Air flow meter	K41

1. Disconnect the electrical connection from the injection/ignition control unit.

	Name	Connector
1	Engine management ECU	M10

2. Disconnect the electrical connection for the dashboard wiring from the injection/ignition single/separable wiring.

	Name	Connector
2	Front/engine connection	D4

3. Disconnect the electrical connection for the Lambda sensor.

	Name	Connector
3	Lambda sensor	K40

4. Disconnect the electrical connection for the detonation sensor.

	Name	Connector
4	Detonation sensor - 1	K50

5. Disconnect the electrical connection for the rpm and timing sensor.

	Name	Connector
5	Rpm sensor	K46

Drain the brake-clutch fluid from the reservoir using a suitable syringe.1. Lift up the retaining spring (1a) and disconnect the coupling (1b) for the hydraulic clutch actuator connecting pipe.2. Disconnect the battery earth lead.

	Name	Connector
2	Battery earth	C1

1. Disconnect the electrical connection from the combined sender unit for the engine coolant temperature gauge and warning light.

	Name	Connector
1	Coolant temperature sender unit	K35

2. Disconnect the electrical connection from the engine coolant temperature sensor.

	Name	Connector
2	Engine temperature sensor	K45

3. Disconnect the coolant supply pipe to the radiator from the thermostat.4. Disconnect the supply pipes (4a) and return pipes (4b) to the climate control system heater from the thermostat and release them from the fixings.

1. Disconnect the coolant supply pipe to the radiator from the thermostat.2. Disconnect the supply pipes (2a) and return pipes (2b) to the climate control system heater from the thermostat and release them from the fixings.

1. Disconnect the vacuum pipe from the brake servo.

Drain the power steering fluid from the reservoir using a suitable syringe.Disconnect the power steering fluid reservoir return pipe.Undo the connector and disconnect the supply pipe for the power assisted steering box from the power assisted steering pump. - 1088E10 radiator cooling fan - r + r - 5040A10 Air conditioning refrigerant CIRCUIT - Draining and Refilling1. Undo the bolts and disconnect the coolant inlet and outlet pipes from the air conditioning compressor, then move them aside.

1. Disconnect the gear control and engagement cables from the support and rod idler.

Disconnect the electrical connections from the starter motor.

	Name	Connector
-	Starter' motor	A20

- 1076B50 exhaust pipe attachment to engine - r + r1. Undo the bolts for the driveshaft constant velocity joint flanges.

The bolts fixing the front driveshafts, intermediate driveshaft/differential internal driveshaft, are treated with eslok; therefore they should be replaced each time they are removed.

2. 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

Disconnect the front brake caliper flexible pipes and the A.B.S. active sensor cables from the mounting brackets.Move the left driveshaft as far away as possible from the differential and the right one away from the intermediate shaft.1. Position tools (1a) and (1b) 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.

- 1008A42 gear box left rigid mount - r r1. Undo the bolt fixing the timing side engine 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 and fix the power unit to 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 fixing the timing side engine support to the flexible mounting to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	ENGINE MOUNT TIMING SIDE	M12	7.5 - 9.2

- 1008A42 gear box left rigid mount - r r1. Tighten the bolt fixing the power unit rigid rear support to the flexible mounting to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	POWER UNIT RIGID REAR MOUNT	M12	7.5 - 9.2

Remove the tools used for the refitting from the power unit and return them to their place.Place the driveshafts back in their housings.Connect the front brake caliper flexible pipes and the A.B.S. active sensor cables to the mounting brackets.Connect the steering knuckles to the upper track control arms and fix them tightening the nut to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	FRONT HUB STEERING KNUCKLE.	M10	4.3 - 4.7

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

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	DRIVESHAFT CONSTANT VELOCITY JOINTS	M8	3.6 ÷ 4.4

- 1076B50 exhaust pipe attachment to engine - r + rConnect the electrical connections to the starter motor.Connect the gear control and engagement cables to the support and rod idler.Place the coolant inlet and outlet pipes back in their housings and connect them to the compressor tightening the appropriate bolts.

Check that the O-Rings are present.

- 1088E10 radiator cooling fan - r + rConect the power assisted steering box supply pipe connector to the power assisted steering pump and tighten it to torque.

	Fastening	Component	Ø	Value(daNm)
-	Connector	PIPE BTWN PUMP + POWER STEERING BOX	M16	3.8 - 4.2

Connect the vacuum pipe to the brake servo.Connect the climate control system heater supply and return pipes to the thermostat.Connect the coolant supply pipe to the radiator to the thermostat. Connect the electrical connection to the engine coolant temperature sensor.Connect the electrical connection to the combined sender unit for the coolant temperature gauge and overheating warning light. Connect the battery earth lead to the gearbox.Connect the connecting pipe coupling to the clutch hydraulic actuator. Place the corrugated hose, complete with air flow meter and intake air temperature sensor, back in its housing, then connect it to the air filter and to the butterfly casing.Connect the electrical connection to the air flow meter.Connect the electrical connection to the intake air temperature sensor.Connect the accelerator cable to the butterfly casing.Connect the oil vapour recirculation duct to the tappet cover and fix it using the bolt. Connect the electrical connection for the rpm and timing sensor.Connect the electrical connection for the detonation sensor.Connect the electrical connection for the Lambda sensor.Connect the electrical connection for the dashboard wiring to the injection/ignition single/separable wiring.Connect the electrical connection to the injection/ignition control unit.Place the corrugated hose, complete with air flow meter, back in its housing and connect it to the air filter and the butterfly casing.Connect the electrical connection to the air flow meter. Connect the accelerator cable to the throttle body integral with the M.D.S. and adjust it (refer to op. 1068A30 accelerator control cable - r + r ). Connect the oil vapour recirculation pipe to the tappet cover. - 1048A10 air cleaner filtering element - replace - 1048A28 vacuum air circuit resonator pipe - r+r - 1016A40 ignition coil cover on cylinder head- r+r - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. - 5530B10 battery - r+r - 1008C10 power unit upper reaction link r rConnect the fuel system pipe to the water pump rigid inlet pipe.Connect the coolant return pipe from the thermostat to the coolant reservoir. Connect the electrical connection for the cam angle sensor.Connect the electrical connection for the detonation sensor.Connect the electrical connection for the rpm and timing sensor.Connect the fuel vapour recirculation pipe to the inlet chamber.Connect the fuel inlet and outlet pipe from the fuel distributor manifold. Connect the electrical connection for the cam angle sensor.Connect the coupling for the fuel vapour recirculation pipe.Connect the fuel supply pipe to the fuel distribution manifold. - 1088D10 lower sleeve for coolant outlet from radiator - r + r - 7055B54 under-engine guard - r r - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. - 4450B12 front or rear wheels (two) - r+r - 1820B08 Clutch release HYDRAULIC SYSTEM - Bleeding air and restoring level - 5040A10 Air conditioning refrigerant CIRCUIT - Draining and RefillingConnect the battery terminal (-).Fill the power steering circuit with the recommended fluid.

	Type	Component	Name	Qty.
-	Fluid	POWER ASSISTED STEERING CIRCUIT	TUTELA GI/A	-

Bleed the power steerign system as described below.With the front wheels raised off the ground, with the engine switched off, carry out 4-5 complete steering wheel rotation cycles (left and right).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 rotations (right and left).Top up the fluid level in the reservoir.