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 rDrain the coolant. - 5040A10 Air conditioning refrigerant CIRCUIT - Draining and Refilling - 7055B10 Front BUMPER - R.R. - 1088D10 lower sleeve for coolant outlet from radiator - r + r - 1088D14 upper sleeve for coolant inlet to radiator - r + r - 1088B24 engine cooling radiator - r r for air conditioned versionsDrain the power steering fluid from the reservoir using a suitable syringe.1. Working from the passenger compartment, undo the bolts (1a) and remove the injection-ignition guard (1b).

1. Disconnect the electrical connections from the injection-ignition electronic control unit.

Follow the disconnection order: D - E - F - C - B - A.

	Name	Connector
1	Engine management ECU	M10

1. Disconnect the electrical connection from the fuel vapour cut-out solenoid valve from the filter.

	Name	Connector
1	Fuel vapour recovery solenoid	L10

1. Undo bolts (1a) and remove the right windscreen base trim (1b) after disconnecting from the washer spray pipe.

1. Undo the bolts (1a) for the wiring (1b) to the engine compartment bulkhead, then remove it and fix it temporarily to the engine.

- 1048A34 sleeve(s) from flow meter to air supply capacity case - r + r - 5530B10 battery - r+r - 5530B52 Battery DRIP TRAY/SUPPORT - R.R.1. Disconnect the electrical connection from the air flow meter.

	Name	Connector
1	Air flow meter	K41

2. Undo the bolts (2a) and remove the air filter cover (2b) complete with air flow meter (2c).

- 1008C10 power unit upper reaction link r r1. Undo the nuts (1a) and disconnect the positive battery terminal (1b) from the leads (1c).

1. Disconnect the coolant return pipe from the engine coolant tank.2. Disconnect the supply system pipe from the engine coolant reservoir.

1. Disconnect the fuel/oil vapour recirculation pipe from the air chamber.2. Disconnect the vacuum intake pipe from the air chamber.

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

	Name	Connector
1a	Front/engine connection	D4A

	Name	Connector
1b	Front/engine connection	D4B

1. Disconnect the coolant supply and return pipes to the climate control system heater.

1. Disconnect the gear selector and engagement cables from the gearbox.

1. Disconnect the coolant inlet and outlet pipes from the compressor.2. Disconnect the fluid inlet and outlet pipes from the power assisted steering pump.

1. Undo the bolts (1a) and move the clutch operating cylinder (1b), complete with bracket (1c), aside without disconnecting the pipe (1d).

1. Disconnect the electrical connection from the reversing lights switch.

	Name	Connector
1	Reversing lights switch	I20

1. Undo the bolt (1a) and move the drier filter/accumulator (1b).

1. Release the power assisted steering heat exchanger pipe from the bands on the radiator lower crossmember.

- 1076B52 exhaust pipe (one) leaving l/h or r/h exhaust manifold - r + r1. Disconnect the power assisted steering pump fluid supply and return pipes (1a) from the fixings (1b) on the crankcase sump and the engine support.

1. Undo the bolts (1a) and disconnect the right driveshaft (1b) from the intermediate shaft.

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.

1. Undo the bolts (1a) and disconnect the left driveshaft (1b) from the differential inner shaft.

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.

- 1008A44 rear rigid mount - r r1. Fit the tools (1a), (1b), (1c), (1d) for removing the power unit on the hydraulic jack and fix it to the power unit.

	Name	Country
1a	Mount	1.870.644.000

	Name	Country
1b	Mount	1.870.644.001

	Name	Country
1c	Adaptor	1.860.910.001

	Name	Country
1d	Crossmember	1.820.225.000

- 1008A42 gear box left rigid mount - r r - 1008A46 cam shaft left rigid mount - r rLower the hydraulic jack slowly and remove the power unit from the engine compartment.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 the tools to be used for the refitting.Place the power unit back in the engine compartment using the hydraulic jack. - 1008A46 cam shaft left rigid mount - r r - 1008A42 gear box left rigid mount - r rRemove the tools used for the refitting from the power unit and return them to their place. - 1008A44 rear rigid mount - r r1. Connect the left driveshaft (1a) to the differential inner shaft and fix it tightening the new bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M10	5.0 ÷ 6.1

1. Connect the right driveshaft (1a) to the intermediate shaft and fix it tightening the new bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M10	5.0 ÷ 6.1

Fix the power assisted steering pump fluid supply and return pipes to the fixings on the crankcase sump and the engine support. - 1076B52 exhaust pipe (one) leaving l/h or r/h exhaust manifold - r + rFix the power assisted steering heat exchanger pipe using the bands to the radiator lower crossmember.Place the drier filter/accumulator in its housing and fix it to the bodyshell using the bolt.Connect the electrical connection to the reversing lights switch.1. Place the clutch operating cylinder (1a), complete with mounting bracket (1b), back in its housing and fix it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	CLUTCH SLAVE CYLINDER	M8	1.4

Connect the fluid inlet and outlet pipes to the power assisted steering pump.Connect the coolant inlet and outlet pipes to the compressor. Connect the gear selector and engagement cables to the gearbox as described in op. 2110C50 gear selection and engagement unit - r r . Conect the coolant supply and return pipes to the climate control system heater.Connect the engine wiring electrical connections.Connect the brake servo vacuum intake pipe to the air chamber.Connect the fuel vapour recirculation pipe to the air chamber.Connect the supply system pipe to the engine coolant reservoir.Connect the coolant return pipe to the engine coolant tank.Connect the leads to the positive battery terminal and fix them using the nuts. - 1008C10 power unit upper reaction link r rFit the air filter cover complete with air flow meter and fix it using the bolts.Connect the electrical connection to the air flow meter. - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. - 5530B10 battery - r+r - 1048A34 sleeve(s) from flow meter to air supply capacity case - r + rPlace the engine wiring back in its housing and pass it through the special opening in the engine compartment bulkhead, then fix it using the bolts.Connect the windscreen base trim to the windscreen washer spray pipe, then fit and secure using the bolts.Connect the electrical connection to the fuel vapour cut-out solenoid valve.Connect the electrical connections to the injection-ignition control unit.

Follow the connection order: A - B - C - F - E - D.

Fit the injection-ignition control unit protection and bolt in place. - 1088B24 engine cooling radiator - r r for air conditioned versions - 1088D14 upper sleeve for coolant inlet to radiator - r + r - 1088D10 lower sleeve for coolant outlet from radiator - r + r - 7055B10 Front BUMPER - R.R. - 5040A10 Air conditioning refrigerant CIRCUIT - Draining and Refilling - 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+rConnect 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.

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

- 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 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.

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 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.