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. Proceed with removal - 1016A10 sound-proofing cover - r + r . Drain the air conditioner coolant circuit - 0010T84 coolant for air conditioning system dehydrate and recharge . Proceed with removal - 4450B12 front or rear wheels (two) - r+r . Proceed with removal - 7055B54 under-engine guard - r r . Proceed with removal - 7055A43 central front grille - r r . Proceed with removal - 7055A41 RIGHT FRONT GRILLE - R.R. . Proceed with removal - 7210E10 R.R. FRONT BUMPER . Proceed with removal - 1084C40 Air DUCT for engine oil cooling radiator - R.R . . 1. Undo the bolt (1a) and disconnect the cooling radiator engine oil supply pipe (1b), engine oil filter mounting side. 2. Undo the bolt (2a) and disconnect the cooling radiator engine oil return pipe (2b), engine oil filter mounting side.

Collect the engine oil which comes out in a suitable container.

1. Undo the nuts (1a) and remove the engine oil cooling radiator (1b) complete with pipes (1c).

1. Undo the nut (1a) and move the bracket (1b) complete with power assisted steering system heat exchanger pipe (1c) aside.

Proceed with removal - 5530B10 battery - r+r . Proceed with removal - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. . 1. Loosen the band and disconnect the lower radiator coolant outlet hose from the radiator, water pump rigid inlet pipe end.

Recover the coolant using a suitable container.

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

1. Loosen the 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.

Proceed with removal - 1048A50 air inlet pipe to turbo charger - r + r . 1. Loosen the band and disconnect the coolant outlet pipe from the climate control heater, water pump rigid inlet pipe side.

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

1. Loosen the band and disconnect the air intake hose from the connector on the throttle casing.

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

	Name	Connector
1	Air flow meter	K41

2. Release earth lead (2a) from collar (2b) on the air cleaner.

1. Loosen the bands (1a) and remove the air supply hose between the turbocharger and the heat exchanger (1b). 2. Disconnect the cold air intake from the air filter.

1. Loosen the band and disconnect the the turbocharger air inlet hose from the rigid pipe, turbocharger side.2. Loosen the band and disconnect the oil vapour recirculation pipe from the turbocharger air intake hose.

1. Move the air cleaner assembly aside as far as necessary, then unscrew the lower bolts securing the resonator device to the air cleaner.2. Working from beneath the car, remove the air filter (2a), complete with air flow meter (2b) and sleeve (2c).3. Remove lower resonator device (3a) complete with sleeves(3b).

1. Disconnect the single-acting valve for the vacuum pipe from the brake servo.

Remove the protective cap on the master cylinder bleed valve. Connect the collection system (pipe and reservoir) to the bleed valve on the master cylinder. Operate the clutch pedal until the brake-clutch fluid reservoir is empty. 1. Undo the connector (1a) and disconnect the pipe from the vibration damper to the operating cylinder (1b), operating cylinder side and release it from the band (1c).2. Disconnect the electrical connection from the reversing lights switch.

	Name	Connector
2	Reversing lights switch	I20

1. Disconnect the gear selector and engagement cables2. Undo the nuts (2a) and move the mounting brackets (2b) complete with gear selector and engagement cables aside.

1. Undo the nut (1a) and lift up the heater plugs control unit (1b) as much as necessary.2. Disconnect the electrical connection from the pre-heating control unit.

	Name	Connector
2	Plug preheating control unit	M15

1. Disconnect the rapid attachment for the fuel return pipe to the tank, fuel return manifold pipe side. 2. Disconnect the rapid attachment for the fuel return pipe from the fuel filter, return manifold pipe side. 3. Disconnect the quick-release connector for the fuel supply pipe to the pressure pump, fuel filter side.

1. Undo the bolts (1a) and remove the power unit reaction rod (1b).

1. Disconnect the electrical connections (1a) and (1b) from the diesel electronic injection system control unit.

	Name	Connector
1a	Engine management ECU	M10A

	Name	Connector
1b	Engine management ECU	M10B

1. Undo the nuts (1a) and remove the diesel electronic injection system control unit (1b) complete with slides (1c).

Remove the power steering fluid reservoir cap and drain the fluid using a suitable syringe.Refit the brake fluid reservoir cap.1. Disconnect the rapid connector for the supply pipe from the fluid reservoir to the power assisted steering pump, reservoir side.

1. Undo the connector (1a) and disconnect the delivery pipe from pump to power steering box (1b), steering box side. 2. Release the supply pipe from the pump to the steering box from the retaining band on the power steering box.

1. Undo the bolt (1a) and disconnect the flange for the coolant inlet and outlet pipes (1b) from the air conditioner compressor. 2. Undo the nut (2a) and disconnect the intermediate coupling for the pipe from the air conditioning compressor to the evaporator (2b).

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

1. Undo the bolts (1a) and disconnect the coolant inlet and outlet pipes (1b) from the air conditioner condenser.

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

1. Undo the upper bolt fixing the engine cooling radiator to the upper crossmember. 2. Disconnect the electrical connections from the engine fan motors.

	Name	Connector
2	Engine fan motor - 1	N11

	Name	Connector
2	Engine fan motor - 2	N12

3. Disconnect the electrical connections from the resistors for the engine cooling fans and move the electrical wiring aside.

	Name	Connector
3	Engine fan adjustment resistor - 1	O10

	Name	Connector
3	Engine fan adjustment resistor - 2	O12

4. Disconnect the pipes from the solenoid valve for the turbocharger vanes actuator.Disconnect the control pipe from turbocharger vane position actuator.

1. Disconnect the earth lead from the gearbox.

	Name	Connector
1	Battery earth	C1

1. Position a hydraulic jack under the radiator lower crossmember. 2. Undo the bolts securing the radiator bottom crossmember to the bodywork. 3. Lower the hydraulic jack and remove the lower radiator crossmember (3a), the climate control system condenser (3b), the engine cooling radiator (3c) and the fans (3d).

1. Unscrew the bolts securing the drive shafts to the internal differential/drive shaft. 2. Release the front brake caliper hoses, the electrical wiring for the brake pad sensor and the electrical wiring for the wheel rpm sensors (A.B.S.) from the fastenings.

1. Undo the nuts (1a) and disconnect the front wishbones (1b) from the vertical links with the tool (1c).

	Name	Country
1c	Extractor	1.821.169.000

Move the drive shafts away from the differential internal drive shaft/intermediate drive shaft.

Proceed with removal - 1076B70 exhaust pipe between pre-catalytic converter and catalytic converter - r r . Proceed with removal - 1008A44 rear rigid mount - r r . Position a suitable support under the power unit.1. Fit the bracket (1a) and fasten it using the bolt (1b) as indicated in the diagram to the bracket on the engine for the reaction rod.2. Fit the bracket (2a) and fasten to the gearbox it using the bolt (2b) as illustrated in the diagram. 3. Support the power unit using a hydraulic hoist (3a), fitted with suitable chains (3b) connected to the brackets fitted previously and to the bracket (3c) already on the gearbox.

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

1. Undo the bolt fixing the power unit gearbox side rigid support to the flexible mounting.

Slowly lower the power unit with the hydraulic hoist until it is resting on the support positioned previously.

Take great care when removing the power unit not to damage the components fitted on the vehicle and, in particular, check that the gearbox-differential unit does not impact against the A.B.S. unit.

Refitting ( Removing

) Place the power unit back in the engine compartment using the hydraulic hoist. 1. Tighten the bolt fixing the power unit gearbox side rigid support to the flexible mounting.

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

1. Tighten the bolt securing timing side rigid engine 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

Remove the hydraulic hoist fitted with suitable chains for supporting the power unit. Remove the brackets fitted for supporting the power unit.Remove the support positioned previously under the power unit. Proceed with refitting - 1008A44 rear rigid mount - r r . Proceed with refitting - 1076B70 exhaust pipe between pre-catalytic converter and catalytic converter - r r . Refit the drive shafts in their seating in contact with the internal differential drive shaft/intermediate drive shaft.1. Connect the front upper track control arms (1a) to the steering knuckles and tighten the nuts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	FRONT SUSPENSION TOP LEVER	M10	(Steering knuckle side) 4.3 ÷ 4.7

1. Tighten the bolts securing the drive shafts to the differential internal drive shaft/intermediate drive shaft to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	DRIVESHAFT	M8	(Differential internal driveshaft side) 3.6 ÷ 4.4

	Fastening	Component	Ø	Value(daNm)
1	Bolt	DRIVESHAFT	M10	(Intermediate driveshaft side) 5.8 ÷ 7.0

2. Secure the front brake hoses, brake pad wear wiring and ABS inductive sensor wiring.

Place the lower radiator crossmember, complete with climate control system condenser, engine cooling radiator and fans, back in its housing using the hydraulic jack.Tighten the bolts securing the radiator bottom crossmember to the bodywork.Remove the hydraulic jack from underneath the lower radiator crossmember.Connect the earth lead to the gearbox.Connect the control pipe to the turbocharger vane position actuator.Connect the pipes to the solenoid valve for the turbocharger vanes actuator.Connect the electrical connections to the engine cooling fan resistors and move the electrical wiring aside.Connect the electrical connections to the engine fan motors. Tighten the upper bolt fastening the engine cooling radiator to the upper crossmember.1. Connect the coolant inlet and outlet pipes (1a) from the air conditioning condenser and tighten the bolts (1b) to the recommended torque.

Replace the O-rings for the connectors using green coloured seals only, resistant to R134a refrigerant fluid. Lubricate the thread of the connectors using anti-freeze.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	COOLANT SYSTEM FITTINGS	M6	0.7 ÷ 1.1

1. Connect the intermediate coupling for the pipe from the air conditioning compressor to the evaporator (1a) and tighten the nut (1b) to the recommended torque.

Replace the O-rings for the connectors using green coloured seals only, resistant to R134a refrigerant fluid. Lubricate the thread of the connectors using anti-freeze.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	COOLANT SYSTEM FITTINGS	M6	0.7 ÷ 1.1

2. Connect the flange for the coolant inlet and outlet pipes (2a) to the air conditioning compressor and tighten the bolt (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	COOLANT SYSTEM FITTINGS	M10	(Compressor side) 3.2 ÷ 3.9

1. Secure the supply pipe from the pump to the steering box to the retaining band on the power steering box. 2. Connect the supply pipe from the pump to the power assisted steering box (2a), power assisted steering box side, and tighten the connector (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Connector	PIPE BTWN PUMP + POWER STEERING BOX	M14	(Power assisted steering box side) 3.6 ÷ 4.4

Connect the rapid connector for the supply pipe from the power steering fluid reservoir to the pump, reservoir side. Place the diesel electronic injection control unit complete with slides back in its housing with its bracket and secure it using the nuts. Connect the electrical connections to the diesel electronic injection control unit. 1. Place the power unit reaction rod (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	REACTION ROD	M10	4.5 ÷ 5.5

Connect the quick-release connector for the fuel supply pipe to the pressure pump, fuel filter side. Connect the rapid attachment for the fuel return pipe from the fuel filter, return manifold pipe side. Connect the rapid attachment for the fuel return pipe to the tank, fuel return manifold pipe side. Connect the electrical connection to the pre-heating control unit.Place the plug preheating control unit back in its housing and secure with the relevant nut.Place the gear selector and engagement cables mounting bracket back in its housing and secure it.Connect the gear selector and engagement cables.Connect the electrical connection to the reversing lights switch. Connect the pipe from the vibration damper to the operating cylinder, operating cylinder side and tighten the connector to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Connector	HOSE FROM VIBRATION DAMPER	M12	(Operating cylinder side) 1.4 ÷ 2.2

Fasten the pipe from the vibration damper to the operating cylinder using the band.Connect the vacuum pipe single-acting valve to the brake servo.Refit the lower resonator with sleeves.Replace the air filter, complete with air flow meter and sleeve, in its housing.Tighten the lower bolts securing the resonator to the air cleaner.Connect the oil vapour recirculation pipe, air inlet hose side, to the turbocharger and tighten the band.Connect the air intake sleeve to the rigid sleeve, turbocharger side, and tighten the band.Connect the cold air intake to the air filter.Refit in its seating the air supply duct between turbocharger and heat exchanger and tighten the bands. Secure the earth lead to the collar on the air cleaner.Connect the electrical connection to the air flow meter.Connect the air inlet hose to the connector on the throttle casing and tighten the band. Connect the flexible pipe to the coolant return pipe to the engine coolant reservoir and tighten the band. Connect the coolant outlet hose from the climate control system heater on the side of the rigid inlet pipe to the water pump. Proceed with refitting - 1048A50 air inlet pipe to turbo charger - r + r . 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 system supply pipe to the water pump rigid inlet pipe and tighten the band. Connect the lower radiator coolant outlet hose to the water pump rigid inlet pipe and tighten the band. Proceed with refitting - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. . Proceed with refitting - 5530B10 battery - r+r . Place the bracket complete with power assisted steering system heat exchanger pipe back in its housing and fasten it using the nut.Place the engine oil cooling radiator complete with pipes back in its housing and fix it using the nuts. Connect the engine oil return pipe from the cooling radiator, engine oil filter mounting side, and tighten the bolt. Connect the engine oil supply pipe to the cooling radiator, engine oil filter mounting side, and tighten the bolt. Proceed with refitting - 1084C40 Air DUCT for engine oil cooling radiator - R.R . . Proceed with refitting - 7210E10 R.R. FRONT BUMPER . Proceed with refitting - 7055A41 RIGHT FRONT GRILLE - R.R. . Proceed with refitting - 7055A43 central front grille - r r . Proceed with refitting - 7055B54 under-engine guard - r r . Proceed with refitting - 4450B12 front or rear wheels (two) - r+r . Refill the engine oil lubrication system - 0010T11 engine oil check level and top up . Refill the engine cooling system with coolant - 0010T20 coolant change . Proceed with refitting - 0010T67 hydraulic clutch system bleed air . Fill the air conditioner coolant circuit - 0010T84 coolant for air conditioning system dehydrate and recharge . Refill the power assisted steering circuit using the recommended fluid.

	Type	Component	Name	Qty.
-	Oli [l]	POWER ASSISTED STEERING CIRCUIT	TUTELA GI/A	1.3

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

The table shows the total quantity of fluid present in the power assisted steering circuit.

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. Remove the car from the ramps.Start the engine and turn the steering wheel to full lock, left and right, 4 - 5 times.Top up the fluid level in the reservoir. Proceed with refitting - 1016A10 sound-proofing cover - r + r .