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

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.

Removing ( Refitting

) Position the vehicle on the ramp. - 5530B10 battery - r+r - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. - 4450B10 Front WHEEL (one) - R.R. - 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R. - 7055A43 central front grille - r r - 7055B10 Front BUMPER - R.R. - 5040A10 Air conditioning refrigerant CIRCUIT - Draining and RefillingDrain the power steering fluid from the reservoir using a suitable syringe.Raise the car.1. Disconnect the lower coolant outlet hose from the radiator and drain the engine coolant.

Recover the coolant using a suitable container.

2. Disconnect the lower radiator coolant outlet hose from the pump rigid coolant inlet pipe and remove it.3. Disconnect the system supply pipe from the water pump rigid inlet pipe.

- 1048A50 air inlet pipe to turbo charger - r + r1. Disconnect the coolant outlet hose from the thermostat.

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

	Name	Connector
1	Air flow meter	K41

2. Remove the air filter complete with air flow meter.

1. Disconnect and remove the air supply hose from the heat exchanger to the inlet manifold.2. Disconnect the brake servo vacuum intake pipe from the vacuum pump.

1. Disconnect the fuel supply pipe from the filter.2. Disconnect the fuel return pipe to the tank from the fuel return manifold pipe.3. Disconnect the electrical connection from the supercharging sensor.

	Name	Connector
3	Turbocharging sensor	K82

4. Disconnect the electrical connection from the pressure regulator on the pressure pump.

	Name	Connector
4	Fuel pressure regulator	N77

5. Disconnect the electrical connection from the fuel pressure sensor.

	Name	Connector
5	Fuel pressure sensor	K83

6. Disconnect the electrical connection from the fuel temperature sensor.

	Name	Connector
6	Fuel temperature sensor	K81

1. Undo nuts (1a) and move fuel filter assembly (1b) away from the intake manifold.2. Undo nuts (2a) and move oil vapour separator (2b) away from the intake manifold.3. Undo the bolts (3a) and move the coolant rigid return pipe (3b) to the engine cooling system reservoir away.4. Disconnect the electrical connections from the heater plugs.

	Name	Connector
4	Heater plug	A40

5. Disconnect the electrical connections from the injectors, then move the wiring to the side.

	Name	Connector
5	Injector	N70

Place the oil vapour separator back in its housing and fix it to the inlet manifold using the nuts.Place the fuel filter back in its housing and fix it to the inlet manifold using the nuts.1. Disconnect the vacuum intake pipe from the EGR valve.2. Disconnect the vacuum intake pipe from the E.G.R. solenoid valve and remove it.3. Disconnect the timing sensor electrical connection.

	Name	Connector
3	Timing sensor	K47

4. Disconnect the electrical connection from the E.G.R. valve.

	Name	Connector
4	EGR solenoid	L30

5. Disconnect the electrical connections from the pre-heating control unit.

	Name	Connector
5	Plug preheating control unit	M15

1. Disconnect the starter motor electrical connection.

	Name	Connector
1	Starter' motor	A20

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

	Name	Connector
2	Reversing lights switch	I20

3. Disconnect the electrical connection from the engine temperature sensor.

	Name	Connector
3	Engine temperature sensor	K45

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

	Name	Connector
4	Coolant temperature sender unit	K35

5. Disconnect the coolant supply pipe to the climate control system heater from the thermostat.6. Disconnect the return pipe from the climate control system heater from the water pump rigid inlet pipe.

1. Undo the bolt (1a), remove the circlip (1b), then remove the operating cylinder (1c), complete with pipe, and move it sideways.

1. Disconnect the gear engagement/selector cables.2. Undo the bolts (2a) and move the mounting bracket (2b), complete with gear selector/engagement cables.

1. Undo the bolts (1a) and remove the power unit reaction rod (1b).2. Disconnect the electrical connection for the rpm sensor.

	Name	Connector
2	Rpm sensor	K46

3. Disconnect the coolant supply pipe to the engine coolant reservoir from the rigid pipe.4. Disconnect the fluid supply pipe from the power assisted steering pump.5. Disconnect the fluid supply pipe from the power assisted steering pump.

1. Undo the bolts fixing the right driveshaft.

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.

2. Release the A.B.S. sensor cable and the brake fluid pipe for the right front brake caliper from the bands.3. Undo the nut (3a) and disconnect the steering knuckle (3b) from the upper track control arm using the tool (3c).

	Name	Country
3c	Extractor	1.821.169.000

Move the right driveshaft away from the intermediate shaft.

Move the left driveshaft away from the differential, following the instructions for the right one.1. Disconnect the electrical connections from the air conditioning compressor.2. Undo the bolts (2a) and disconnect the coolant inlet and outlet pipes (2b) from the air conditioning compressor.

- 1076B50 exhaust pipe attachment to engine - r + r1. Disconnect and remove the air supply hose between the turbocharger and the air/air heat exchanger.2. Release the air conditioning system pipes from the fixings on the radiator lower crossmember.3. Undo the bolts and disconnect the intermediate couplings for the air conditioning system pipes.

1. Undo the bolts (1a) and disconnect the coolant inlet and outlet pipes (1b) from the air conditioning system condenser.2. Disconnect the electrical connection from the four stage pressure switch.

	Name	Connector
2	4 stage pressure switch	K10

1. Remove the coolant inlet and outlet pipes for the air conditioning system compressor.2. Undo the fixings and remove the drier filter, complete with mounting bracket and pipes.

Disconnect the electrical connections from the cooling fans.1. Disconnect the power assisted steering system fluid cooling pipe from the bands on the radiator lower crossmember.

1. Position a hydraulic jack under the radiator lower crossmember.2. Undo the bolts (2a) and remove the radiator lower crossmember (2b), complete with radiator, condenser and cooling fans.

1. Undo the bolts (1a) and remove the air duct (1b) for the supercharging air/air heat exchanger.2. Undo the bolts (2a) and remove the supercharging air/air heat exchanger (2b).3. Remove the air filter cold air intake.

1. Undo the nut (1a) and disconnect the earth lead (1b) from the gearbox.2. Position a hydraulic jack under the gearbox.3. Undo the bolts (3a) and remove the gearbox side power unit rigid support (3b).4. Fit the tool.

	Name	Country
4	Mount	1.870.644.001

Remove the hydraulic jack positioned under the gearbox.

1. Position tools 1a, 1b, 1c for removing the power unit on the hydraulic jack.

	Name	Country
1a	Crossmember	1.820.225.000

	Name	Country
1b	Adaptors	1.860.910.002

	Name	Country
1c	Mount	1.870.644.000

1. Position the tool for removing the power unit, assembled in this way, under the power unit and fix it to the tool fitted previously.2. Undo the bolts (2a) and remove the power unit intermediate support (2b).3. Recover the rigid support for the exhaust pipe.4. Undo the bolt fixing the timing side rigid power unit support to the flexible mounting.

Lower the hydraulic jack and remove the power unit from the engine compartment.1. Secure and support the power unit (1a) using a hydraulic hoist, then releaseit from the tools (1b) used for the removal.

Refitting ( Removing

) Using a hydraulic hoist, position and fix the power unit to the tools to be used for refitting.1. Place the power unit back in the engine compartment using the hydraulic jack.2. Tighten the bolt securing the timing side power unit rigid support to the flexible mounting.

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

3. Fit the power unit intermediate support (3a), complete with rigid support for the exhaust pipe (3b), and fix it tightening the bolts (3c) and (3d) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3c	Bolt	GEARBOX SIDE RUBBER MOUNT	M8	2.7 - 3.4

	Fastening	Component	Ø	Value(daNm)
3d	Bolt	POWER UNIT RIGID REAR MOUNT	M12	7.5 - 9.2

	Fastening	Component	Ø	Value(daNm)
3d	Bolt	POWER UNIT RIGID REAR MOUNT	M16	10.2 - 12.6

Remove the tools used for the refitting from the power unit and return them to their place.1. Position a hydraulic jack under the gearbox.2. Fit the gearbox side power unit rigid support (2a) and fix it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10	4.2 ÷ 5.1

Remove the hydraulic jack positioned under the gearbox.Connect the earth lead to the gearbox and fix it using the nut.

Fit the air filter cold air intake.Fit the supercharging air/air heat exchanger and fix it using the bolts.Fit the supercharging air/air heat exchanger air duct and fix it using the bolts.Using a hydraulic jack, fit the radiator lower crossmember, complete with radiator, condenser and cooling fans and fix it using the bolts.Connect the power assisted steering system fluid cooling pipe to the radiator lower crossmember bands.Connect the electrical connections to the cooling fans.Fit the drier filter, complete with mounting bracket and pipes, and fix it using the bolts.Fit the coolant inlet and outlet pipes from the air conditioning system compressor.Connect the electrical connection to the four stage pressure switch.Connect the coolant fluid inlet and outlet pipes to the air conditioning system condenser and fix them using the bolts.Connect the intermediate couplings for the air conditioning system pipes and fix them using the bolts.Fix the air conditioning system pipes to the bands on the radiator lower crossmember.Fit the air supply hose between the turbocharger and the air/air heat exchanger. - 1076B50 exhaust pipe attachment to engine - r + rConnect the coolant inlet and outlet pipes to the air conditioning compressor and fix them using the bolt.Connect the electrical connection for the air conditioning compressor.Move the right driveshaft closer to the differential.Connect the steering knuckle to the upper track control arm and fix it tightening the nut to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	FRONT SUSPENSION TOP LEVER	M10	(Wheel damper side) 4.3 - 4.7

Fix the A.B.S. sensor cable and the brake fluid pipe for the right front brake caliper to the bands.Tighten the new bolts fixing the right driveshaft to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M8	(Intermediate driveshaft side) 3.6 ÷ 4.4

Connect the left driveshaft to the differential, following the instructions for the right one.Connect the fluid supply pipe to the power assisted steering pump and tighten it to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Connector	PIPE BTWN PUMP + POWER STEERING BOX	M18	3.8 - 4.2

Connect the fluid supply pipe to the power assisted steering pump.Connect the coolant supply pipe to the engine coolant reservoir to the rigid pipe.Connect the electrical connection for the rpm and timing sensor.Fit the reaction rod for the power unit and fix it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	REACTION ROD	M10	4.2 ÷ 5.1

Fit the mounting bracket complete with gear selector/engagement cables and fix it using the bolts.Connect the gear engagement/selector cables.Place the operating cylinder, complete with pipe, back in its housing and fix it using the circlip and the bolt.Connect the return pipe from the climate control system heater to the water pump rigid inlet pipe.Connect the coolant supply pipe to the climate control system heater to the thermostat.Connect the electrical connection to the combined sender unit for the coolant temperature gauge and overheating warning light.Connect the electrical connection to the engine temperature senor.Connect the electrical connection for the reversing lights switch.Connect the electrical connection for the starter motor.Connect the electrical connections to the pre-heating control unit.Connect the electrical connection to the EGR solenoid. Connect the timing sensor electrical connection.Fit the vacuum intake pipe and connect it to the E.G.R. solenoid valve and the E.G.R. valve.Undo the nuts and move the fuel filter away from the inlet manifold.Undo the nuts and move the oil vapour separator away from the inlet manifold.Position the electrical wiring and connect the electrical connections to the injectors.Connect the electrical connections to the heater plugs.Place the coolant rigid return pipe to the engine cooling system reservoir back in its housing and fix it using the bolts.Place the oil vapour separator back in its housing and fix it to the inlet manifold using the nuts.Place the fuel filter back in its housing and fix it to the inlet manifold using the nuts.Connect the electrical connection to the fuel temperature sensor.Connect the electrical connection to the fuel pressure sensor.Connect the electrical connection to the pressure regulator to the pressure pump.Connect the electrical connection to the supercharging sensor.Connect the fuel return pipe to the tank to the fuel return pipe.Connect the fuel supply pipe to the filter.Connect the brake servo vacuum intake pipe to the vacuum pump.Fit the air supply hose from the heat exchanger to the inlet manifold.Fit the air filter complete with air flow meter.Connect the electrical connection to the air flow meter.Connect the coolant outlet hose to the thermostat. - 1048A50 air inlet pipe to turbo charger - r + rConnect the system supply pipe to the water pump rigid inlet pipe.Fit the coolant lower outlet hose from the radiator to the water pump rigid inlet pipe.Supply the engine cooling system with the recommended fluid.

	Type	Component	Name	Qty.
-	Fluid [l]	ENGINE COOLING CIRCUIT	Mixture 50% Paraflu11 for Alfa Romeo/distilled water	6.8

- 5040A10 Air conditioning refrigerant CIRCUIT - Draining and Refilling - 7055B10 Front BUMPER - R.R. - 7055A43 central front grille - r r - 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R. - 4450B10 Front WHEEL (one) - R.R. - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. - 5530B10 battery - r+rFill the power steering circuit with the recommended fluid.

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

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.