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

125000864 - 1004B10 POWER UNIT WITH MANUAL GEARBOX - R + R

) Position the vehicle on a lift.Proceed with removal - 1016A10 SOUNDPROOFING COVER - R&R. .Drain the air conditioning refrigerant circuit Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE.Proceed with the removal Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R.Proceed with the removal Op. 7055B54 UNDER-ENGINE GUARD - R R.Proceed with the removal Op. 7055B64 LH OR RH REFLECTOR(ONE) ON REAR BUMPERS - R R.Proceed with the removal Op. 7055B42 LH OR RH REFLECTOR(ONE) ON REAR BUMPERS - R R.Proceed with the removal Op. 7210E10 R.R. FRONT BUMPER.Proceed with the removal Op. 1084C40 CONVOGLIATORE ARIA PER RADIATORE RAFFREDDAMENTO OLIO MOTORE - S.R..1. Undo the bolt (1a) and disconnect the engine oil supply pipe to the cooling radiator (1b), engine oil filter mounting side.2. Undo the bolt (2a) and disconnect the engine oil return pipe from the cooling radiator (2b), engine oil filter mounting side.

Collect the engine oil that 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 bolt (1a) and move the bracket (1b) to the side complete with power assisted steering system heat exchanger pipe (1c).

Proceed with the removal Op. 5530B10 BATTERY - R+R.Proceed with the removal Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R..1. Loosen the band and disconnect the lower coolant inlet hose from the radiator, water pump rigid coolant inlet pipe side.

Collect the coolant in a suitable container.

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

1. Loosen the band and disconnect the upper radiator coolant inlet hose, thermostat side.2. Loosen the band and disconnect the climate control system heater coolant supply pipe, thermostat side.

1. Loosen the band and disconnect the coolant outlet pipe from the climate control system heater, water pump rigid inlet pipe side.

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

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

1. Undo the bolts (1a) and move the bracket (1b) complete with turbocharger vane position actuator solenoid valve (1c) away from the air filter.

1. Undo the bolt fixing the cold air intake to the upper radiator crossmember.

1. Loosen the band (1a) and remove the cold air intake (1b).

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

	Description	Connector
1	Air flow meter	Vedere K41 MISURATORE PORTATA ARIA ( ANTERIORE )

2. Loosen the band securing the corrugated hose to the air flow meter.

1. Disconnect the electrical connections for the engine cooling fan resistor.

	Description	Connector
1	Engine fan adjustment resistance	See O10 ENGINE FAN ADJUSTMENT RESISTOR - 1

2. Disconnect the electrical connection from the engine fan motor and move the electrical wiring sideways.

	Description	Connector
2	Engine fan motor	See N11 ENGINE FAN MOTOR - 1

1. Remove the air filter (1a) complete with air flow meter (1b).

1. Disconnect the rapid connector for the brake servo vacuum pipe.

Remove the protective cap from the bleed valve on the clutch operating cyliner.Connect the recovery device (pipe and reservoir) to the bleed valve on the operating cylinder.Operate the clutch pedal until the brake/clutch reservoir is drained.1. Undo the connector (1a) and disconnect the pipe from the vibration damper to the clutch operating cylinder (1b), operating cylinder side.2. Disconnect the electrical connection from the reversing light switch.

	Description	Connector
2	Reversing lights switch	See I20 REVERSING LIGHTS SWITCH

1. Disconnect the gear selector and engagement cables.2. Undo the fastenings and move the mounting bracket aside complete with gear selection and engagement cables.

1. Undo the nuts (1a) and lift up the heater plugs control unit (1b) as necessary.2. Disconnect the electrical connection from the heater plugs from the control unit.

	Description	Connector
2	Heater plugs control unit	See M15 PLUG PREHEATING CONTROL UNIT

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

	Description	Connector
1a	Engine management control unit	Vedere M10A CENTRALINA CONTROLLO MOTORE ( ANTERIORE )

	Description	Connector
1b	Engine management control unit	See M10B ENGINE MANAGEMENT CONTROL UNIT ( CONNECTORS )

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

Remove the power assisted steering fluid reservoir cap and draw off the fluid using a suitable syringe.Place the power assisted steering fluid cap in position.1. Undo the bolts fixing the power assited steering fluid reservoir.

1. Move the power assisted steering fluid reservoir away positioning it as illustrated.2. 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 supply pipe from the pump to the power assisted steering box (1b), power assisted steering box side.2. Release the supply pipe from the pump to the power assisted steering box from the fastening bands on the power assisted steering box.

1. Undo the bolt (1a) and disconnect the coolant inlet/outlet pipes flange (1b) from the air conditioning 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 connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.

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

Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.

1. Undo the upper bolt fixing the engine cooling radiator to the upper crossmember.

1. Loosen the bands (1a) and remove the air supply hose between the turbocharger and the heat exchanger (1b).2. Disconnect the earth lead from the gearbox.

	Description	Connector
2	Battery earth	See C1 BATTERY EARTH

1. Position a hydraulic jack under the lower radiator crossmember.2. Release the two buttons fastening the air duct on the supercharging air/air heat exchanger to the engine cooling radiator duct.3. Unscrew the bolts securing the lower radiator crossmember to the bodyshell.4. Lower the hydraulic jack and remove the lower radiator crossmember (4a), the climate control system condenser (4b), the engine cooling radiator (4c) and the fan.

1. Loosen the bands fixing the driveshaft boots to the differential internal driveshaft/intermediate driveshaft.2. Release the front brake caliper flexible pipes, the electrical wiring for the pad wear sensor and the electrical wiring for the wheel rpm sensors (A.B.S.) from the fastenings.

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

	Description	Code
1c	Extractor	1.821.169.000

Move the driveshafts away from the differential internal driveshaft/intermediate driveshaft.

Proceed with the removal Op. 1076B70 EXHAUST PIPE BETWEEN PRE-CATALYTIC CONVERTER AND CATALYTIC CONVERTER - R R.Proceed with the removal Op. 1008A44 REAR RIGID MOUNT - R R.Postion a suitable footboard beneath the power unit.1. Fit the bracket (1a) and secure it as illustrated to the bracket on the engine for the reaction using the bolt (1b).2. Fit the bracket (2a) and fasten it to the gearbox as illustrated using the bolt (2b).3. 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, support the power unit.

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

1. Unscrew the bolt securing the power unit rigid mount to the flexible block.

Slowly lower the power unit with the hydraulic hoist until it rests on the board positioned previously.

Take great care during the removal of 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. assembly.

Refitting ( Removing

) Replace the power unit in the engine compartment using a hydraulic hoist.1. Tighten the bolt securing the gearbox side power unit rigid support to the flexible mounting.

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

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

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

Remove the hydraulic hoist with the chains used to support the power unit.Remove the brackets fitted for supporting the power unit.Remove the support positioned previously underneath the power unit.Proceed with the refitting Op. 1008A44 REAR RIGID MOUNT - R R.Proceed with the refitting Op. 1076B70 EXHAUST PIPE BETWEEN PRE-CATALYTIC CONVERTER AND CATALYTIC CONVERTER - R R.Place the driveshafts in their housings in contact with the differential internal driveshaft/intermediate driveshaft.1. Connect the upper track control arms (1a) to the steering knuckles and secure them tightening the nuts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	UPPER FRONT TRACK CONTROL ARMS	M10	(Steering knuckle) 4.3 - 4.7

Tighten the bands fixing the driveshaft boots to the differential internal driveshaft/intermediate driveshaft.Fasten the front brake caliper flexible pipes, the electrical wiring for the pad wear sensors and the A.B.S. sensors electrical wiring.Connect the earth lead to the gearbox.Place the air supply hose between the turbocharger and the heat exchanger in position and tighten the bands.Place the lower radiator crossmember in its housing using the hydraulic jack complete with climate control system condenser, engine cooling radiator and fan.Tighten the bolts securing the lower radiator crossmember to the bodyshell.Remove the hydraulic jack from underneath the lower radiator crossmember.Fit the two buttons fastening the air duct on the supercharging air/air heat exchanger to the engine cooling radiator duct.Tighten the upper bolt fixing the engine cooling radiator to the upper crossmember.1. Connect the coolant fluid inlet and outlet pipes (1a) to the air conditioning condenser and tighten the bolts (1b) to the recommended torque.

Replace any O-Rings for the connectors using green coloured seals only which are resistant to the R134a refrigerant fluid.Lubricate the connector threads 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 any O-Rings for the connectors using green coloured seals only which are resistant to the R134a refrigerant fluid.Lubricate the connector threads 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/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 power assisted steering box to the fastening bands on the power assisted 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 fluid reservoir to the power assisted steering pump, reservoir side.Place the power assisted steering fluid reservoir in its housing and secure it using the bolts.Place the control unit for the diesel electronic injection system complete with guides in its housing and secure it using the nuts.Connect the electrical connections to the diesel electronic injection system control unit.1. Place the power unit reaction rod (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

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

Connect the rapid connector for the fuel supply pipe to the pressure pump, fuel filter side.Connect the rapid connector for the fuel return pipe from the fuel filter, fuel return manifold pipe side.Connect the rapid connector for the fuel return pipe to the tank, fuel return manifold pipe side.Connect the electrical connection to the heater plugs from the control unit.Place the heater plugs control unit in position and secure it using the nuts.Place the mounting bracket in position complete with gear selection and engagement cables and secure it.Connect the gear selector and engagement cables.Connect the electrical connection to the reversing light 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)
-	-	-	-	-

Connect the rapid connector for the brake servo vacuum pipe.Refit the air filter with air flow meter in its seat.Place the electrical wiring back in its housing, then connect the electrical connection to the engine fan motor.Connect the electrical connections to the engine cooling fan resistor.Tighten the band securing the corrugated hose to the air flow meter.Connect the electrical connection to the air flow meter.Place the cold airintake back in its housing and tighten the band.Tighten the bolt fixing the cold air intake to the crossmember.Place the bracket complete with turbocharger vane position actuator solenoid valve and secure it using the bolts.Connect the air inlet hose to the connector on the throttle casing and tighten the band.Connect the flexible pipe to the engine coolant reservoir rigid coolant return pipe and tighten the band.Connect the coolant outlet pipe from the climate control system heater, water pump rigid inlet pipe side.Connect the coolant delivery pipe to the climate control system heater, thermostat side, and tighten the band.Connect the upper coolant input sleeve to the radiator, thermostat side, and tighten the band.Connect the system supply pipe, water pump rigid inlet side and tighten the band.Connect the lower coolant inlet hose from the radiator, water pump rigid coolant inlet pipe side and tighten the band.Proceed with the refitting Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R..Proceed with the refitting Op. 5530B10 BATTERY - R+R.Place the bracket complete with power assisted steering system heat exchanger pipe in osition and secure it using the bolt.Place the engine oil cooling radiator complete with pipes back in its housing and tighten 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 the refitting Op. 1084C40 CONVOGLIATORE ARIA PER RADIATORE RAFFREDDAMENTO OLIO MOTORE - S.R..Proceed with the refitting Op. 7210E10 R.R. FRONT BUMPER.Proceed with the refitting Op. 7055B42 LH OR RH REFLECTOR(ONE) ON REAR BUMPERS - R R.Proceed with the refitting Op. 7055B64 LH OR RH REFLECTOR(ONE) ON REAR BUMPERS - R R.Proceed with the refitting Op. 7055B54 UNDER-ENGINE GUARD - R R.Proceed with the refitting Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R.Refill the engine oil lubrication system Op. 0010T11 ENGINE OIL CHECK LEVEL AND TOP UP.Refill the engine cooling system Op. 0010T20 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY.Proceed with the refitting Op. 0010T67 HYDRAULIC CLUTCH SYSTEM BLEED AIR.Refill the air conditioning refrigerant circuit Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE.Refill the power assisted steering circuit Op. 0010T71 POWER STEERING FLUID CHECK LEVEL AND TOP UP IF NECESSARY.Proceed with refitting - 1016A10 SOUNDPROOFING COVER - R&R. .Remove the vehicle from the lift.