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 DRAINING THE HIGH PRESSURE FUEL SYSTEM FOLLOWING THE INSTRUCTIONS GIVEN BELOW.Start the engine.Keep the engine idling for 2 minutes.Detach the fuel pump relay.Wait until the engine cuts out.Try and start the engine: if the engine starts within 10 seconds wait for it to cut out, then try and start the engine again; if the engine does not start within 10 seconds, continue for another 5 seconds.Wait for the engine to cool down.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. 7055B64 LH OR RH REFLECTOR(ONE) ON REAR BUMPERS - R R.Proceed with the removal Op. 7055B54 UNDER-ENGINE GUARD - R R.1. Disconnect the rapid connector for the lower coolant outlet hose from the radiator and drain the engine cooling system.

Manually press the clips and release the hose rapid connector.

Reconnect the rapid connector for the radiator lower coolant outlet hose.

Proceed with the removal Op. 1016A40 IGNITION COIL COVER ON CYLINDER HEAD- R+R.1. Disconnect the rapid connector for the fuel supply pipe and release it from the fastening on the modular intake manifold.2. Disconnect the rapid connector for the fuel vapour recovery pipe.

1. Loosen the coolar and disconnect the coolant return pipe from the engine coolant reservoir.

1. Loosen the band and disconnect the system supply pipe from the water pump rigid inlet pipe.2. Undo the bolt (2a) and disconnect the inlet/outlet pipes flange (2b) from the air conditioning compressor.

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

3. Disconnect the electrical connection for the right upper Lambda sensor.

	Description	Connector
3	Lambda sensor on pre-catalyzer - 2	See K16 LAMBDA SENSOR ON PRE-CATALYZER -2 ( CONNECTORS )

4. Disconnect the electrical connection for the right rear Lambda sensor to the catalytic converter.

	Description	Connector
4	Lambda sensor on catalyzer - 2	See K18 LAMBDA SENSOR ON CATALYZER 2 ( CONNECTORS )

Proceed with the removal Op. 1008C10 POWER UNIT UPPER REACTION LINK R R.Proceed with the removal Op. 1048A59 PIPE from flow meter to throttle casing hose - R.R..Proceed with the removal Op. 5530B10 BATTERY - R+R.Proceed with the removal Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R..1. Disconnect the electrical connection from the air flow meter.

	Description	Connector
1	Air flow meter	See K41 AIR FLOW METER ( FRONT )

1. Undo the nut (1a) and disconnect the earth lead (1b).

	Description	Connector
1b	Battery earth	See C1 BATTERY EARTH

2. Loosen the band and disconnect the cold air intake from the air filter.

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

1. Remove the clip (1a), press the springs (1b) and disconnect the gear engagement cable (1c).2. Press the springs (2a) and disconnect the gear selector cable (2b).3. Undo the bolts (3a) and move the bracket (3b) complete with gear selector and engagement cables to the side.

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

	Description	Connector
1	Reversing lights switch	See I20 REVERSING LIGHTS SWITCH

1. Move the protective cover away.2. Remove the cap from the bleed valve.3. Connect the recovery device (pipe and reservoir) to the bleed valve on the clutch hydraulic actuator.4. Raise the retaining clip (4a) until the first click is heard and remove pipe (4b) by a sufficient amount to uncover the bleed hole.Leave the hydraulic clutch system to drain completely.Lift up the spring completely and disconnect the pipe from the hydraulic clutch control actuator.

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

	Description	Connector
1a	Front/engine coupling	See D4A FRONT/ENGINE CONNECTION ( CONNECTORS )

	Description	Connector
1b	Front/engine coupling	See D4B FRONT/ENGINE CONNECTION ( CONNECTORS )

2. Loosen the band and disconnect the vacuum intake pipe from the modular intake manifold.

1. Loosen the collar and disconnect the upper coolant input sleeve to the radiator, thermostat side.2. Loosen the collar and disconnec the coolant delivery pipe to the climate control system heater, thermostat side.3. Loosen the collar and disconnect the coolant outlet pipe from the climate control system heater, on the side of the rigid pipe carrying coolant into the coolant pump.4. Loosen the band and disconnect the lower coolant inlet hose from the radiator, water pump rigid coolant inlet pipe side.

Drain the power assisted steering fluid reservoir using a suitable syringe.1. Disconnect the electrical connection from the switching control actuator enablement solenoid valve.

	Description	Connector
1	Variable geometry solenoid valve	See L15 VARIABLE GEOMETRY CONTROL SOLENOID ( CONNECTORS )

2. Disconnect the vacuum intake pipe from the air flow switching device actuator and release it from the fastening on the latter.3. Disconnect the air flow switching device actuator linkage.4. Undo the bolts (4a) and remove the air flow switching device control actuator (4b).

Release the power assisted steering fluid reservoir supply and return pipes from the connecting band.1. Undo the bolts (1a) and move the power assisted steering fluid reservoir (1b) sideways.

1. Loosen the band and disconnect the power assisted steering fluid reservoir return pipe, reservoir side.

1. Undo the connector and disconnect the supply pipe from the pump to the power assisted steering box, power assisted steering pump side.

Proceed with the removal Op. 1088E10 RADIATOR COOLING FAN - R + R.1. Disconnect the electrical connection for the left upper Lambda sensor.

	Description	Connector
1	Lambda sensor on pre-catalyzer	See K15 LAMBDA SENSOR ON PRE-CATALYZER

2. Disconnect the electrical connection for the left rear Lambda sensor to the catalytic converter.

	Description	Connector
2	Lambda sensor on catalyzer	See K17 LAMBDA SENSOR ON CATALYZER ( CONNECTORS )

Proceed with the removal Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R.Disconnect the electrical connections from the starter motor.

	Description	Connector
-	Starter motor	See A20 STARTER'' MOTOR

1. Undo the bolts (1a) and disconnect the flanges for the driveshaft constant velocity joints (1b).

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

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).

	Description	Code
1c	Extractor	1.821.169.000

Release the front brake caliper flexible pipes and the A.B.S. sensor cables from the mounting brackets.Move the left driveshaft as far away as possible from the differential and the right driveshaft away from the intermediate driveshaft.Postion a suitable footboard beneath the power unit.1. Position suitable brackets on the power unit as illustrated in the diagram.

1. Support the power unit using a hydraulic hoist (1a) and the tool (1b) connected to the brackets fitted previously.

	Description	Code
1b	Balance	1.871.001.700

1. Unscrew the bolt securing the power unit rigid rear support to the flexible mounting.

1. Undo the bolts (1a), (1b) and remove the power unit gearbox side rigid support (1c).

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

Slowly lower the power unit with the hydraulic hoist until it rests on the board positioned previously.Hoist and support the power unit using a hydraulic hoist, then release it from the tools used for the removal.

Refitting ( Removing

) Place the power unit in the engine compartment using a hydraulic hoist fitted with a suitable tool.

	Description	Code
2b	Balance	1.871.001.700

1. Tighten the bolt securing the timing side rigid engine support to the flexible mounting to the recommended torque.

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

1. Place the power unit gearbox side rigid support (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10	(Gearbox side) 4.5 - 5.5

2. Tighten the bolt securing the power unit gearbox side rigid support to the flexible mounting to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	-	-	-	-

1. Tighten the bolt securing the power unit rigid rear support to the flexible mounting.

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

Remove the tools used for refitting the power unit and put them away.Fasten the front brake caliper flexible pipes and the A.B.S. sensor cables to the mounting brackets.1. Connect the steering knuckles to the upper track control arms (1a) and secure them tightening the nut (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	FRONT HUB STRUT	M10	(Upper track control arm side) 4.3 - 4.7

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

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	DRIVESHAFT COMPLETE WITH JOINTS	M8	(Intermediate driveshaft/differential internal shaft side) 3.6 - 4.4

Connect the electrical connections to the starter motor.Proceed with the refitting Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R.Connect the electrical connection for the left rear Lambda sensor to the catalytic converter.Connect the electrical connection for the left upper Lambda sensor.Proceed with the refitting Op. 1088E10 RADIATOR COOLING FAN - R + R.1. Connect the supply pipe from the pump to the power assisted steering box, power assisted steering pump side and tighten the connector to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Connector	PIPE BTWN PUMP + POWER STEERING BOX	M16	(Power assisted steering pump side) 4.5 - 5.5

Connect the power assisted steering fluid return pipe to the reservoir and tighten the band.Place the power assisted steering fluid reservoir in its housing and secure it using the bolts.Fasten the power assisted steering fluid reservoir supply and return pipes to the connecting band.Place the air flow switching device control actuator back in its housing and secure it using the bolts.Connect the air flow switching device actuator linkage.Connect the vacuum intake pipe from the air flow switching device actuator and secure it to the latter.Connect the electrical connection to the switching control actuator enablement solenoid valve.Connect the lower coolant inlet hose from the radiator, water pump rigid coolant inlet pipe side and tighten the band.Connect the coolant outlet pipe from the climate control system heater, on the side of the rigid pipe carrying coolant into the coolant pump and tighten the collar.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 vacuum intake pipe to the modular intake manifold and tighten the band.Connect the electrical connections for the engine wiring.Fit the pipe fully home in its seat on the hydraulic clutch actuator and secure with the retaining clip.Place the cap in its housing on the bleed valve.Place the protective cover in its housing.Connect the electrical connection to the reversing light switch.Place the bracket complete with gear selector and engagement cables in position and secure it using the bolts.Connect the gear selector cable.Connect the gear engagement cable and fasten it using the clip.Refit the air filter with air flow meter in its seat.Connect the cold air intake to the air filter and fasten it using the band.Connect the earth lead and tighten the nut.Connect the electrical connection to the air flow meter.Proceed with the refitting Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R..Proceed with the refitting Op. 5530B10 BATTERY - R+R.Proceed with the refitting Op. 1048A59 PIPE from flow meter to throttle casing hose - R.R..Proceed with the refitting Op. 1008C10 POWER UNIT UPPER REACTION LINK R R.Connect the electrical connection for the right rear Lambda sensor to the catalytic converter.Connect the electrical connection for the right upper Lambda sensor.Connect the flange for the air conditioning compressor inlet/outlet pipes and secure it by tightening the bolt to the recommended torque.

Replace the O rings for the connectors. Only use green coloured seals that are resistant to R134a refrigerant fluid. Lubricate the connector thread using anti-freeze.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	Air conditioning compressor inlet/outlet pipes	M10	(Air conditioning compressor side) 3.2 - 3.9

Connect the system supply pipe to the water pump rigid inlet pipe and tighten the band.Connect the coolant return pipe to the engine coolant reservoir to the coolant reservoir and tighten the collar.Connect the rapid connector for the fuel vapour recovery pipe.Cconnect the rapid connector for the fuel supply pipe and secure it to the fastening on the modular intake manifold.Proceed with the refitting Op. 1016A40 IGNITION COIL COVER ON CYLINDER HEAD- R+R.Proceed with the refitting Op. 7055B54 UNDER-ENGINE GUARD - R R.Proceed with the refitting Op. 7055B64 LH OR RH REFLECTOR(ONE) ON REAR BUMPERS - R R.Proceed with the refitting Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R.Proceed with the refitting Op. 0010T20 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY.Proceed with the refitting Op. 0010T67 HYDRAULIC CLUTCH SYSTEM BLEED AIR.Proceed with the refitting Op. 0010T71 POWER STEERING FLUID CHECK LEVEL AND TOP UP IF NECESSARY.Refill the air conditioning refrigerant circuit Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE.Remove the vehicle from the lift.