1004B18 POWER UNIT WITH MANUAL GEARBOX, WITH SUPPORT FRAME, FRONT SUSPENSION R + R FOR VERSIONS WITH A/C - Alfa - 166 - eLearn

3314029 - 1004B18 power unit with manual gearbox, with support frame, front suspension r + r for versions with a/c

) Make sure that the wheels are perfectly straight and the ignition key is not inserted.1. Remove the rubber protector (1a) and the accelerator pedal travel stop (1b).

1. Move aside the floor carpet, unscrew the nuts (1a) and remove the steering column universal joint guard (1b).2. Undo the bolt securing the steering column to the power steering box.

The bolt is pre-treated with sealant and so a new one should be fitted whenever it is replaced.

Position the vehicle on the rampEnsure that the ignition key is in the OFF position, then disconnect the battery negative terminal (-).

	Name	Connector
-	Battery	A1B

Drain the air conditioner coolant circuit - 0010T84 coolant for air conditioning system dehydrate and recharge . Proceed with the removal - 7040D12 engine front side cover (one) lh or rh - r r (Left and right sides). Proceed with removal - 7040D30 engine bay front beam cover - r r . Proceed with the removal - 7040D14 engine bay rear side cover (one) lh or rh - r r (Left and right sides). Proceed with removal - 1016A10 sound-proofing cover - r + r . Proceed with removal - 4450B12 front or rear wheels (two) - r+r . Proceed with removal - 7055B54 under-engine guard - r r . Proceed with removal - 7210E10 R.R. FRONT BUMPER . Proceed with the removal - 7055B39 front additional wheel arch half (one), lh or rh, front element - r r (Right and left sides). 1. Undo the drain plug in the radiator and drain the engine coolant.

Collect the fluid in a suitable container.

1. Loosen the bands and remove the air supply duct from heat exchanger to inlet manifold.

1. Loosen the band and disconnect the coolant return pipe to the water pump rigid inlet pipe, three-way connector side.

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

	Name	Connector
1	Reversing light control	I20

2. Disconnect the gear selector and engagement cables3. Remove the cap on the bleed valve.4. Connect the collection system (pipe and reservoir) to the bleed valve on the hydraulic clutch actuator. 5. Lift the retaining clip (5a) and extract the bleed device as much as necessary (5b).Let the hydraulic clutch system drain completely.6. Lift the retaining clip (6a) and disconnect the pipe (6b) from the clutch hydraulic control actuator and move it aside after releasing it from the bands (6c).

1. Undo the bolts (1a) and remove the bracket (1b) after releasing it from the electrical wiring.

1. Undo the nut and disconnect the starter motor supply lead from the junction unit.

	Name	Connector
1	Starter motor	A20

2. Loosen the band and disconnect the coolant supply pipe to the climate control system heater from the connector.3. Loosen the band and disconnect the flexible coolant return pipe to the engine coolant reservoir from the rigid section.

1. Disconnect the electrical connection (1a) from the diesel electronic injection system control unit and release the electrical wiring from the band (1b).

	Name	Connector
1a	Engine management control unit	M10

2. Undo the nut fixing the heater plugs control unit.

1. Rotate the heater plugs control unit as necessary and disconnect the electrical connection.

	Name	Connector
1	Heater plugs 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 to the fuel return manifold pipe, fuel return manifold pipe side.3. Disconnect the front engine coupling.

	Name	Connector
3	Engine front connection	D4

4. Disconnect the intermediate joint on the wiring loom for the independent additional heater unit.

	Name	Connector
4	Additional heater junction	D22

Proceed with removal - 1008C10 power unit upper reaction link r r . 1. Disconnect the electrical connection for the air conditioning system multi-stage pressure switch.

	Name	Connector
1	4 stage pressure switch	K10

2. Undo the nut (2a) and disconnect the intermediate coupling (2b) for the pipe from the air conditioning condenser to the expansion valve.

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

1. Undo the bolt (1a) and disconnect the pipe from the expansion valve to the air conditioning compressor (1b), compressor side.

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

1. Disconnect the electrical connections from the engine fan motors.

	Name	Connector
1	Engine electric fan motor	N11

	Name	Connector
1	Engine electric fan motor	N12

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

	Name	Connector
2	Engine fan adjustment resistor	O10

	Name	Connector
2	Engine fan adjustment resistor	O12

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

1. Undo the bolt fixing the supercharging air/air heat exchanger to the upper radiator crossmember.

1. Undo the nuts (1a) and remove the bonnet lid lock (1b) sideways.2. Undo the bolts (2a) and remove the upper radiator crossmember (2b).

1. Undo bolt (1a) and disconnect battery earth lead (1b) from the power unit gearbox end rigid mount.

	Name	Connector
1b	Battery earth	C1

1. Disconnect the electrical connection for the left front brake pad wear sensor.

	Name	Connector
1	Left brake pad wear sensor (switch)	K20

Release the flexible pipes to the front brake calipers from the mounting brackets.2. Undo the bolts (2a) and move the front brake calipers (2b) sideways securing them.

Proceed with the removal - 4410A80 damper lower fork - r r (Right and left sides). 1. Disconnect the cold air intake from the air filter.

1. Disconnect the electrical connection from the light cluster alignment front sensor.

	Name	Connector
1	Front xenon lamps sensor	K28

2. Disconnect the connecting rod from the front sensor for correcting the light cluster alignment.3. Loosen the bands and disconnect the power assisted steering system pipes.

Collect the power assisted steering fluid that comes out in a suitable container.

Proceed with removal - 1076B70 exhaust pipe between pre-catalytic converter and catalytic converter - r r . 1. Loosen the band (1a), undo the nut (1b) and remove the drain pipe (1c) for the additional independent heater.2. Loosen the band and disconnect the intermediate coupling for the fuel supply pipe to the additional independent heater.

1. Position the tool supporting the power unit/chassis (1a) complete with hydraulic jack (1b) by the housings in the engine support frame.

	Name	Country
1a	Power unit support frame	1.870.835.000

2. Undo the front bolts fixing the front suspension frame to the bodyshell.3. Undo the rear bolts fixing the front suspension frame to the bodyshell.

Lower the hydraulic jack and remove the power unit complete with support frame and front suspension.

Refitting ( Removing

) Place the power unit complete with support frame and front suspension back in its housing using the hydraulic jack and support tool. 1. Tighten the rear bolts fixing the front suspension frame to the bodyshell to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Rear bolts	FRONT SUSPENSION SUBFRAME	M12	(Bodyshell side) 12.4 - 13.7

2. Tighten the front bolts fixing the front suspension frame to the bodyshell.

	Fastening	Component	Ø	Value(daNm)
2	Front bolts	FRONT SUSPENSION SUBFRAME	M12	(Bodyshell side) 10.5 -11.6

3. Remove the power unit support tool (3a) and hydraulic jack (3b).

	Name	Country
3a	Power unit support frame	1.870.835.000

Connect the intermediate coupling for the fuel supply pipe to the additional independent heater and tighten the band.Place the additional independent heater drain pipe back in its housing and secure it using the nut and the band. .Proceed with refitting - 1076B70 exhaust pipe between pre-catalytic converter and catalytic converter - r r . Connect the power assisted steering system pipes and tighten the bands.Connect the connecting rod to the front sensor for the alignment of the light clusters.Connect the electrical connection to the light cluster alignment front sensor.Connect the cold air intake to the air filter. Proceed with the refitting - 4410A80 damper lower fork - r r (Right and left sides). 1. Place the front brake calipers (1a) back in their seatings and secure them tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FRONT BRAKE CALIPER ASSEMBLY	M14	(Hub steering knuckle side) 2.5 ÷ 3.0

Fix the flexible pipes to the front brake calipers to their mounting brackets.2. Connect the electrical connection for the left brake pad wear sensor.

Connect the battery earth lead to the gearbox side rigid power unit support and fix it using the bolt. Place the lower radiator crossmember back in its housing and secure it using the bolts.Place the bonnet lid lack back in its housing and fix it using the nuts.Tighten the bolt fixing the supercharging air/air heat exchanger to the upper radiator crossmember.Tighten the bolt fixing the engine cooling radiator to the upper crossmember.Place the electrical wiring back in its housing and connect the electrical connections to the resistors for the engine cooling fans.Connect the electrical connections to the engine fan motors. 1. Connect the pipe from the air conditioning compressor expansion valve (1a), compressor side and tighten the bolt (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	-	-	-	-

1. Connect the intermediate coupling (1a) for the pipe from the air conditioning condenser to the expansion valve 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)
-	-	-	-	-

2. Connnect the electrical connection to the air conditioning system multi-stage pressure switch.

Proceed with refitting - 1008C10 power unit upper reaction link r r . Connect the intermediate joint on the wiring loom for the additional independent heater unit.Connect the front engine coupling.Connect the rapid attachment of the return pipe from fuel filter to fuel return manifold pipe, fuel 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 plug preheating control unit, then refit it in its seating and secure it with the nut. Connect the electrical connection to the diesel electronic injection control unit and fasten the electrical wiring using the band. Connect the coolant return pipe to the engine coolant reservoir and to the rigid section and tighten the band. Connect the engine coolant return pipe to the climate control system heater and to the connector and tighten the band. Connect the starter motor supply lead to the junction unit and secure it using the nut.Connect the one-way valve to the brake servo.Connect the clutch hydraulic actuator pipe and secure it with its clip.Connect the gear selector and engagement cables.Connect the electrical connection to the reversing lights switch. Connect the coolant return pipe to the water pump rigid inlet pipe, three-way connector side and tighten the band.Refit the air supply duct from heat exchanger to inlet manifold and tighten the relevant bands.Tighten the drain plug on the engine cooling radiator. Proceed with the refitting - 7055B39 front additional wheel arch half (one), lh or rh, front element - r r (Right and left sides). Proceed with refitting - 7210E10 R.R. FRONT BUMPER . Proceed with refitting - 4450B12 front or rear wheels (two) - r+r . Proceed with refitting - 0010T71 power steering fluid check level and top up if necessary . Proceed with refitting - 0010T64 brake and or clutch fluid check level and top up as necessary . Proceed with refitting - 0010T67 hydraulic clutch system bleed air . Proceed with refitting - 0010T20 coolant change . Proceed with refitting - 0010T84 coolant for air conditioning system dehydrate and recharge . Proceed with refitting - 5540B38 headlamp/light cluster light beam - position . Proceed with refitting - 7055B54 under-engine guard - r r . Proceed with refitting - 1016A10 sound-proofing cover - r + r . Proceed with refitting - 7040D14 engine bay rear side cover (one) lh or rh - r r (Left and right sides). Proceed with refitting - 7040D30 engine bay front beam cover - r r . Proceed with refitting - 7040D12 engine front side cover (one) lh or rh - r r . Proceed with refitting - 4450A10 front wheel geometry - check using optical equipment - includes front wheel tow-in adjustment if necessary . Connect the negative (-) battery terminalRemove the car from the ramps.