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

) Position the vehicle on the ramp. Make sure that the ignition is OFF (STOP position), then disconnect the negative battery terminal (refer to op. 5530B10 battery - r+r ).

	Name	Connector
-	Battery	A1B

- 7040D12 engine front side cover (one) lh or rh - r r (left and right). - 7040D30 engine bay front beam cover - r r . - 7040D14 engine bay rear side cover (one) lh or rh - r r (left and right). - 4450B12 front or rear wheels (two) - r+r . - 1016A40 ignition coil cover on cylinder head- r+r . - 1048A48 throttle heater sleeve - r r . - 1048A10 air cleaner filtering element - replace . - 7055B54 under-engine guard - r r . 1. Disconnect the lower engine radiator hose from the water pump rigid inlet pipe.

Collect the coolant in a suitable container.

2. Disconnect the coolant return pipe from the coolant reservoir from the water pump rigid inlet pipe.3. Disconnect the upper radiator hose from the engine thermostat.4. Disconnect the coolant supply pipe to the climate control system heater from the engine thermostat.5. Disconnect the coolant pipe to the engine coolant reservoir from the engine thermostat.6. Disconnect the return pipe from the climate control system heater from the water pump rigid inlet pipe.

1. Disconnect the accelerator cable from the cam on the butterfly casing.

1. Release the pipes (1a) from the band (1b).2. Disconnect the electric connection.3. Undo the bolts (3a) and move the clutch operating cylinder (3b), complete with pipe and bracket, to the side.

1. Disconnect the brake servo vacuum pipe from the brake servo one-way valve.2. Disconnect the gear engagement/selector cables.3. Undo the bolts (3a) and move the two mounting brackets (3b) complete with gear engagement/selection cables.

1. Remove the cover from the junction unit.2. Disconnect the starter motor supply cable from the junction unit.

	Name	Connector
2	Data not available yet	-

1. Disconnect the battery earth lead from the power unit rigid mounting, gearbox side.

	Name	Connector
1	Battery earth	C1

1. Disconnect the two electrical connections (1a) and (1b) from the injection/ignition control unit.

	Name	Connector
1a	Data not available yet	-

	Name	Connector
1b	Data not available yet	-

1. Undo the nuts (1a) and remove the bulkhead protection on the left side (1b).2. remove the power steering fluid reservoir cap and drain the fluid using a suitable syringe.

1. Disconnect the electrical connection for the Lambda sensor.

	Name	Connector
1	Lambda sensor	K40

Discharge the fuel supply pressure.2. Disconnect the fuel supply pipe from the injector fuel manifold.

- 1092G10 single engine belt r r . 1. Undo the bolts (1a) and move the dehumidifier filter/accumulator (1b) complete with mounting bracket and pipes.

1. Disconnect the electrical connection for the air conditioning compressor electro-magnet.

	Name	Connector
1	Air conditioning compressor engagement electro-magnet	L20

2. Undo the bolts (2a) and move the complete air conditioning compressor (2b).

Suitably fix the air conditioning compressor to the bodyshell.

- 1008C10 power unit upper reaction link r r . 1. Disconnect the reservoir - power assisted steering pump pipe from the power assisted steering pump.2. Disconnect the pump/power assisted steering box pipe from the power assisted steering pump.3. Disconnect the supply pipe for the fuel vapour recovery system.

Temporarily fix the engine radiator to the upper crossmember.1. Undo the bolts fixing the engine radiator to the lower crossmember.2. Undo the bolt fixing the air filter mounting to the lower crossmember.

1. Undo the nuts fixing the front upper track control arm supports to the bodyshell.

Disconnect the brake caliper flexible pipes from the mounting brackets.Disconnect the pad wear sensor cables from the mounting brackets.1. Undo the bolts (1a) and move the front disc brake calipers (1b).

Suitably fix the front disc brake calipers so that they do not hinder future operations.

1. Undo the nuts (1a) and disconnect the steering box track rods (1b) from the front hub vertical links using tool (1c).

	Name	Country
1c	Extractor	1.821.169.000

2. Undo the bolts (2a) and disconnect the front wheel rpm sensors (2b) from the front hub steering knuckles.

Undo the bolt fixing the right wheel arch to the front suspension frame.Undo the nuts fixing the engine radiator to the front suspension frame. - 1076B50 exhaust pipe attachment to engine - r + r . 1. Undo the nuts fixing the power assisted steering box to the front suspension frame.

1. Position the tools (1a) and (1b) for removing the power unit under the vehicle.

	Name	Country
1a	Pulley	1.860.823.000

	Name	Country
1b	Adaptors	1.860.823.001

Lower the vehicle until the front suspension frame is positioned on the tool.2. Remove the bolts fixing the front suspension frame to the bodyshell.

1. Raise the vehicle until the power unit is completely separated from the manual gearbox complete with front suspension frame.

Refitting ( Removing

) Position the power unit with the manual gearbox, complete with front suspension frame, under the vehicle.1. Lower the vehicle until the power unit is correctly positioned in its housing.2. Tighten the bolts(2a) and (2b) securing the front suspension frame to the bodyshell to the recommended torque.

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

	Fastening	Component	Ø	Value(daNm)
2b	Rear bolts	FRONT SUSPENSION SUBFRAME	M12	(Bodyshell side) 12.4 - 13.7

Raise the vehicle and remove the tools used for removing-refitting the power unit.

	Name	Country
-	Pulley	1.860.823.000

	Name	Country
-	Adaptors	1.860.823.001

1. Tighten the nuts fixing the power assisted steering box to the front suspension frame to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Nut	POWER STEERING BOX	M12	Front suspension frame side 10.5 - 11.5

- 1076B50 exhaust pipe attachment to engine - r + r . Tighten the nuts fixing the engine radiator to the front suspension frame.Tighten the bolt fixing the right wheel arch to the front suspension frame.Fit the front wheel rpm sensors on the front steering knuckles.Connect the power steering box track rods to the front hub vertical links, and tighten the nuts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	ADJUSTABLE STEERING LINKS	M10	(Front wheel hub steering knuckle side) 4.3 ÷ 4.7

1. Fit the front disc brake calipers (1a) and tighten the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FRONT BRAKE CALIPER BRACKET	M14	(Steering knuckle side) 15.2 - 16.8

Connect the pad wear cables to the mounting brackets.Connect the brake caliper flexible pipes to the mounting brackets.1. Tighten the nuts fixings the front upper track control arm supports, left and right, to the bodyshell to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Nut	FRONT UPPER SWINGING ARM MOUNT	M8	Bodyshell side 1.8 - 2.0

Tighten the bolt fixing the air filter mounting to the lower crossmember.Tighten the bolts fixing the radiator to the lower crossmember.Connect the supply pipe for the anti-evaporation system to the power assisted steering pump.Connect the pump/power assisted steering box pipe to the power assisted steering pump and tighten the connector to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Connector	PIPE BTWN PUMP + POWER STEERING BOX	M16	(Power steering pump side) 3.8 ÷ 4.2

Connect the supply pipe for the anti-evaporation system. - 1008C10 power unit upper reaction link r r . 1. Place the air conditioning compressor (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	AIR CONDITIONER ASSEMBLY COMPRESSOR	M8	2.7 - 3.4

2. Connect the electrical connection for the air conditioning compressor electro-magnet.

Place the drier filter/accumulator, complete with mounting bracket and pipes, back in its housing, then fix it using the bolts. - 1092G10 single engine belt r r . Connect the fuel pipe to the injector fuel manifold.Connect the electrical connection for the Lambda sensor.Fit the services chamber side protection and fix it using the nuts.Connect the two electrical connections to the injection/ignition control unit.Connect the battery earth lead to the gearbox side power unit rigid support.Connect the starter motor supply cable to the junction unit and fit it with the cover.Replace the two mounting brackets, complete with gear selector/engagement cables and fix them using the bolts.Connect the gear selector/engagement cables.Connect the brake servo vacuum pipe to the brake servo one-way valve.Fit the operating cylinder, complete with pipe and bracket, then fix it using the bolts.Connect the electrical connectionConnect the return pipe from the climate control system heater to the water pump rigid inlet pipe.Connect the coolant return pipe to the tank to the engine thermostat.Connect the coolant supply pipe to the climate control system heater to the engine thermostat.Connect the upper engine radiator hose to the thermostat.Connect the coolant return pipe from the tank to the water pump rigid inlet pipe.Connect the engine radiator lower hose to the water pump rigid inlet pipe. - 7055B54 under-engine guard - r r . - 1048A10 air cleaner filtering element - replace . - 1048A48 throttle heater sleeve - r r . - 1016A40 ignition coil cover on cylinder head- r+r . - 4450B12 front or rear wheels (two) - r+r . - 7040D14 engine bay rear side cover (one) lh or rh - r r (left and right). - 7040D30 engine bay front beam cover - r r . - 7040D12 engine front side cover (one) lh or rh - r r (left and right). Connect the battery terminal (-).Supply the engine cooling system with the recommended fluid.

	Type	Component	Name	Qty.
-	Fluid [l]	ENGINE COOLING CIRCUIT	Alfa Romeo Climafluid Super Permanent -40	7.9

Top up the power assisted circuit with the recommended fluid.

	Type	Component	Name	Qty.
-	Fluid [l]	POWER ASSISTED STEERING CIRCUIT	TUTELA GI/A	1.4

Bleed the power steerign system as described below.With the front wheels raised off the ground, with the engine switched off, carry out 4-5 complete steering wheel rotation cycles (left and right).Check and, if necessary, top up the fluid level in the reservoir.Remove the car from the ramp.Start the engine and carry out 4 - 5 full steering wheel turn cycles (right and left).Top up the fluid level in the reservoir.