1004D11 POWER UNIT (MANUAL GEARBOX) WITH SUPPORT FRAME, FRONT SUSPENSION DETACHED SEPARATE AND REBUILD - Alfa - 166 - eLearn

3314031 - 1004D11 power unit (manual gearbox) with support frame, front suspension detached separate and rebuild

1. Undo the bolts (1a) and disconnect the right front driveshaft (1b) from the intermediate shaft.2. Undo the bolts (2a) and disconnect the left front driveshaft (2b) from the differential.

The above bolts have been treated with an eslok type material therefore they should be replaced each time they are removed.

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

	Name	Connector
3	Data not available yet	-

1. Undo the bolts (1a) and remove the intermediate shaft (1b).2. Disconnect the supply cable from the alternator.

	Name	Connector
2	Alternator	A10

3. Disconnect the supply cable from the starter motor.

	Name	Connector
3	Data not available yet	-

1. Undo the bolts (1a) and remove the starter motor (1b), complete with wiring.

Secure the power unit for hoisting using a hydraulic hoist fitted with suitable chains.1. Undo the bolts and the nut fixing the timing side rigid engine support to the front suspension frame.2. Undo the bolts and the nut fixing the power unit rigid rear support to the front suspension frame.3. Undo the bolts and the nut fixing the gearbox side power unit rigid support to the front suspension frame.

Raise the power unit and separate it from the front suspension frame.Position the power unit on a suitable support.1. Undo the bolts (1a) and remove the lower flywheel protection (1b).2. Undo the nuts (2a) and the bolts (2b), then remove the gearbox/differential (2c) from the engine.

Two operators are needed for this operation.

1. Fit the flywheel lock (1a) and fix it using the bolt (1b).

	Name	Country
1a	Counter-torque	1.820.624.000

2. Undo the bolts (2a) and remove the clutch drip tray (2b).3. Remove the clutch driven disc.

1. Fit the clutch driven disc (1a) and the clutch cover (1b) centring them with the tool (1c).

	Name	Country
1c	Centering	1.820.124.000

2. Tighten the bolts fixing the complete clutch mechanism to the flywheel to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	CLUTCH ASSEMBLY	M8	Engine flywheel side 2.4 - 2.9

3. Remove the flywheel lock.

	Name	Country
3	Counter-torque	1.820.624.000

1. Fit the gearbox/differential (1a) on the engine and fix it using the nuts (1b) and the bolts (1c).

	Fastening	Component	Ø	Value(daNm)
1b	Nut	MANUAL GEARBOX	M12	Engine side 4.7 - 5.8

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	MANUAL GEARBOX	M12	Engine side 6.8 - 8.4

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	MANUAL GEARBOX	M10	(Engine side) 3.7 - 4.5

2. Fit the lower flywheel protection (2a) and fix it using the bolts (2b).

Secure the power unit for hoisting using a hydraulic hoist fitted with suitable chains.Place the power unit back in its housing on the front suspension frame.1. Tighten the bolts (1a) and the nut (1b) fixing the gearbox side power unit rigid support to the front suspension frame to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	GEARBOX SIDE RUBBER MOUNT	M8	(Front suspension frame side) 2.4 - 2.9

	Fastening	Component	Ø	Value(daNm)
1b	Nut	POWER UNIT GEAR BOX END RIGID MOUNT	M10	(Flexible mounting side) 3.8 - 4.7

2. Tighten the bolts (2a) and the nut (2b) fixing the rear power unit rigid support to the front suspension frame to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	INTERM RUBBER MOUNT	M10	(Front suspension frame side) 4.9 - 6.1

	Fastening	Component	Ø	Value(daNm)
2b	Nut	POWER UNIT RIGID REAR MOUNT	M10	(Flexible mounting side) 3.8 - 4.7

3. Tighten the bolts (3a) and the nut (3b) fixing the timing side power unit rigid support to the front suspension frame to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3a	Bolt	FRONT RUBBER MOUNTS	M10	(Suspension support frame side) 4.9 - 6.1

	Fastening	Component	Ø	Value(daNm)
3b	Nut	ENGINE MOUNT TIMING SIDE	M10	(Flexible mounting side) 3.8 - 4.7

1. Fit the starter motor (1a), complete with wiring, and tighten the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	STARTER MOTOR	M8	(Gearbox side) 2.3 - 2.8

1. Connect the supply cable to the starter motor.2. Connect the supply cable to the alternator.

Take special care to ensure that the alternator cables are correctly positioned in their housings, following the routing exactly.

3. Fit the intermediate driveshaft (3a) and fix it tightening the bolts (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	INTERMEDIATE DRIVE SHAFT	M8	(Support side) 2.6 - 3.2

1. Connect the electrical connection to the reversing lights switch.2. Connect the left front driveshaft (2a) to the differential and fix it tightening the bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M8	Differential side 4.0 - 4.4

3. Connect the right front driveshaft (3a) to the intermediate driveshaft and fix it tightening the bolts (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M8	Intermediate drive shaft side 4.0 - 4.4

The above bolts have been treated with an eslok type material therefore they should be replaced each time they are removed.