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. Disconnect the supercharging air by-pass valve connecting hose from the rigid pipe.2. Disconnect the supercharging air by-pass valve vacuum intake pipe from the air chamber.

1. Disconnect the fuel/oil vapour recirculation pipe from the hose between the flow meter and the turbocharger air inlet pipe.

1. Disconnect the turbocharger air inlet pipe.2. Disconnect the control pipe from the waste-gate valve actuator.3. Disconnect the vacuum intake pipe for the supercharging pressure soleniod valve from the turbocharger.

1. Remove the air filter (1a), complete with air flow meter (1b), supercharging air by-pass valve (1c), supercharging pressure solenoid valve (1d) and connecting pipes (1e).

1. Disconnect the air supply hose from the heat exchanger to the rigid pipe.2. Disconnect the air inlet hose from the butterfly casing integrated with the D.V.L.3. Undo the nuts (3a) and remove the rigid air supply pipe from the heat exchanger to the inlet manifold (3b) complete with hoses.

1. Undo the bolt (1a) and remove the pipe from the air conditioning compressor to the condenser (1b).2. Disconnect the air supply hose to the heat exchanger from the turbocharger.3. Remove the air/air supercharging heat exchanger complete with hose.

1. Undo the nuts fixing the exhaust manifold/turbocharger hose, turbocharger side.2. Undo the nuts (2a) and remove the exhaust manifold/turbocharger hose (2b) complete with seals.

1. Undo the nuts (1a) and the bolts (1b), then remove the right side exhaust manifold (1c).2. Remove the gaskets.

1. Release the electrical wiring from the securing bands.2. Undo the nuts (2a) and remove the electrical connections (2b) from the starter motor.

	Name	Connector
2b	Starter motor	A20

3. Undo the bolts (3a) and remove the starter motor (3b).4. Remove the spacer.

1. Undo the connectors (1a) and disconnect the fluid supply and return pipes (1b) to the cooling radiator.

1. Undo the bolt fixing the mounting bracket for the fluid supply and return pipes to the cooling radiator.

1. Undo the nut fixing the mounting bracket for the fluid supply and return pipes to the cooling radiator.

1. Undo the bolt fixing the mounting bracket for the fluid supply and return pipes to the cooling radiator.2. Undo the bolts fixing the engine oil cooling radiator to the radiator supporting crossmember.Release the cooling radiator oil supply and return pipes from the power unit.

1. Disconnect the upper radiator coolant inlet hose from the ignition coil mounting.

1. Disconnect the lower radiator coolant outlet hose from the water pump rigid inlet pipe.

1. Use a spanner on the moving tensioner (1a) to insert a suitable peg (1b) to keep the tensioner in the 'belt slack' position.2. Remove the single drive belt.

1. Release the power assisted steering system pipes from the bands on the power unit.2. Undo the bolt fixing the power assisted steering fluid reservoir.

1. Release the electrical wiring for the Lambda sensor from the fixing on the power assisted steering pump rear mounting bracket.2. Undo the bolts fixing the power assisted steering pump front and rear mounting brackets.3. Move the power assisted steering pump, complete with reservoir and pipes, and fix it to the front suspension frame.

1. Undo the bolts (1a) and the nut (1b) and remove the lower flywheel protection (1c).

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

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

1. Fit a suitable engine lifting bracket to the left cylinder head. 2. Fit a suitable engine lifting bracket to the right cylinder head. 3. Secure the power unit (3a) for hoisting using a hydraulic hoist (3b) fitted with suitable chains.

1. Undo the nut fixing the timing side rigid engine support to the flexible mounting.2. Undo the nut securing the power unit rigid rear support to the flexible mounting.3. Undo the bolts fixing the gearbox side flexible mounting to the front suspension frame.Raise the power unit using the hydraulic hoist and separate it from the front suspension frame.

1. Position the power unit on a suitable support using the hydraulic hoist.Release the hydraulic hoist chain from the gearbox side rigid power unit support.2. Undo the bolts (2a) and remove the intermediate driveshaft (2b).3. Undo the rear bolt fixing the gearbox/differential to the engine.

1. Undo the remaining bolts (1a) and remove the manual gearbox and differential (1b).

Two operators are needed for this operation.

2. Undo the bolts (2a) and remove the clutch cover (2b) complete with thrust bearing (2c).3. Remove the clutch driven disc.

1. Remove the clutch release bearing (1a) from the clutch cover using the tool (1b).

	Name	Country
1b	Extractor	1.821.215.000

Reassembling ( Dismantling

) 1. Lift up the tapered seal (1a) for the clutch release bearing until the spring (1b) is covered.2. Fit the clutch release bearing (2a) on the main shaft and match it with the clutch release fork (2b).

1. Fit the clutch driven disc (1a) and clutch cover (1b) on the flywheel, centering them using the tool (1c).

	Name	Country
1c	Centering	1.820.124.000

2. Tighten the clutch cover bolts to the specified torques.

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

3. Place the gearbox with differential (3a) back in its housing and fix it tightening the bolts (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	MANUAL GEARBOX	M10	Engine side 3.7 - 4.5

Act on the gear control lever to engage the clutch release bearing in the clutch.Fit the intermediate drive shaft and tighten the bolts to the specified torque.

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

Connect the hydraulic hoist chain to the gearbox side rigid power unit support.1. Place the power unit back in its housing on the front suspension frame using the hydraulic hoist.2. Tighten the bolts for the gearbox side support flexible mounting to the front suspension frame to the recommended torque.

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

3. Tighten the nut securing the rigid rear power unit support to the flexible mounting to the recommended torque.

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

4. Tighten the nut ecuring the timing side rigid power unit support to the flexible mounting to the recommended torque.

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

Remove the hydraulic hoist supporting the power unit.Remove the engine lifting brackets from the cylinder head.1. Connect the left driveshaft (1a) to the differential and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M8	Differential side 4.0 - 4.4

2. Connect the right driveshaft (2a) to the intermediate driveshaft 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	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.

Fit the lower flywheel protection and fix it using the bolts and the nut.Place the power assisted steering pump, complete with reservoir and pipes, back in its housing.Tighten the bolts fixing the power assisted steering pump front and rear mounting brackets to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	POWER STEERING PUMP SUPPORT/BRACKET	M8	Cylinder head side 1.9 - 2.3

	Fastening	Component	Ø	Value(daNm)
-	Bolt	POWER STEERING PUMP SUPPORT/BRACKET	M8	Engine support side 1.9 - 2.3

Fix the electrical wiring for the Lambda sensor to the band on the power assisted steering pump rear mounting bracket.Tighten the bolt fixing the power assisted steering fluid reservoir to the protective timing cover.Fix the power assisted steering system pipes to the bands on the power unit.Fit the drive belt.Use a spanner on the moving tensioner and extract the peg.Connect the lower radiator coolant outlet hose to the water pump rigid inlet pipe.Connect the upper radiator coolant inlet hose to the ignition coil support.Place the cooling radiator oil supply and return pipes back in their housings.Tighten the bolts fixing the engine oil cooling radiator to the radiator supporting crossmember.Fix the radiator oil supply and return pipe brackets using the bolts and the nut.Connect the cooling radiator oil supply and return pipes and fix them tightening the connectors to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Connector	PIPE DELIVERING OIL TO RADIATOR	-	Rigid rear. power unit support side -

	Fastening	Component	Ø	Value(daNm)
-	Connector	OIL RETURN PIPE FROM RADIATOR	-	Rigid rear. power unit support side -

Fit the starter motor, complete with spacer, and fix it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	STARTER MOTOR	M8	Gearbox side 1.8 - 2.2

Connect the electrical connections to the starter motor and fix the electrical wiring using the bands.1. Fit the right side exhaust manifold (1a), complete with gaskets (1b), and fix it tighten the nuts (1c) and the bolts (1d) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Nut	EXHAUST MANIFOLD/S	M8	Cylinder head side 2.2 - 2.7

	Fastening	Component	Ø	Value(daNm)
1d	Bolt	EXHAUST MANIFOLD/S	M8	(Cylinder head side) 2.2 - 2.7

Fit the exhaust manifold/turbocharger hose, complete with seals, and fix it tightening the nuts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	'UNO' MANIFOLD SLEEVE TO TURBO	-	Exhaust manifold side -

	Fastening	Component	Ø	Value(daNm)
-	-	'UNO' MANIFOLD SLEEVE TO TURBO	-	Turbocharger side -

Place the supercharging air/air heat exchanger, complete with hose, back in its housing.Connect the heat exchanger air supply hose to the turbocharger.Fit the pipe from the compressor to the condenser and fix it using the bolt.Fit the rigid air supply pipe from the heat exchanger to the inlet manifold, complete with hose, and fix it using the nuts.Fit the air filter, complete with air flow meter, supercharging air by-pass valve, supercharging pressure solenoid valve and connecting pipes.Connect the pressure inlet pipe for the supercharging pressure solenoil valve to the turbocharger.Connect the control pipe to the waste-gate valve actuator.Connect the air inlet pipe to the turbocharger.Connect the fuel/oil vapour recirculation pipe to the hose between the flow meter and the turbocharger air inlet pipe.Connect the vacuum intake pipe for the supercharging air by-pass valve to the air chamber.Connect the hose connecting the supercharging air by-pass valve to the rigid pipe.