1004D13 POWER UNIT (AUTOMATIC TRANSMISSION), COMPLETE WITH SUBFRAME, FRONT SUSPENSION REMOVED - SEPERATE AND REBUILD (AUTOMATIC TRANSMISSION) - Alfa - 166 - eLearn

3314291 - 1004D13 power unit (automatic transmission), complete with subframe, front suspension removed - seperate and rebuild (Automatic transmission)

) 1. Fit the engine mounting bracket on the right cylinder head and fix it using the bolt.2. Fit the power unit mounting bracket on the left cylinder head and fix it using the bolt.3. Fit the power unit mounting bracket on the differential.4. Secure and support the power unit using a hydraulic hoist fitted with suitable chains connected to the brackets mounted previously.

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

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

1. Undo the bolts (1a) and disconnect the right front half shaft (1b) from the intermediate half shaft.

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

1. Undo the bolts fixing the gearbox side support flexible mounting to the front suspension frame.

1. Undo the nut fixing the rear power unit rigid support to the flexible mounting.

1. Undo the nut fixing the timing side rigid engine support to the flexible mounting.2. Undo the bolts securing the power steering pump to its mounting.

1. Undo the bolt fixing the power steering fluid reservoir to the timing cover.2. Release the power steering pipes from the clips securing them to the engine.Secure the reservoir and power steering pump to the front suspension frame.

1. Raise the power unit (1a) using the hydraulic hoist and separate it from the front suspension frame (1b).

1. Undo the bolts (1a) and remove the lower engine flywheel protection (1b).2. Undo the bolts (2a) and remove the rpm and timing sensor (2b).

1. Undo the nuts (1a) and remove the right exhaust manifold (1b) complete with heat shield.

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

	Name	Connector
1b	Starter motor	A20

2. Undo the bolts (2a) and nut (2b) and remove the starter motor (2c) complete with rear bracket.3. Remove the spacer (3a) and the wiring mounting bracket (3b).

Rotate the crankshaft until one of the bolts securing the torque converter to the flywheel lines up with the starter motor seat.1. Fit the flywheel lock.

	Name	Country
1	Counter-torque	1.820.088.000

2. Undo the accessible torque converter bolt.Remove the flywheel lock.Do the same to undo the two remaining bolts securing the torque converter to the flywheel.

1. Undo the bolts (1a) and remove the front intermediate half shaft (1b).

1. Undo the bolts (1a) and remove the bracket securing the gear selection/engagement cables (1b).2. Undo the bolts (2a) and remove the automatic transmission (2b) from the engine.

Two operators are needed for this operation.Take the utmost care not to damage the torque converter.

Refitting ( Removing

) 1. Fit the automatic transmission (1a) and tighten its bolts (1b) to the specified torque.

Check that the torque converter couplings are correctly positioned in relation to the gearbox shaft.Line up the holes for the bolts securing the flywheel to the torque converter.

2. Fit the bracket securing the gear selection/engagement cables (2a) and tighten its bolts (2b).

	Fastening	Component	Ø	Value(daNm)
-	Bolt	AUTO TRANSMISSION	M10	(Engine side) 3.8 - 4.7

1. Refit the front intermediate half shaft (1a) in its seating and tighten its bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	INTERMEDIATE DRIVE SHAFT	M6	(Support side) 0.5 - 0.8

Rotate the crankshaft until one of the holes of the bolts securing the torque converter bolt to the flywheel lines up with the starter motor seat.1. Fit the flywheel lock.

	Name	Country
1	Counter-torque	1.820.088.000

2. Tighten the accessible torque converter bolt to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	AUTO TRANSMISSION TORQUE CONVERTER	M10	(Flywheel side) 4.3 - 5.3

Remove the flywheel lock.Do the same to tighten the two remaining bolts securing the torque converter to the flywheel.

1. Fit the starter motor (1a) complete with spacer (1b) and wiring support bracket (1c) and fix it tightening the bolts (1d) to the specified torque.

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

2. Connect the electrical connections (3a) to the starter motor and fix them using the nuts (2b).Fix the starter motor electrical wiring to the bands.

1. Fit the right exhaust manifold (1a) complete with heat shield and fix it tightening the nuts (1b) to the specified torque.

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

Fit the rpm and timing sensor and fix it with its bolts.Fit the lower engine flywheel protection and fix it using the bolts.Put the power unit back in its seating on the front suspension frame using the hydraulic hoist.Secure the power steering pipes to the retaining clips on the engine.Fix the engine coolant reservoir to the timing cover using the bolt.Fix the power steering pump to the mounting, tightening the bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	POWER STEERING PUMP	M8	(Support side) 1.9 ÷ 2.3

1. Tighten the nut securing the rigid engine support, timing gear side, to the relevant mounting, to the specified torque.

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

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

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

1. Tighten the bolts fixing the gearbox side support flexible mounting to the front suspension frame to the recommended torque.

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

Connect the front right half shaft to the intermediate half shaft and fix it tightening the bolts to the specified torque.

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

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M10	(Intermediate driveshaft side) 5.2 - 5.8

Connect the front left drive shaft to the differential and fix it tightening the bolts to the specified torque.

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

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M10	Differential side 5.2 - 5.8

Remove the hydraulic hoist complete with chains used to support the power unit.Remove the mounting brackets from the power unit.