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 and left driveshafts (1b), respectively, from the intermediate driveshaft and the differential.2.

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

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

1. Undo the bolts securing the flexible mounting for the gearbox side support to the suspension support frame.

1. Undo the bolts securing the flexible mounting for the front power unit support to the suspension support frame.2. Disconnect the oil supply and return pipes to the engine oil cooling radiator from the engine oil filter mounting.Release the oil supply and return pipes to the engine oil cooling radiator from the mounting bracket.

Secure the power unit for hoisting using a hydraulic hoist fitted with suitable chains.Raise the power unit and separate it from the suspension support frame.Place the power unit on a suitable workbench.1. Disconnect and remove the electrical wiring from the power unit.2. Undo the bolts (2a) and remove the intermediate shaft (2b).3. Undo the bolts (3a) and remove the starter motor (3b).

1. Undo the fixings and remove the gearbox - differential assembly from the engine.2. Undo the bolts (2a) and remove the clutch drip tray (2b).3. Remove the clutch 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

) Fit the clutch disc and clutch cover, centring them using the tool.

	Name	Country
-	Centering	1.820.124.000

Tighten the clutch cover bolts to the specified torques.

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

1. Lift up the plastic tapered seal (1a) for the thrust bearing until the spring (1b) is covered.2. Fit the thrust bearing (2a) on the main shaft and attach it to the fork bearing (2b).

Fit the gearbox - differential assembly and fix it tightening the nuts and bolts to the recommended torque.

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

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

Act on the clutch control lever to engage the thrust bearing in the clutch cover.1. Fit the starter motor (1a) and fix it tightening the bolts (1b) to the recommended torque.

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

2. Fit the intermediate shaft (2a) and fix it tightening the bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	INTERMEDIATE DRIVE SHAFT	M8	(Support side) 2.6 - 3.2

3. Place the electrical wiring in its housing and connect it.

Secure the power unit for hoisting using a hydraulic hoist fitted with suitable chains.Place the power unit back in its housing on the suspension support frame.Fix the oil supply and return pipes to the engine cooling radiator to the mounting bracket.1. Connect the oil supply and return pipes to the engine oil cooling radiator to the oil filter mounting.2. Tighten the bolts fixing the flexible mounting for the power unit front support to the suspension support frame to the recommended torque.

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

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

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

1. Tighten the nut securing the rigid rear power unit 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

2. Connect the right and left driveshafts (2a) to the intermediate driveshaft and the differential, respectively, then fix them tightening the bolts (2b) to the recommended 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)
2b	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M10	Intermediate driveshaft/differential side 5.2 - 5.8