1004B10 POWER UNIT WITH MANUAL GEARBOX - R.R - Alfa - 159 - eLearn

939010395 - 1004B10 POWER UNIT WITH MANUAL GEARBOX - R.R

) - Position the vehicle on a lift. Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 1016A10 SOUND-PROOFING COVER - R.R Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE Op. 1048A28 VACUUM AIR CIRCUIT RESONATOR PIPE - R+R Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R. Op. 1088D14 UPPER RADIATOR COOLANT OUTLET HOSE - R.R. Op. 1088D10 LOWER RADIATOR COOLANT OUTLET HOSE - R.R. Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R. Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R. Op. 7210E10 R.R. FRONT BUMPER Op. 5540B70 LEFT FRONT LIGHT CLUSTER WITH DIRECTION INDICATOR - R.R. Op. 5540B71 RIGHT FRONT LIGHT CLUSTER WITH DIRECTION INDICATOR - R.R. Op. 7025A34 BONNET LID LOCK (ONE) - R+R OR REPAIR Op. 7210A15 R.R. FRONT WING/HEADLAMP HOUSING CROSSMEMBER Op. 7210A18 R.R FRONT CROSSMEMBER Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R 1. Undo the gearbox drain plug and collect the fluid in a suitable container.

Collect the transmission fluid in a suitable container.

Do not let the oil disperse into the environment as indiscriminate dispersion of this product causes pollution.

1. Disconnect the fuel supply pipe rapid connector, pressure pump side.2. Disconnect the rapid connector for the fuel return pipe, fuel return manifold side.

- Draw off the power assisted steering fluid from the reservoir using a suitable syringe.1. Disconnect the rapid connector for the power assisted steering system heat exchanger inlet pipe.

1. Disconnect the rapid connector for the power assisted steering system heat exchanger outlet pipe.

1. Undo the nuts (1a) and disconnect the inlet/outlet pipes from the air conditioning condenser (1b).

Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.

2. Loosen the band and disconnect the air supply hose between the turbocharger and the heat exchanger, heat exchanger side.

1. Loosen the band and disconnect the air supply hose from the heat exchanger to the rigid pipe, heat exchanger side.

- Position a hydraulic jack underneath the engine cooling radiator.- Undo the bolts fixing the engine cooling radiator mounting brackets to the front suspension crossmember.- Remove the engine cooling radiator mounting brackets.- Remove the engine cooling radiator complete with heat exchanger and air conditioning condenser.- Open the junction unit cover.- Release the clips and rotate the junction unit.1. Disconnect the electrical connection (connector E) for the radiator cooling fan wiring.

	Description	Connector
1	Engine compartment junction unit	See B001 JUNCTION UNIT

1. Undo the bolt (1a) and disconnect the inlet/outlet pipes from the air conditioning compressor (1b).

Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.

2. Loosen the band and disconnect the power assisted steering pump inlet pipe, power assisted steering pump side.3. Undo the connector and disconnect the supply pipe from the pump to the power assisted steering box, power assisted steering pump side.

1. Disconnect the electrical connection from the air flow meter.

	Description	Connector
1	Air flow meter	See K041 AIR FLOW METER

1. Disconnect the electrical connections from the glow plug control unit.

	Description	Connector
1	Heater plugs control unit	See M015 PLUG PREHEATING CONTROL UNIT

1. Disconnect the rapid connector for the vacuum intake pipe from the vacuum pump and move the latter to the side.2. Loosen the band and disconnect the flexible hose from the rigid coolant return pipe to the engine coolant reservoir.3. Undo the bolts (3a) and disconnect the air supply hose from the heat exchanger to the intake manifold (3b).

1. Undo the bolt (1a) and remove the air supply hose from the heat exchanger to the intake manifold (1b).

1. Disconnect the rapid connectors for the climate control system heater coolant inlet and outlet pipes.

1. Undo the nut (1a) and disconnect the starter motor supply lead (1b) from the contact board.

	Description	Connector
1b	Maxifuse box on battery	See B099 MAXIFUSE BOX ON BATTERY

1. Disconnect the electrical connection from the reversing light switch.

	Description	Connector
1	Reversing lights switch	See I020 REVERSING LIGHTS SWITCH

2. Release the retaining clip (2a) and disconnect the pipe between the damper and the clutch operating cylinder (2b), operating cylinder side.

Collect the bake/clutch fluid that comes out in a suitable container.

1. Disconnect the gear selector cable.2. Disconnect the gear engagement cable.

1. Open the clips (1a) and release the gear selector and engagement cables (1b) from the mounting bracket.

Op. 4410A80 DAMPER LOWER FORK - R R (left side).1. Undo the nut (1a) and disconnect the upper left track control arm for the front suspension (1b) from the steering knuckle (1c).

1. Disconnect the left driveshaft from the differential.

Op. 4410A80 DAMPER LOWER FORK - R R (right side).1. Remove the two stakings and undo the nut (1a) securing the right front hub to the driveshaft using the tool (1b) for counter-torque.

Tool	Description	Function	Validity
1870815000	Counter-torque	Loosen/ tighten nut securing front driveshaft to wheel hubLoosen/ tighten bolt securing exhaust side camshaft drive toothed drive pulley

1. Undo the nut (1a) and disconnect the upper right track control arm for the front suspension (1b) from the steering knuckle (1c).

1. Use the tool to move the right driveshaft back from the wheel hub.

Tool	Description	Function	Validity
2000001600	Extractor	Retract driveshaft from front wheel hub

1. Loosen the bolts fixing the intermediate driveshaft to the mounting.2. Disconnect the intermediate driveshaft (2a) from the differential and remove it together with the right driveshaft (2b).

1. Support the power unit using a hydraulic hoist (1a) and the tool (1b) connected to the mounting brackets (1c).

Tool	Description	Function	Validity
1871001700	Balance	Removing/ refitting power unit

1. Undo the bolts (1a), (1b), then remove the power unit timing side front support flexible mounting (1c).

1. Undo the bolts fixing the gearbox side power unit flexible mounting to the rigid support.

- Using the hydraulic hoist, remove the power unit from the engine compartment and place it on a suitable support.- Release the power unit from the support tools.

Refitting ( Removing

) - Secure the power unit using the support tools.- Place the power unit in its housing using the hydraulic hoist.1. Tighten the new bolts fixing the gearbox side flexible mounting to the rigid support to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side support flexible mounting	Bolt (to be replaced)	M12	(support side) 6.3 - 7.7 + 45°

1. Place the timing power unit front support flexible mounting (1a) in its housing and secure it tightening the new bolts (1b), bolts (1c) and the new bolts (1d) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support flexible mounting	Bolt (to be replaced)	M12	(bodyshell side) 6.3 - 7.7 + 90°

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support flexible mounting	Bolt	M10	(bodyshell side) 5.4 - 6.6

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support flexible mounting	Bolt (to be replaced)	M12	(rigid support side) 6.3 - 7.7 + 90°

- Remove the hydraulic hoist and tool used for supporting the power unit safely.

Tool	Description	Function	Validity
1871001700	Balance	Removing/ refitting power unit

- Connect the intermediate driveshaft complete with right driveshaft to the differential.- Tighten the bolts fixing the intermdiate driveshaft to the mounting to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Intermediate driveshaft	Bolt	M6	(support side) 0.7 - 1.1

- Place the right driveshaft in its housing on the hub and tighten a new nut to the recommended torque using the tool for counter-torque.

Component	Fastening	dia	Value (daNm)	Validity
Front wheel hub	Nut	M24	(driveshaft side) see operation 4450C28

Tool	Description	Function	Validity
1870815000	Counter-torque	Loosen/ tighten nut securing front driveshaft to wheel hubLoosen/ tighten bolt securing exhaust side camshaft drive toothed drive pulley

1. Make two stakings on the nut collar as illustrated in the diagram.

1. Connect the upper right track control arm for the front suspension (1a) to the steering knuckle (1b) and tighten the nut (1c) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Front suspension upper track control arms	Nut	M10	(steering knuckle side) 4.1 - 5.0

Op. 4410A80 DAMPER LOWER FORK - R R (right side).- Connect the left driveshaft to the differential.1. Connect the upper left track control arm for the front suspension (1a) to the steering knuckle (1b) and tighten the nut (1c) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Front suspension upper track control arms	Nut	M10	(steering knuckle side) 4.1 - 5.0

Op. 4410A80 DAMPER LOWER FORK - R R (left side).- Fasten the gear selection and engagement cables to the mounting bracket securing them using the clips.- Connect the gear engagement cable.- Connect the gear selector cable.- Connect the pipe between the damper and clutch operating cylinder, operating cylinder side and secure it using the retaining clip.- Connect the electrical connection to the reversing light switch.- Connect the starter motor earth lead to the contact board and secure it using the nut.- Connect the rapid connectors for the climate control system heater coolant inlet and outlet pipes.- Place the air supply pipe from the heat exchanger to the intake manifold back in its housing and secure it using the bolt.- Connect the air supply hose from the heat exchanger to the intake manifold, throttle body side and secure it using the bolts.- Connect the flexible hose to the rigid coolant return pipe to the engine coolant reservoir and tighten the band.- Connect the rapid connector for the vacuum intake pipe to the vacuum pump.- Connect the electrical connections to the glow plug control unit.- Connect the electrical connection to the air flow meter.1. Connect the supply pipe from the pump to the power assisted steering box, power assisted steering pump side and tighten the connector to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Supply pipe from pump to power assisted steering box	Connector	M16	(power assisted steering pump side) 3.6 - 4.4

2. Connect the power assisted steering pump inlet pipe, power assisted steering pump side and tighten the band.3. Connect the air conditioning compressor inlet/outlet pipes (3a) and secure them by tightening the bolt (3b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
COMPRESSOR SIDE PIPE CONNECTOR	Bolt	M8x90	2.2 ÷ 2.6

Replace any O-Rings for the connectors using green coloured seals only which are resistant to the R134a refrigerant fluid.Lubricate the connector threads using anti-freeze.

- Connect the electrical connection for the radiator cooling fan wiring.- Place the junction unit in its housing and secure it using the clips.- Close the junction unit cover.- Place the engine cooling radiator in its housing complete with heat exchanger and air conditioning condenser using the hydraulic jack.- Place the engine cooling radiator mounting brackets in their housings and secure them using the bolts.- Remove the hydraulic jack from underneath the engine coolant radiator.- Connect the air supply hose from the heat exchanger to the rigid pipe, heat exchanger side and tighten the band.- Connect the air supply hose between the turbocharger and the heat exchanger, heat exchanger side, and tighten the band.- Connect the air conditioning condenser inlet/outlet pipes and secure them by tightening the nuts to the recommended torque.

Replace any O-Rings for the connectors using green coloured seals only which are resistant to the R134a refrigerant fluid.Lubricate the connector threads using anti-freeze.

Component	Fastening	dia	Value (daNm)	Validity
PIPE CONNECTOR ON CONDENSER	Nut	M8	1.8 ÷ 2.2

- Connect the rapid connectors for the inlet and outlet pipes to the power assisted steering system heat exchanger pipe.- Connect the rapid connector for the fuel return pipe, fuel return manifold side.- Connect the fuel supply pipe rapid connector, pressure pump side.- Tighten the gearbox oil drain plug to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox oil drain plug	-	-	1.7 (gearbox side)

Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R Op. 7210A18 R.R FRONT CROSSMEMBER Op. 7210A15 R.R. FRONT WING/HEADLAMP HOUSING CROSSMEMBER Op. 7025A34 BONNET LID LOCK (ONE) - R+R OR REPAIR Op. 5540B71 RIGHT FRONT LIGHT CLUSTER WITH DIRECTION INDICATOR - R.R. Op. 5540B70 LEFT FRONT LIGHT CLUSTER WITH DIRECTION INDICATOR - R.R. Op. 7210E10 R.R. FRONT BUMPER Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R. Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R. Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 1088D10 LOWER RADIATOR COOLANT OUTLET HOSE - R.R. Op. 1088D14 UPPER RADIATOR COOLANT OUTLET HOSE - R.R. Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R. Op. 1048A28 VACUUM AIR CIRCUIT RESONATOR PIPE - R+R Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. Op. 1016A10 SOUND-PROOFING COVER - R.R Op. 0010T64 BRAKE AND/OR CLUTCH FLUID CHECK LEVEL AND TOP UP AS NECESSARY Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 5530B10 BATTERY - R+R Op. 0010T20 ENGINE COOLANT - CHANGE Op. 0010T71 POWER STEERING FLUID CHECK LEVEL AND TOP UP IF NECESSARY Op. 0010T75 HYDRAULIC POWER STEERING SYSTEM BLEED AIR - Remove the vehicle from the lift.