1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, DISMANTLE AND REASSEMBLE - Alfa - 159 - eLearn

939010397 - 1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, DISMANTLE AND REASSEMBLE

) 1. Undo the nuts (1a) and disconnect the electrical connections (1b) from the starter motor.

	Description	Connector
1b	Starter motor	See A020 STARTER MOTOR

1. Loosen the band and disconnect the condensate engine oil recovery pipe,crankcase sump side.

1. Undo the bolts (1a) and remove the starter motor (1b).

1. Undo the bolts (1a) and remove the left side engine support flexible mounting (1b).

1. Undo the bolts (1a) and remove the bracket on the gearbox for the lower reaction rod (1b).

1. Undo the bolts (1a), (1b) and the nut (1c) and remove the manual gearbox (1d).

1. Fit the flywheel lock.

Tool	Description	Function	Validity
1860846000	Counter-torque	Flywheel lock

2. With the centering tool (2) fitted, undo the bolts (2b) and remove the clutch drip tray (2c).

Tool	Description	Function	Validity
1870447000	Centering	Removing-refitting clutch plate/drip tray	1.9 JTD 8V1.9 JTD 16V

- Remove the clutch plate.

Refitting ( Removing

) 1. Place the clutch plate and the clutch tray (1a) in their housing using the tool (1b) for centering.

Tool	Description	Function	Validity
1870447000	Centering	Removing-refitting clutch plate/drip tray	1.9 JTD 8V1.9 JTD 16V

2. Tighten the new bolts securing the clutch tray to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Clutch drip tray	Bolt (pretreated to be replaced)	M8	(engine flywheel side) 2.3 - 2.8	1.9 JTD 16v1.9 JTD 8v

- Remove the clutch plate and clutch tray centering tool.

Tool	Description	Function	Validity
1870447000	Centering	Removing-refitting clutch plate/drip tray	1.9 JTD 8V1.9 JTD 16V

3. Remove the flywheel lock.

Tool	Description	Function	Validity
1860846000	Counter-torque	Flywheel lock

1. Place the manual gearbox (1a) in its housing and secure it tightening the bolts (1b) and (1c) and the nut (1d) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox	Bolt	M12	(engine crankcase side) 4.8 - 7.2	1.9 JTD 16v1.9 JTD 8v

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump	Bolt	M10	(gearbox side) 3.2 - 4.8	1.9 JTD 16v 1.9 JTD 8v

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox	Nut	M12	(engine crankcase side) 4.8 - 7.2	1.9 JTD 16v1.9 JTD 8v

1. Refit the lower reaction rod bracket (1a) in its seat on the gearbox and secure it by tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Bracket on gearbox for lower reaction rod	Bolt	M12	(gearbox side) 7.5 - 8.5

1. Place the left side engine support flexible mounting (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Flexible mounting for left side engine support	Bolt	M12	(gearbox side) 7.5 - 8.5

1. Place the starter motor (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Starter motor assembly	Bolt	M8	2,25 ÷ 2,75	1.9 JTD 8v1.9 JTD 16v

- Connect the condensate engine oil recovery pipe to the crankcase sump and tighten the band.- Connect the electrical connections to the starter motor and secure them using the nuts.