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.- Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).

	Description	Connector
-	Battery	See A001 BATTERY

Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE Op. 7210A18 R.R FRONT CROSSMEMBER - Using a suitable syringe, draw off the power assisted steering fluid from the reservoir. Op. 4130B40 SUPPLY PIPE FROM PUMP TO POWER STEERING BOX - R.R.1. Loosen the band and disconnect the supply pipe from the power assisted steering fluid reservoir to the pump, power assisted steering pump side.2. Disconnect the rapid connector for the return pipe from the heat exchanger pipe to the power assisted steering fluid reservoir, heat exchanger side.3. Undo the bolts (3a) and remove the power assisted steering fluid reservoir (3b) complete with pipes (3c).4. Loosen the band and disconnect the coolant return pipe, cylinder head side.

1. Disconnect the rapid connector for the power assisted steering system heat exchanger inlet pipe, heat exchanger side.2. Remove the heat exchanger pipe (2a) after having released it from the securing band (2b).

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. Undo the nut (2a) and disconnect the air conditioning pipes intermediate flange (2b).

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

3. Remove the air condtioning system pipes.

Op. 5530B10 BATTERY - R+R 1. Disconnect the electrical connections from the injection/ignition system control unit.

	Description	Connector
1	Engine management control unit	See M010 ENGINE MANAGEMENT ECU

2. Undo the bolts (2a) and remove the battery drip tray (2b) complete with injection/ignition system control unit (2c).

1. Open the junction unit cover, rotate the junction unit and disconnect the electrical connection (connector A).

	Description	Connector
1	Front/engine coupling	See D004 FRONT/ENGINE COUPLING

1. Loosen the band and disconnect the brake servo vacuum intake pipe, air chamber side.

1. Disconnect the rapid connector for the fuel vapour pipe intermediate coupling.2. Disconnect the rapid connector for the fuel supply pipe, multiple connector side.- Discharge the fuel supply system pressure.

1. Disconnect the electrical connection for the left upper Lambda sensor.

	Description	Connector
1	Lambda sensor on pre-catalyzer	See K015 LAMBDA SENSOR ON PRE-CATALYZER

2. Disconnect the electrical connection for the right upper Lambda sensor.

	Description	Connector
2	Lambda sensor on pre-catalyzer -2	See K016 LAMBDA SENSOR ON PRE-CATALYZER -2

3. Disconnect the electrical connection for the left rear Lambda sensor to the catalytic converter.

	Description	Connector
3	Lambda sensor on catalyzer	See K017 LAMBDA SENSOR ON CATALYZER

4. Disconnect the electrical connection for the right rear Lambda sensor to the catalytic converter.

	Description	Connector
4	Lambda sensor on catalyzer 2	See K018 LAMBDA SENSOR ON CATALYZER - 2

Mark the electrical connections for disconnect them so that they can be correctly refitted.

1. Disconnect the rapid connectors for the air conditioning system heater coolant inlet and outlet pipes.

1. Loosen the collar and disconnect the supply pipe from the engine coolant reservoir.

- Replace the brake-clutch fluid reservoir plug using the tool.

Tool	Description	Function	Validity
2000001400	Plug	Brake-clutch fluid reservoir cap

1. Release the retaining clip (1a) and disconnect the pipe (1b) between the damper and the clutch operating cylinder (1b), operating cylinder side.2. Undo the bolt (2a) and disconnect the earth lead (2b) (connector B) from the gearbox.

	Description	Connector
2b	Battery earth on engine	See C002 BATTERY EARTH ON ENGINE

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

	Description	Connector
1	Reversing lights switch	See I020 REVERSING LIGHTS SWITCH

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

1. Unscrew the bolts (1a) and move aside the bracket (1b) complete with gear selection and engagement cables (1c).

Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R 1. Undo the bolts (1a) and move the brake caliper assemblies (1b) to the side and secure them appropriately.

1. Undo the nuts fixing the steering rods to the front steering knuckles.2. Disconnect the steering rods (2a) from the front steering knuckle using the tool (2b).

Tool	Description	Function	Validity
1871000700	Extractor	Extracting steering rod from steering knuckle

1. Undo the nuts (1a) and disconnect the front suspension upper track control arms (1b) from the steering knuckles (1c).

1. Undo the pins (1a) and remove the front brake discs (1b).

1. Undo the nuts (1a) and disconnect the lower track control arms (1b) from the steering knuckles.

1. Remove the left front wheel steering knuckle (1a) complete with driveshaft (1b).

Collect the gearbox oil that comes out in a suitable container.

1. Loosen the bolts fixing the intermediate driveshaft to the mounting.2. Remove the right front wheel steering knuckle (2a) complete with driveshaft (2b) and intermediate driveshaft (2c).

- Position a hydraulic jack under the engine crankcase sump.1. Undo the bolts fixing the power unit lower reaction rod, engine crankcase sump side.

1. Undo the bolts fixing the power unit rear support flexible mounting, rigid support side.

- Remove the hydraulic jack under the engine crankcase sump.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) and remove the flexible mounting for the power unit timing side front support (1c) complete with power assisted steering fluid reservoir mounting bracket (1d).

1. Undo the bolts (1a), (1b), then remove the gearbox side support flexible mounting (1c).

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

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side support flexible mounting	Bolt	M10	(bodyshell side) 5.4 - 6.6

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side power unit rigid support	Bolt (to be replaced)	M12	(gearbox side) 6.3 - 7.7 + 45°

1. Place the timing side power unit front support flexible mounting (1a) in its housing complete with power assisted steering fluid reservoir mounting bracket (1b) and secure it tightening the bolts (1c) and (1d) to the recommended torque.

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°

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°

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

Tool	Description	Function	Validity
1871001700	Balance	Removing/ refitting power unit

- Position a hydraulic jack under the engine crankcase sump.1. Tighten the bolts fixing the power unit rear support flexible mounting, rigid support side to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Power unit rigid rear support flexible mounting	Bolt	M10	(rigid support side) 5.4 - 6.6

1. Tighten the bolts fixing the power unit lower reaction rod, engine crankcase sump side to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Power unit lower reaction rod	Bolt	M10	(engine crankcase sump side) 5.4 - 6.6

- Remove the hydraulic jack under the engine crankcase sump.- Place the right front wheel steering knuckle in its housing complete with driveshaft and intermediate driveshaft.- 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 left front wheel steering knuckle in its housing complete with driveshaft.1. Connect the lower track control arms (1a) to the steering knuckles and secure them tightening the nuts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Front suspension lower track control arm	Nut	M14	(strut side) 8.1 - 9.9

1. Position the front brake discs (1a) in their housings and secure them tightening the pins (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Front brake discs	Bolt	M10	(wheel hub side) 0.6 - 0.8

1. Connect the front suspension upper track control arms (1a) to the steering knuckles (1b) and secure them tightening the nuts (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

1. Connect the steering links (1a) to the front steering knuckles and secure them tightening the new nuts (1b) to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Steering rods	Nut	M12	(steering knuckle side) 9.0 - 11.0

1. Position the brake caliper assemblies (1a) in their housings and secure them tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Front brake caliper brackets	Bolt	M14	(steering knuckle side) 19.0 - 27.0	1.81.9 JTS2.2 JTS3.2 JTS1.9 JTD 8V1.9 JTD 16V

Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R Op. 4450B12 FRONT WHEELS (TWO) - R+R 1. Refit the bracket (1a) complete with gear selection and engagement cables (1b) and secure them tightening the bolts (1c) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gear selection-engagement cables mounting bracket	Bolt	M8	(gearbox side) 1.9 - 2.9

- Connect the gear selector and engagement cables.- Connect the electrical connection to the reversing light switch.- Connect the earth lead to the gearbox and secure it using the bolt.- Connect the pipe between the damper and clutch operating cylinder, operating cylinder side and secure it using the retaining clip.- Replace the tool with the brake-clutch fluid reservoir plug.

Tool	Description	Function	Validity
2000001400	Plug	Brake-clutch fluid reservoir cap

- Connect the coolant return pipe to the engine coolant reservoir and tighten the collar.- Connect the rapid connectors for the air conditioning system heater coolant inlet and outlet pipes.- Connect the electrical connections for the Lambda sensors.- Connect the rapid connector for the fuel supply pipe, multiple connector side.- Connect the rapid connector for the fuel vapour pipe intermediate coupling.- Connect the brake servo vacuum intake pipe, air chamber side and tighten the band.- Connect the electrical connection, place the junction unit in its housing and close the cover.- Place the battery drip tray complete with injection/ignition system control unit in its housing and secure it using the bolts.- Connect the electrical connections to the injection/ignition system control unit. Op. 5530B10 BATTERY - R+R - Place the air conditioning system pipes in their housings.- Connect the air conditioning pipes intermediate flange and tighten the nut 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
EXPANSION VALVE SIDE PIPE CONNECTOR	Nut	M8	1.8 ÷ 2.2

- Connect the air conditioning compressor inlet/outlet pipes and secure them by tightening the bolt 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
COMPRESSOR SIDE PIPE CONNECTOR	Bolt	M8x90	2.2 ÷ 2.6

- Place the heat exchanger in position and fasten it with the band.- Connect the rapid connector for the power assisted steering system heat exchanger inlet pipe, heat exchanger side.- Connect the coolant return pipe, cylinder head side, and tighten the band.- Place the power assisted steering fluid reservoir complete with pipes in its housing and secure it using the bolts.- Connect the rapid connector for the return pipe from the heat exchanger pipe to the power assisted steering fluid reservoir, heat exchanger side.- Connect the supply pipe from the fluid reservoir to the power assisted steering pump, power assisted steering pump side, and tighten the band. Op. 4130B40 SUPPLY PIPE FROM PUMP TO POWER STEERING BOX - R.R. Op. 7210A18 R.R FRONT CROSSMEMBER - Connect the negative battery terminal. Op. 0010T20 ENGINE COOLANT - CHANGE Op. 0010T41 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY Op. 0010T64 BRAKE AND/OR CLUTCH FLUID CHECK LEVEL AND TOP UP AS NECESSARY Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR Op. 0010T71 POWER STEERING FLUID CHECK LEVEL AND TOP UP IF NECESSARY Op. 0010T75 HYDRAULIC POWER STEERING SYSTEM BLEED AIR Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE - Remove the vehicle from the lift.