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 fastenings and remove the heat shield for the catalytic preconverter for the right head.

1. Undo the fastenings and remove the exhaust manifold/catalytic preconverter for the right head complete with Lambda sensor.

1. Undo the fastenings and remove the inner heat shield for the catalytic preconverter for the right head.

1. Undo the fastenings and remove the heat shield for the catalytic preconverter for the left head.

1. Undo the bolt securing the oil dipstick pipe to the head and remove it.2. Undo the fastenings and remove the exhaust manifold/catalytic preconverter for the left head complete with Lambda sensor.

1. Undo the nuts and disconnect the wiring from the starter motor.

	Description	Connector
1	Starter motor	See A020 STARTER MOTOR

2. Undo the fixing bolts and remove the starter motor.

1. Undo the bolts fixing the gearbox to the engine and remove it.

1. Undo the two bolts fastening the rear drive idler casing and remove it.- Remove the O-ring from the rear drive idler casing-gearbox flange.

If the rear drive idler casing is being refitted, the gearbox side O-ring removed previously must be replaced.

1. Fit the flywheel lock.

Tool	Description	Function	Validity
1860846000	Counter-torque	Flywheel lock

2. Unscrew the three bolts spaced at 120 ° securing the clutch mechanism.3. Fit the locating pin (3a) and the remaining part of tool (3b), tightening the bolts (3c) into the seats of the bolts removed previously.

Tool	Description	Function	Validity
1871003100	Extractor/ fitting tool	Clutch mechanism removal	3.2 JTS2.4 JTD 20V

4. Turn the tool handwheel until the pins (4a) are in contact with the disc (4b).5. Undo the remaining bolts securing the clutch mechanism.6. Undo the tool handwheel to discharge the clutch mechanism diaphragm spring.- Remove the tool.

Tool	Description	Function	Validity
1871003100	Extractor/ fitting tool	Clutch mechanism removal	3.2 JTS2.4 JTD 20V

7. Remove the clutch mechanism.- Remove the clutch plate.

1. Undo the bolts and remove the flywheel.

Refitting ( Removing

) - Place the flywheel in its housing and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine flywheel	Bolt	-	3.0 + 45°	3.2 JTS

1. Fit the tool locating pin into the crankshaft.2. Refit the clutch mechanism in position.

It is not possible to replace the cltuch plate on its own. Instead the clutch plate/mechanism assembly must be replaced.

When fitting the clutch plate the correct position is shown by the words "engine side" and "gearbox side".

Handle the clutch plate carefully. Do not touch the surfaces of the friction linings with your hands.

Clean any anti-corrosion protection or detergents from the friction surface of the clutch mechanism.

3. Fit the remaining part of tool (3a) for fitting the clutch device and tighten the bolts (3b).4. Turn the tool handwheel until the pins (4a) are in contact with the disc (4b).5. Hand tighten the three free retaining bolts until the clutch device is packed together.6. Undo the tool handwheel to discharge the clutch mechanism diaphragm spring.- Remove the tool.

Tool	Description	Function	Validity
1871003100	Extractor/ fitting tool	Clutch mechanism removal	3.2 JTS2.4 JTD 20V

- Tighten the remaining clutch fixing bolts by hand.- Gradually tighten the bolts fixing the clutch diagonally until the recommended torque is reached.7. Remove the flywheel lock.

Tool	Description	Function	Validity
1860846000	Counter-torque	Flywheel lock

- Fit a new O-ring on the rear drive idler casing-gearbox flange.- Position the rear drive idler casing in its housing and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Rear drive idler casing to engine	Bolt	M8	2.2 ÷ 2.6	3.2 JTS

Component	Fastening	dia	Value (daNm)	Validity
Rear drive idler casing to engine	Bolt	M6	0.7 ÷ 1.1	3.2 JTS

- Assemble the gearbox and the engine and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox to engine	Bolt	M10	5.4 ÷ 6.6	3.2 JTS

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox to rear drive idler casing	Bolt	M12	10.9 ÷ 12.1	3.2 JTS

- Place the starter motor in its housing and secure it tightening the bolts to the recommended torque.- Connect the starter motor wiring and secure it using the nuts.- Place the exhaust manifold/catalytic preconveter for the left head in its housing complete with Lambda sensor and tighten the fastenings.- Place the oil dipstick pipe back in its housing and fasten it with the bolt.- Place the heat shield for the catalytic preconverter for the left head in its housing and tighten the fastenings.- Place the inner heat shield for the catalytic preconverter for the right head in its housing and tighten the fastenings.- Place the exhaust manifold/catalytic preconveter for the right head in its housing complete with Lambda sensor and tighten the fastenings.- Place the heat shield for the catalytic preconverter for the right head in its housing and tighten the fastenings.