1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, REMOVE AND RE-BUILD - Lancia - Ypsilon - eLearn

2428849 - 1004D10 power unit (manual gearbox), removed, remove and re-build

) 1. Open the cover (1a), undo the nuts (1b) and disconnect the electrical connections (1c) for the alternator.

	Name	Connector
1c	Starter' motor	A20

2. Undo the bolts (2a) and remove the starter motor (2b).

1. Undo the bolt (1a) and the bolt (1b) fixing the manual gearbox and differential to the manual gearbox/engine bracket. 2. Undo the bolt fixing the engine flywheel protective cover to the manual gearbox and differential.3. Loosen the bolt fixing the manual gearbox and differential to the crankcase.4. Remove the remaining bolts fixing the manual gearbox and differential to the cylinder block/crankcase.5. Remove the manual gearbox and differential from the engne block.

1. Fit the flywheel lock.

	Name	Country
1	Counter-torque	1.860.846.000

2. Undo the bolts (2a) and remove the clutch cover (2b).Remove the clutch disc.

Refitting ( Removing

) 1. Place the clutch disc and the clutch drip tray (1a) back in its housing using the centering tool (1b).

	Name	Country
1b	Clutch centering	1.875.086.000

2. Tighten the bolts fixing the clutch cover to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	-	-	-	-

Remove the clutch disc and clutch cage centring tool.

	Name	Country
-	Clutch centering	1.875.086.000

Remove the flywheel lock.

	Name	Country
-	Counter-torque	1.860.846.000

1. Tighten the bolt fixing the manual gearbox and differential to the crankcase to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	MANUAL GEARBOX	M12	(Crankcase side) 7.2 ÷ 8.8

2. Tighten the bolts fixing the manual gearbox and differential to the crankcase to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	MANUAL GEARBOX	M12	(Crankcase side) 7.2 ÷ 8.8

3. Tighten the bolt (3a) and the bolt (3b) fixing the manual gearbox and differential to the manual gearbox/engine bracket to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3a	Bolt	MANUAL GEARBOX	M12	(Gearbox/engine bracket side) 5.0 ÷ 6.1

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	MANUAL GEARBOX	M12	(Gearbox/engine bracket side) 3.6 ÷ 4.4

4. Tighten the bolts fixing the engine flywheel protective cover to the manual gearbox and differential.

1. Place the starter motor (1a) back in its housing and fix it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	STARTER MOTOR	M8	2.4 ÷ 3.0

2. Connect the electrical connections (3a) to the starter motor, fix them using the nut (2b) and close protective cover (2c).