1004B10 POWER UNIT WITH MANUAL GEARBOX - R + R - Lancia - Ypsilon - eLearn

2428847 - 1004B10 power unit with manual gearbox - r + r

) Place the car on a lift. Drain the air conditioner coolant circuit - 0010T84 coolant for air conditioning system dehydrate and recharge . Proceed with removal - 4450B12 front or rear wheels (two) - r+r . Proceed with removal - 7055B66 Engine compartment DUST SHIELD protection in right front wheel arch - R.R. . Proceed with removal - 7055B91 Right front WHEEL ARCH LINER - R.R. . Proceed with removal - 5530B10 battery - r+r . Proceed with removal - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. . Proceed with removal - 1048A10 air cleaner filtering element - replace . Position a suitable container to collect the coolant.1. Disconnect upper sleeve (1a) and lower sleeve (1b) on the radiator side by removing collars (1c).

1. Undo the bolt securing the coolant pipe mounting bracket to the air conditioner compressor.2. Undo the bolts (2a) and disconnect the coolant fluid inlet and outlet pipes (2b) from the air conditioning compressor and move aside.

Remove the cover from the junction unit.1. Release the junction unit from its seat.2. Disconnect the electrical connection from the junction unit.

	Name	Connector
2	Front / dashboard coupling	D1

3. Disconnect the electrical connections (3a) and (3b).

	Name	Connector
3a	Front / engine coupling	D4a

	Name	Connector
3b	Front / engine coupling	D4b

1. Undo the bolts (1a) fixing the gear selector and engagement cables mounting bracket (1b).2. Press the release button (2a) and disconnect the gear selector cable (2b). 3. Disconnect the gear engagement cable.Move the gear selector and engagement cables, complete with mounting bracket, sideways.

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

	Name	Connector
1	Reversing lights switch	I20

1. Undo the bolts (1a) and move aside the clutch slave cylinder (1b).

1. Undo the nut (1a) and disconnect the earth lead (1b) from the gearbox.

	Name	Connector
1b	Battery earth	C1

1. Prise out pipe (1a) of brake servo vacuum pump (1b) and release from the retaining clip.2. Remove the fastening bands and disconnect the heater side heater coolant supply/return pipes.

1. Remove the protective cap (1a) for the fuel manifold vent (1b) and use the tool (1c) to discharge the fuel pressure from the fuel system.

Recover the fuel which comes out in a suitable container.

	Name	Country
1c	Rapid connector	1.870.684.000

1. Disconnect the intermediate rapid attachment for the fuel vapour recirculation pipe.

1. Disconnect the quick-release fitting on the fuel supply pipe to the manifold pipe.2. Disconnect the accelerator control cable (2a) from the throttle valve (2b) and remove the cable from the mounting bracket (2c).Place the accelerator cable to one side.

Proceed with removal - 1072C44 exhaust manifold heat shield on bulkhead - r+r . Proceed with removal - 1072C16 exhaust manifold with catalytic converter - r r . 1. Undo the nuts (1a) and disconnect the track rods (1b) from the steering knuckles usiing the tool (1c).

	Name	Country
1c	Extractor	1.871.000.700

2. Undo the bolts fixing the front hub steering knuckle to the front shock absorbers.

1. Loosen the bands (1a) and disconnect the driveshafts (1b ).

secure the drive shafts.

1. Undo the bolt fixing the air conditioning pipe mounting bracket to the alternator.

Position a hydraulic jack under the gearbox.1. Undo the bolt (1a) and the bolt (1b) and remove the power unit lower reaction rod (1c).Remove the hydraulic jack from under the gearbox.

1. Secure ordinary brackets to the crankcase.Use a hydraulic lift with chains and hooks.2. Anchor the hooks to the brackets.

Position a suitable support under the power unit.1. Undo the nuts (1a) and (1b), then remove the timing side power unit support flexible mounting (1c).

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

Slowly lower the power unit with the hydraulic hoist until it is resting on the support positioned previously.

Refitting ( Removing

) Place the power unit back in the engine compartment using the hydraulic hoist and rest on the board positioned previously.1. Tighten the bolt securing the gearbox side rigid power unit support to the flexible mounting to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M12	(Flexible mounting side) 8.1 ÷ 9.9

1. Place the timing side power unit support flexible mounting (1a) in position and secure it tightening the nuts (1b) and (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	FRONT RUBBER MOUNTS	M10	(Rigid support side) 4.5 ÷ 5.5

	Fastening	Component	Ø	Value(daNm)
1c	Nut	FRONT RUBBER MOUNTS	M10	(Bodyshell side) 4.1 ÷ 5.0

Remove the hydraulic hoist fitted with suitable chains used for supporting the power unit.Position a hydraulic jack under the gearbox. 1. Place the power unit reaction rod (1a) back in its housing, then fasten by tightening bolts (1b) and (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	LOWER ROD ON ENGINE	M12	(Gearbox side) 7.2 ÷ 8.8

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	LOWER ROD ON ENGINE	M12	(Front suspension crossmember side) 11.4 ÷ 12.6

Remove the hydraulic jack from under the gearbox.

Tighten the bolt fixing the air conditioning pipe mounting bracket to the alternator. Connect the driveshafts and tighten the bands.1. Tighten the front wheel hub fastening bolts to the front shock absorbers to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	FRONT HUB STEERING KNUCKLE.	M10	(Shock absorber side) 6.2 ÷ 6.8

2. Connect the steering rods (2a) to the front steering knuckles and tighten the nut (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Nut	ADJUSTABLE STEERING LINKS	M10	(Steering knuckle side) 3.6 ÷ 4.4

Proceed with refitting - 1072C16 exhaust manifold with catalytic converter - r r . Proceed with refitting - 1072C44 exhaust manifold heat shield on bulkhead - r+r . Connect the accelerator cable to the throttle valve.Connect the rapid attachment for the fuel supply pipe to the manifold pipe.Connect the rapid connector for the fuel vapour recirculation pipe.Connect the coolant outlet/inlet pipes to the heater on the heater side and secure with collars.Connect the vacuum pump pipe and secure with the collar.Connect the battery earth lead and fix it using the nut.Position the clutch slave cylinder and tighten bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CLUTCH SLAVE CYLINDER	M8	(Gearbox side) 1.6 ÷ 2.4

Connect the electrical connection to the reversing lights switch.Place the gear selector and engagement cables, complete with mounting bracket, back in their housings.Connect the gear selector cable.Connect the gear engagement cable.Tighten the bolts fixing the gear selector and engagement mounting bracket.Connect the electrical connections to the junction unit.Refit the junction unit in its seating.Refit the junction unit cover.Connect the coolant inlet and outlet pipes to the air conditioner compressor and secure by tightening the bolt to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	PIPES FROM COMPRESSOR TO CONDENSOR	M6	(Compressor side) 09.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	EXPANSION VALVE - COMPRESSOR PIPE	M6	(Compressor side) 09.

Tighten the bolt securing the coolant pipe mounting bracket to the air conditioner compressor.Connect the lower and upper radiator hoses to the radiator and secure with collars. Proceed with refitting - 1048A10 air cleaner filtering element - replace . Proceed with refitting - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. . Proceed with refitting - 5530B10 battery - r+r . Proceed with refitting - 7055B91 Right front WHEEL ARCH LINER - R.R. . Proceed with refitting - 7055B66 Engine compartment DUST SHIELD protection in right front wheel arch - R.R. . Proceed with refitting - 4450B12 front or rear wheels (two) - r+r . Proceed with refitting - 1068A10 accelerator pedal control - check, adjust if necessary and lubricate . Refill the engine cooling system with coolant - 0010T20 coolant change . Fill the air conditioner coolant circuit - 0010T84 coolant for air conditioning system dehydrate and recharge . Remove the vehicle from the ramp.