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

	Name	Connector
1b	Starter' motor	A20

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

1. Loosen the bolt fixing the manual gearbox and differential to the crankcase.2. Undo the bolt fixing the engine flywheel protective cover to the manual gearbox and differential.3. Undo the bolt (3a) and the bolt (3b) fixing the manual gearbox/engine bracket, gearbox side.4. Undo the bolt fixing the exhaust manifold and catalytic converter mounting bracket to the gearbox.5. Undo the bolt fixing the manual gearbox and differential to the cylinder block/crankcase.Remove the manual gearbox and differential from the engine.

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/engine mounting bracket, gearbox side, to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3a	Bolt	GEARBOX/ENGINE COUPLING BRACKET	M12	(Gearbox side) 5.0 ÷ 6.1

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	GEARBOX/ENGINE COUPLING BRACKET	M12	(Gearbox side) 5.0 ÷ 6.1

4. Tighten the bolt fixing the exhaust manifold and catalytic converter mounting bracket to the gearbox to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
4	Bolt	MANUAL GEARBOX	M10	(Bracket side) 4.5 ÷ 5.5

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

Refit the starter motor in its housing and fix it tightening the bolts to the recommended torque.

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

Connect the electrical connections to the starter motor and fix them using the nuts.