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

2400052 - 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 bolts fixing the manual gearbox and differential to the crankcase sump.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. Undo the remaining bolts securing the manual gearbox and differential to the cylinder block/crankcase.5. Remove the manual gearbox and differential from the engine 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 cover (1a) back in its housing using the centring 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	Bolt	CLUTCH ASSEMBLY	M8	(Engine flywheel side) 2.5 ÷ 3.1

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

	Fastening	Component	Ø	Value(daNm)
3	Bolt	MANUAL GEARBOX	M10	(Engine crankcase sump 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).