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. Release the electrical wiring (1a) from the band (1b).2. Undo the nut (2a), loosen the band (2b) and remove the air supply pipe from the heat exchanger to the intake manifold (2c).

1. Undo the plug and drain the gearbox-differential oil.

Collect the gearbox-differential oil in a suitable container.

2. Undo the bolts (2a) and remove the intermediate driveshaft (2b).3. Remove the dust excluder.

If the engine is being separated from the gearbox for subsequent overhauling, prepare the engine as a precaution following the instructions given below.1. Remove the plug (1a) and, in its place, fit the tool (1b) on the exhaust side camshaft.

Fit the tool positioning it with the references in a horizontal direction and checking that it is correctly inserted in the housing in the camshaft.

	Name	Country
1b	Template	1.871.000.900

2. Fit a suitable (8 mm diameter) pin via the special opening in the gearbox, then remove it.

Check that the pin is correctly inserted in the housing in the engine flywheel.

1. Undo the bolts (1a) and the nut (1b), then separate the manual gearbox and differential (1c) 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).3. Remove the clutch disc.

1. Place the clutch disc (1a) and the clutch cage (1b) back in its housing using the centring tool (1c).

	Name	Country
1c	Clutch centering	1.870.447.000

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	1.870.447.000

3. Remove the flywheel lock.

	Name	Country
3	Counter-torque	1.860.846.000

1. Connect the manual gearbox and differential (1a) to the engine and secure it tightening the bolts (1b) and (1c) and the nut (1d) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	MANUAL GEARBOX	M8	(Engine/gearbox bracket side) 2.3 ÷ 2.8

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

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

1. Place back in its housing the intermediate drive shaft (1a) complete with dust cover (1b) and secure it with its bolts (1c) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1c	-	-	-	-

2. Tighten the gearbox-differential drain plug to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2	Drain plug	GEAR CASING PADS	M22	(Differential side) 4.6

Place the air supply pipe from the heat exchanger to the intake manifold in its housing, then tighten the band and the nut.Fasten the electrical wiring to the band. Refill the manual gearbox and differential - 0010T40 change manual gearbox oil .