1004B12 POWER UNIT WITH MANUAL GEARBOX - R+R FOR VERSIONS WITH A/C - Fiat - PANDA - eLearn

2752401 - 1004B12 power unit with manual gearbox - r+r for versions with a/c

) Position the vehicle on a lift.1. Move the protective cover away from the positive battery terminal.2. Undo the nut (2a) fixing the starter motor supply lead (2b) and the fuse junction unit supply lead (2c) and disconnect them from the battery.

	Description	Connector
2c	Battery	A1E

3. Undo the fixing nuts (3a) and disconnect the negative battery terminal (3b) and the positive terminal (3c).

	Description	Connector
3b	Battery	A1B

	Description	Connector
3c	Battery	A1A

4. Undo the nut (4a) securing the battery (4b) and remove it.

1. Remove the battery drip tray cover.2. Disconnect the electrical connectors for the engine management control unit.

	Description	Connector
2	Engine management control unit	M10A

	Description	Connector
2	Engine management control unit	M10B

3. Undo the fixing bolt (3a) and disconnect the earth lead (3b).

	Description	Connector
3b	Engine management control unit	M10C

1. Undo the bolts fixing the battery drip tray.2. Move the battery drip tray aside.3. Open the fastening clips (3a) and release the wiring (3b) from the battery drip tray.Remove the battery drip tray complete with engine management control unit.

Op. 1088B10 ENGINE COOLING TANK - R + R Op. 5040A20 AIR CONDITIONER COMPRESSOR - R+R - INCLUDES FLUID LEVEL CHECK AND TOP UP IF NECESSARY Op. 5530A14 ALTERNATOR - R+R FOR VERSIONS WITH AIR CONDITIONER Op. 5040A26 COMPRESSOR MOUNT - R R1. Release the air hose from the cold air intake.2. Undo the fixing bolts (2a) and release the retaining clip (2b).3. Remove the air filter casing complete with hose.

1. Undo the retaining bolts (1a) and remove the wheel (1b).Do the same for both wheels.

Position a suitable container for collecting the coolant.1. Working on the fastening clip (1a) disconnect the lower radiator hose (1b) and drain the system.

1. Remove the protective cover for the engine compartment junction unit (1a) and disconnect the electrical connection underneath (1b).

	Description	Connector
1b	Front/engine coupling	D4

2. Disconnect the electrical connections for the Lambda sensors.

	Description	Connector
2	Lambda sensor on catalyzer	K17

	Description	Connector
2	Lambda sensor on catalyzer - 2	K18

1. Disconnect the single-acting valve (1a) from the brake servo and move the pipe (1b) aside.

1. Open the retaining bands (1a) and the clip (1b) and disconnect the heater pipes (1c).

1. Remove the protective cap (1a) from the single fuel pipe breather valve (1b) and use the tool (1c) to discharge the fuel pressure.Collect the fuel in a suitable container.

	Description	Code
1c	Rapid attachment connector	1.870.684.000

1. Disconnect the fuel supply and recovery pipes.

1. Work on the throttle casing (1a) and disconnect the accelerator cable (1b).

1. Disconnect the reversing sensor switch electrical connection.

	Description	Connector
1	Reversing lights switch	I20

2. Undo nut (2a) and disconnect the earth lead on the gearbox (2b).

	Description	Connector
2b	Battery earth on engine	C2

1. Unscrew the adjustment fastening nut (1a) and disconnect theclutch cable (1b) from thrust bearing control lever (1c).

1. Prise up the gear selection and engagement cable (1b) swivel heads (1a).

1. Unscrew the fixing bolts (1a) for the mounting bracket for the gear selection and engagement cables (1b).Place the cables complete with mounting bracket at the side.

Raise the lift.1. Undo the bolt (1a) securing the exhaust manifold (1b).2. Undo the nut (2a) fixing the coupling for the exhaust pipe (2b) to the exhaust manifold.3. Undo the lower fixing nuts (3a) for the exhaust manifold heat shield (3b).

1. Remove the exhaust tail-pipe flexible block in the wheel arch compartment.2. Remove the exhaust tail pipe flexible block.3. Remove the exhaust pipe flexible block in the underbody.4. Move the exhaust pipe assembly aside, releasing from the exhaust manifold.

1. Remove the fastening clip (1a) and release the brake fluid pipe (1b) from the suspension steering knuckle.Proceed in the same way on both sides of the vehicle.

1. Undo the nut.2. Fit the tool to release the steering heads.

	Description	Code
2	Extractor	1.871.000.700

3. Release the steering heads from the wheel hub.4. Undo bolts (4a) and release front hub axle (4b) from shock absorber (4c).Proceed in the same way on both sides of the vehicle.

Vehicle left side.1. Open the joint boot fastening band.2. Release the driveshaft from the differential side joint.

Do the same on the right side of the vehicle as described above for the left side carrying out the following operation first:1. Undo the fixing nut (1a) and the fixing bolts (1b) and move the wheel arch liner (1c) aside.

1. Undo the retaining bolts (1a) and remove the timing dust cover (1b).

1. Unscrew the fixing bolt (1a) and bolt (1b) and remove the lower reaction link (1c).

Lower the vehicle.1. Undo the upper fastening bolts (1a) and remove the heat shield (1b) for the exhaust manifold.

1. Open the fastening band (1a) and disconnect the cooling system upper hose (1b) from the radiator.

1. Undo the fixing nuts (1a) and remove the exhaust manifold (1b) complete with catalytic converter.Remove the gasket.

1. Fasten the bracket to the crankcase to secure the chains later on.Use a hydraulic lift fitted with suitable chains and hooks.2. Secure the hooks to the brackets.

Lift up the power unit slightly ensuring that the cables are fully taut.1. Undo the bolt securing the engine support to the gearbox side flexible mounting.

1. Undo the nuts (1a) fixing the flexible mounting (1b) to the timing side engine support and remove it.

Manouevre the hydraulic lift carefully and remove the power unit moving it towards the engine compartment taking care not to damage the nearby components.Rest the power unit on a support.

Refitting ( Removing

) Manouevre the hydraulic lift slowly and position the power unit in the engine compartment taking care not to damage the nearby components.Place the flexible mounting in position and tighten the fixing nuts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	FRONT FLEXIBLE MOUNTING BLOCKS, POWER UNIT	M10 X 1.25	5

Tighten the bolt fixing the gearbox side flexible mounting to the engine support to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT FLEXIBLE MOUNTING BLOCKS, POWER UNIT	M12 X 1.25	8

Remove the hooks and the chains from the power unit.Remove the mounting brackets fitted previously from the power unit.Place the exhaust manifold complete with catalytic converter and gasket in position.Tighten the upper nuts fixing the exhaust manifold to the cylinder head and check the torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	EXHAUST MANIFOLD/S	M8 X 1.25	(Cylinder head) 2.5

Connect the upper hose for the cooling system to the engine cooling radiator and renew the fastening band.Fit the heat shield on the exhaust manifold and tighten the fixing bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	LH MANIFOLD HEAT SHIELD BULKHEAD	M6	(Exhaust manifold) 0.9

Raise the vehicle.Position the lower reaction link in its seat and tighten the bolt securing it to the gearbox to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	POWER UNIT REACTION ROD	M12 X 1.25	(Gearbox side) 8

Screw in the bolt securing the lower reaction link to the crossmember to torque and tighten to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	POWER UNIT REACTION ROD	M12 X 1.25	(Crossmember side) 8

Replace the grease inside the driveshafts and the differential housing.

Connect the driveshafts to the gearbox securing the boots with the bands.

	Type	Component	Description	Qty.
-	Grease (g)	ENGINE ASSEMBLY	TUTELA MRM ZERO	100

Place the front hub steering knuckle in position on the shock absorber and tighten the fixing bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	FRONT HUBS COMPLETE WITH BEARING	M10 X 1.25	7.5

Fit the steering head in its seat and tighten the nut to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	ADJUSTABLE STEERING LINKS	M10 X 1.25	4

Fit the timing dust cover and tighten the retaining bolts.Tighten the wheel arch bolts.Secure the brake fluid pipe to the support.Fit the exhaust pipe to the exhaust manifold connector and secure to the rubber mounting blocks.Tighten the nut securing the metal collar securing the flange joining the exhaust manifold to the exhaust pipe central section to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	EXHAUST MANIFOLD/S	M10 X 1.25	4

Fit the transmission swivel head bracket in its seat.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEAR ENGAGEMENT ASSEMBLY CABLE	M8	3

Fit the gear selection and engagement cable swivel heads in their seat in the idler unit.Fit the cables mounting bracket and tighten the fixing bolts.Connect the clutch cable to the thrust bearing control lever and tighten the fixing nut.Connect the reversing sensor electrical connection.

	Description	Connector
-	Reversing lights switch	I20

Connect the earth lead to the gearbox and tighten the nut.

	Description	Connector
-	Battery earth on engine	C2

Fit the accelerator control cable in the housing on the throttle casing.Connect the fuel vapour supply and recovery pipes.Connect the heater pipes to the housings in the bulkhead and renew the fastenings with the bands.Connect the single-acting valve to the brake servo.Connect the electrical connection for the engine compartment junction unit and fit the protective cover.

	Description	Connector
-	Front/engine coupling	D4

Connect the electrical connections for the Lambda sensors.

	Description	Connector
-	Lambda sensor on catalyzer	K17

	Description	Connector
-	Lambda sensor on catalyzer - 2	K18

Op. 5040A26 COMPRESSOR MOUNT - R R Op. 5530A14 ALTERNATOR - R+R FOR VERSIONS WITH AIR CONDITIONER Op. 5040A20 AIR CONDITIONER COMPRESSOR - R+R - INCLUDES FLUID LEVEL CHECK AND TOP UP IF NECESSARY Op. 1088B10 ENGINE COOLING TANK - R + RFit the upper hose for the cooling system to the engine cooling radiator and renew the fastening band.Fit the wheels in place and tighten the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT WHEEL RETAINING BOLT	M12 X 1.25	(Steel rim) 8.6

Fit the air filter casing complete with cold air intake hose in place and tighten the fixing nuts.Fit the battery drip tray complete with engine management control unit and tighten the fixing bolts.Fit the battery drip tray cover.Connect the electrical connectors for the engine ma

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