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

) Disconnect the negative battery terminal.Position the vehicle on a lift. Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE1. Undo the retaining bolts (1a) and remove the wheel (1b).Do the same for both wheels.

Op. 1048A10 AIR CLEANER FILTERING ELEMENT - REPLACE Op. 1048A21 FILTER INPUT SLEEVE - R R Op. 5530B10 BATTERY - R+R Op. 5530B56 BATTERY DRIP TRAY COVER - R.R. Op. 5530B52 BATTERY CRADLE - R R1. Undo the retaining bolts.2. Disconnect the electrical connection for the heater plugs control unit.

	Description	Connector
2	Heater plugs control unit	M15A

3. Disconnect the electrical connection for the heater plugs control unit.

	Description	Connector
3	Heater plugs control unit	M15B

4. Undo the fixing nut (4a) and disconnect the earth lead (4b) from the heater plug control unit.

	Description	Connector
4a	Heater plugs control unit	M15C

5. Remove the heater plug preheating control unit.

1. Disconnect the electrical connector for the ABS control unit

	Description	Connector
1	ABS control unit	M50

2. Disconnect the electrical connection for the brake fluid level sensor.

	Description	Connector
2	Brake fluid level sensor (switch)	K25

1. Disconnect the electrical connection for the reversing sensor.

	Description	Connector
1	Reversing lights switch	I20

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

1. Undo the nut.2. Separate the wiring (2a) from the wiring (2b).

Position a suitable container for collecting the coolant.1. Undo clip (1a) to disconnect the lower radiator hose (1b) and drain the cooling system.

1. Open the retaining band (1a) and release the hose (1b) from the rigid pipe.2. Open retaining collar (2a) and release sleeve (2b) from the fitting on the air-air heat exchanger.3. Undo the fixing bolts (3a) and remove the rigid air pipe (3b).

1. Disconnect the ends of the gear engagement/selector cables.2. Remove the clips (2a) and release the gear engagement/selection cables (2b).

1. Unscrew nut (1a) and disconnect clutch cable (1b) from drive bracket (1c).

1. Open the securing band (1a) and disconnect and remove the coolant pipe (1b).

1. Undo the fixing bolts (1a) and disconnect the air pipe (1b).Keep the gasket.2. Open retaining collar (2a) and remove the turbocharger/air-air heat exchanger air pipe (2b).

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

1. Open the fastening band.2. Disconnect the coolant pipe.

Op. 1088B10 ENGINE COOLING TANK - R + R1. Disconnect the fuel pipe rapid connector.2. Disconnect the fuel pipe rapid connector.3. Disconnect the fuel pipe rapid connector.4. Disconnect the electrical connection from the fuel temperature sensor.

	Description	Connector
4	Fuel temperature sensor	K81

5. Disconnect the electrical connection for the water in the filter sensor.

	Description	Connector
5	Water in diesel filter sensor	K31

1. Undo the retaining bolts.2. Remove the diesel filter with the mounting bracket.

1. Open collars (1a) and (1b) and remove the coolant sleeve (1c).

1. Undo the two fixing bolts (1a) and disconnect the two air conditioning pipes (1b) from the air conditioner compressor.

1. Remove the protective cover for the engine compartment junction unit (1a) and disconnect the electrical connection underneath (1b).2. Disconnect the fuel recovery pipe.

Op. 1076B20 REAR EXHAUST SILENCER - R + R Op. 1076B40 CENTRE EXHAUST PIPE - R.R.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.

Unscrew the nuts securing the stabiliser bar to the link heads.Prise up the stabiliser bar retaining link heads.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).

Op. 1008C32 GEARBOX LOWER REACTION ROD ' -R.R.1. Anchor the power unit using a hydraulic lift (1a) to the brackets (1b) (1c) (1d).

1. Undo the retaining nuts.2. Remove the timing side flexible mounting.

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

Manouevre the hydraulic lift carefully and remove the power unit moving it towards the engine compartment taking care not to damage the nearby components.1. 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.Tighten the bolt securing the gearbox side flexible block to the engine mount and tighten to the specified torque.

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

Fit the flexible mount and tighten the nuts to the torque levels indicated.

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

Remove the hooks and the chains from the power unit. Op. 1008C32 GEARBOX LOWER REACTION ROD ' -R.R.

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.Prise up the stabiliser bar retaining link heads.Tighten the nuts securing the stabiliser bar to the link heads. Op. 1076B40 CENTRE EXHAUST PIPE - R.R. Op. 1076B20 REAR EXHAUST SILENCER - R + RConnect the fuel recovery pipe.Connect the electrical connection and fit the engine compartment junction unit protective cover.Connect the air conditioner pipes to the air conditioner compressor and tighten the bolts to the specified torque.

Replace any O-Rings for the connectors using green coloured seals only which are resistant to the R134a refrigerant fluid.Lubricate the connector threads using anti-freeze.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	PIPES FROM COMPRESSOR TO CONDENSOR	M6	(Compressor side) 0.7 - 1.1

Fit the coolant sleeve and tighten the retaining bands.Fit the diesel filter with bracket and tighten the bolts.Connect the fuel pipes to the diesel filter and connect the fuel temperature sensor and water in diesel filter sensor connections

	Description	Connector
-	Fuel temperature sensor	K81

	Description	Connector
-	Water in diesel filter sensor	K31

Connect the single-acting valve to the brake servo.Connect the heater supply and return pipes and restore the fastening bands.Fit the turbocharger/air-air heat exchanger pipe and tighten the bolts and collar.Fit the coolant sleeve and tighten the retaining bands.Connect the clutch cable to the thrust bearing control lever and tighten the fixing nut.Fit the gear selection and engagement cable swivel heads in their seat in the idler unit.Fit the rigid pipe and air system sleeves from the air-air heat exchanger to the intake chamber and tighten the bolts and collars.Connect the electrical connection for the reversing sensor.

	Description	Connector
-	Reversing lights switch	I20

Connect the earth lead to the gearbox and tighten the nut.Connect the electrical connector for the ABS control unit

	Description	Connector
-	ABS control unit	M50

Connect the electrical connection for the brake fluid level sensor.

	Description	Connector
-	Brake fluid level sensor (switch)	K25

Assemble the alternator wiring to the battery terminal and tighten the nut.Connect the earth lead to the control unit and tighten the nut.Connect the electrical connections for the heater plugs control unit.

	Description	Connector
-	Heater plugs control unit	M15A

	Description	Connector
-	Heater plugs control unit	M15B

	Description	Connector
-	Heater plugs control unit	M15C

Fit the heater plug control unit and bracket in its seat and tighten the bolts. Op. 5530B52 BATTERY CRADLE - R R Op. 5530B56 BATTERY DRIP TRAY COVER - R.R. Op. 5530B10 BATTERY - R+R Op. 1048A21 FILTER INPUT SLEEVE - R R Op. 1048A10 AIR CLEANER FILTERING ELEMENT - REPLACEFit 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

Op. 0010T20 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGEConnect the negative battery terminal.Remove the vehicle from the lift.