1004B10 POWER UNIT WITH MANUAL GEARBOX - R + R - Lancia - MUSA - eLearn

184000785 - 1004B10 POWER UNIT WITH MANUAL GEARBOX - R + R

) - Position the vehicle on a lift. Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY CRADLE - R R Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE1. Compress the springs and remove the cold air intake sleeve.

1. Undo the bolts fixing the air filter.2. Raise the air filter.3. Loosen the collar and discnnect the engine oil vapour pipe from the air filter and remove.

1. Disconnect the degasing pipe intermediate joint.2. Loosen the band (2a) and disconnect the outlet pipe (2b) from the coolant manifold to the radiator.

Collect the coolant that comes out in a suitable container.

1. Loosen the band (1a) and disconnect the radiator upper coolant inlet hose (1b), thermostat side.2. Loosen the band (2a) and disconnect the coolant return pipe from heater (2b).3. Disconnect the degasing pipe from the thermostat.4. Loosen the band (4a) and disconnect the heater coolant (4b), thermostat side.

1. Disconnect the electrical connection from the reversing light switch.

	Description	Connector
1	Reversing lights switch	See I020 REVERSING LIGHTS SWITCH

1. Undo the bolts (1a) and move the clutch operating cylinder (1b) sideways without disconnecting the pipe.

1. Undo the nut (1a) and disconnect the battery earth lead (1b) from the gearbox.

	Description	Connector
1b	Battery earth	See C001 BATTERY EARTH

1. Press the release button and disconnect the gear selector cable.2. Disconnect the gear engagement cable.3. Raise clips (3a) and move aside th gear selection and engagement cables (3b).

1. Disconnect the engine joint (1a) and the electrical connection from injection control unit (1b).

	Description	Connector
1a	Front/engine coupling	See D004 FRONT/ENGINE COUPLING

	Description	Connector
1b	Engine management control unit	See M010 ENGINE MANAGEMENT CONTROL UNIT

1. Disconnect the electrical connection from the fuel vapour solenoid valve.

	Description	Connector
1	Fuel vapour recovery solenoid valve	See L010 FUEL VAPOUR RECOVERY SOLENOID VALVE

2. Disconnect the fuel pipe from the rail.

1. Disconnect the electrical connection from the throttle casing.

	Description	Connector
1	Integrated throttle casing actuator	See N075 INTEGRATED THROTTLE CASING ACTUATOR

1. Disconnect the vacuum single-acting valve from the brake servo.

1. Disconnect the fuel vapour pipe intermediate joint.2. Unscrew bolts (2a)and disconnect the coolant pipes from the air conditioning compressor (2b).

1. Disconnect the electrical connections of the lambda sensors upstream and downstream of the catalytic converter.

	Description	Connector
1	Lambda sensor on catalyzer	See K017 LAMBDA SENSOR ON CATALYZER

1. Undo the nuts (1a) securing the exhaust manifold (1b) to the cylinder head.

1. Undo nuts (1a) and disconnect the exhaust silencer from the manifold-catalytic converter unit (1b) and remove.

1. Unscrew the bolts securing the front stub axles to their shock absorbers.2. Unscrew nut (2a) and use tool (2b) to disconnect the steering links (2c).

Tool	Name	Operation	Function	Validity
1871000700	Estrattore	1004B10	Estrazione tirante sterzo dal montante	1.4 8v

1. Loosen collars (1a) and disconnect drive shafts (1b).

Secure the drive shafts as appropriate.

1. Undo the bolt securing the reaction rod to the suspension crossmember.

- Lower the lift and place a suitable support underneath the power unit.1. Use tool (1a) to attach the power unit to points (1b) and (1c).

Tool	Name	Operation	Function	Validity
1871001700	Bilancino	1004B10	Stacco/riattacco gruppo motopropulsore	1.4 8v

2. Unscrew nuts (2a) securing the power unit timing side flexible mounting block (2b).

1. Undo the nut (1a) securing the power unit gearbox side rigid support to the flexible mounting block (1b).

- Slowly lower the power unit until it rests on the board positioned previously.

Refitting ( Removing

) - Refit the power unit in its seat in the engine compartment using a hydraulic lift until it rests on the previously positioned platform.- Tighten the nut securing the power unit gearbox side rigid support to the flexible mounting block to the recommended torque.

Component	Fastening	Ø	Value (daNm)	Validity
ENGINE MOUNT TIMING SIDE	Bolt	M10	(Engine crankcase side) 5.4 ÷ 6.6	1.2 16v1.4 16v

- Tighten the nuts fixing the timing side power unit flexible mounting block to the support to the recommended torque.

Component	Fastening	Ø	Value (daNm)	Validity
LOWER ROD ON ENGINE	Bolt	M12	(Front suspension crossmember side) 11.4 ÷ 12.6	1.3 JTD 16v

- Remove the hydraulic lift complete with the power unit support tool.- Secure the reaction link to the suspesion beam to the specified torque.

Component	Fastening	Ø	Value (daNm)	Validity
POWER UNIT GEAR BOX END RIGID MOUNT	Nut	M12	(Flexible mounting side) 8.1 ÷ 9.9	1.2 16v1.3 JTD 16v1.4 16v1.9 JTD 8v

- Connect the driveshafts and tighten the bands.- Tighten the bolts securing the front stub axles to their front shock absorbers to the recommended torque.

Component	Fastening	Ø	Value (daNm)	Validity
ALLOY WHEELS	Bolt	M12	7.7 ÷ 9.5

- Connect the steering links to the front steering knuckles and tighten the nut to the specified torque.

Component	Fastening	Ø	Value (daNm)	Validity
TIRANTI STERZO	Dado	M8	(Lato montante) 7.5	1.4 8v

- Connect the exhaust silencer to the manifold-catalytic converter unit and tighten the nuts to the specified torque.

Component	Fastening	Ø	Value (daNm)	Validity
COLLETTORE/CONVERTITORE DI SCARICO	Dado	M10	4.5	1.4 8v

- Connect the manifold-catalytic converter unit to the cylinder head and tighten the nuts to the specified torque.

Component	Fastening	Ø	Value (daNm)	Validity
COLLETTORE DI SCARICO CON CONVERTITORE CATALITICO	Dado	M10	(Lato testa cilindri) 2.5	1.4 8v

- Position and fit the exhaust manifold heat shield.- Connect the electrical connections to the two lambda sensors upstream and downstream of the catalytic converter.- Connect the coolant inlet and outlet pipes to the air conditioner compressor and secure by tightening the bolts to the specified torque.

Component	Fastening	Ø	Value (daNm)	Validity
TUBAZ.COMPRESSORE/CONDENSATORE (C.A)	Vite	M6	0.7 ÷ 1.1	1.2 16v1.4 16v1.4 8v

- Connect the fuel vapour pipe, intake chamber side.- Fit the one-way valve on the brake servo.- Connect the electrical connection to the throttle casing.- Connect the fuel pipe to the rail.- Connect the electrical connection to the fuel vapour solenoid valve.- Connect the electrical connection for the engine wiring to the injection control unit.- Connect the electrical connection for the engine coupling.- Connect the gear selector and engagement cables.- Connect the earth lead to the gearbox.- Place the clutch slave cylinder in its housing and secure it tightening the bolts to the recommended torque.

Component	Fastening	Ø	Value (daNm)	Validity
CLUTCH SLAVE CYLINDER	Bolt	M8	(Gearbox side) 1.8 - 2.2	1.2 16v1.3 JTD 16v1.4 16v

- Connect the electrical connection to the reversing light switch.- Connect the coolant supply pipe to the heater, thermostat side.- Connect the degasing pipe to the thermostat.- Connect the coolant return pipe to the heater, thermostat side.- Connect the coolant supply pipe to the radiataor, thermostat side.- Connect the intermediate degasing pipe.- Connect the engine oil vapour pipe to the air filter and fit using the bolts.- Connect the cold air intake sleeve to the air filter. Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE Op. 5530B52 BATTERY CRADLE - R R Op. 5530B10 BATTERY - R+R Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R- Remove the vehicle from the lift.