1004B10 POWER UNIT WITH MANUAL GEARBOX - R + R - Fiat - MULTIPLA - eLearn

2891178 - 1004B10 power unit with manual gearbox - r + r

) With the ignition key in the OFF position, disconnect the battery negative terminal.Place the car on a ramp. - 4450B10 Front WHEEL (one) - R.R. - 1048A10 air cleaner filtering element - replace - 1088D10 lower sleeve for coolant outlet from radiator - r + r - 1088D14 upper sleeve for coolant inlet to radiator - r + r - 1088E10 radiator cooling fan - r + r - 1088B20 engine cooling radiator - r + r - 5530B10 battery - r+r1. Disconnect the clutch release cable by undoing the nut (1a) and disengaging it from its attachment on the gearbox (1b), then remove the cable (1c).2. Undo the bolts (2a) and remove the air cleaner mounting bracket (2b).3. Undo the nut (3a) securing the earth cable (3b) on the gearbox and move the cable aside.4. Disconnect the electrical connection for the reversing lights.

	Name	Connector
4	Reversing light switch	I20

1. Remove the collection tank from the battery cradle.2. Undo press-fitted fuse boxes (2a) and open engine wiring collar (2b).3. Unscrew nut (3a) and release earth lead ( 3b) from the control unit mount.4. Undo the bolts retaining the battery cradle to the body.5. Disconnect injection control unit electrical connections (5a) and (5b). Then remove battery cradle/injection control unit assembly (5c).

	Name	Connector
5a	Engine management ECU	M10A

	Name	Connector
5b	Engine management ECU	M10B

1. Raise the ramp and unscrew bolts (1a) securing mount (1b).Lower the lift.2. Disconnect the gear selection transmission cable end (2a), remove the dust excluder (2b), then remove the flexible transmission cables unit and mounting from the relay unit.

1. Disconnect electrical connections (1a), (1b), (1c).

	Name	Connector
1a	Front/engine junction	D4

	Name	Connector
1b	Lambda sensor	K40

2. Undo fixing nut (2a) and separate starter motor supply lead (2b) from the battery positive terminal.

1. Undo collars (1a) and disconnect coolant supply and return pipes (1b) from the heater.

1. Remove clip (1a) and disconnect accelerator cable (1b) from its fitting on the throttle body (1c). Then place to one side.

1. Disconnect fuel delivery line (1a) from quick-release fitting (1b).2. Open collar (2a) and disconnect brake servo vacuum pipe (2b). 3. Open collar (3a) and disconnect evaporation control system pipe (3b). 4. Open collar (2a) and disconnect coolant pipe (2b) to the throttle body. 5. Open the collars and release the pipes from the cylinder head.

Position a container to collect the power steering fluid.1. Use a syringe to drain power steering fluid from the reservoir.2. Disconnect piping (2a) from the power steering pump by opening retaining collar (2b).3. Undo connector (3a) and disconnect pipe (3b) from the power steering pump.

Raise the lift about half of its travel.1. Using a hammer and suitable chisel, relieve the staking on the wheel hub nut and undo it. Use a 36 mm diameter socket suitably machined so that it fits snugly on the whole surface of the nut.2. Undo the bolts securing the shock absorber strut.3. Undo the nut (3a) and using tool (3b), remove the tie-rod end from the steering knuckle.

	Name	Country
3b	Head extractor	1.847.035.000

1. Disconnect the electrical connection of the brake pad wear warning light.2. Tip the brake disc/wheel hub assembly downwards.3. Withdraw the drive shaft from its attachment on the wheel hub.

- 1076A74 heat shield for exhaust pipe attachment to manifold - r r - 1076B50 exhaust pipe attachment to engine - r + r - 1008A44 rear rigid mount - r r - 1008B20 power unit intermediate mount flexible block - replace1. Secure the engine using a hydraulic hoist fitted with suitable chains and hooks.

- 1008A42 gear box left rigid mount - r r - 1008B30 gearbox side mount flexible block - replace1. Undo the bolts fixing the camshaft side support flexible mounting to the body. Remove the hydraulic hoist and place the power unit on a stand.

Refitting ( Removing

) Take the power unit off the stand and secure with chains.Prepare the engine compartment for insertion of the gearbox, making sure that all the electrical cables, pipes, etc. are positioned well out of the way.When fitting the power unit, take care not to damage the individual components. - 1008A42 gear box left rigid mount - r r - 1008B30 gearbox side mount flexible block - replace - 1008A44 rear rigid mount - r r - 1008B20 power unit intermediate mount flexible block - replaceTighten the bolts fixing the camshaft side support flexible mounting to the body.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT RUBBER MOUNTS	M12 x 1.25	8

- 1076B50 exhaust pipe attachment to engine - r + r - 1076A74 heat shield for exhaust pipe attachment to manifold - r rWithdraw the drive shaft from its attachment on the wheel hub.Connect the electrical connection of the brake pad wear warning light.Tighten the nut securing the tie-rod end nut.

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

Tighten the bolts securing the shock absorber strut.

	Fastening	Component	Ø	Value(daNm)
-	Nut	FRONT HUB STEERING KNUCKLE.	M10	7

Tighten the nut securing the hub to the steering knuckle to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	FRONT HUB STEERING KNUCKLE.	M24	7 + 62°

1. Using a hammer and suitable chisel, stake the wheel hub nut. The collar should be cut on the notch on the hub, on the side opposite that of tightening the nut, so that the safety lug prevents accidental loosening.

Restore the power steering pump pipe connections.Top up the power steering pump levelUse new collars to secure the pipes to the cylinder headUse new collars to secure the coolant pipe to the throttle bodyUse new collars to secure the evaporation control system pipeUse new collars to secure the brake servo vacuum pipeConnect the fuel pipeFit the accelerator control cable to the throttle body.Use new collars to secure the coolant delivery and return pipes to the heater.Tighten the retaining nut and connect the starter motor supply lead to the battery positive lead.Connect the electrical connections.

	Name	Connector
-	Front/engine junction	D4

	Name	Connector
-	Lambda sensor	K40

	Name	Connector
-	Reversing light switch	I20

Connect gear selection transmission cable end (2a), fit dust excluder (2b), then fit the flexible transmission cables unit and mounting to the relay unit.Lower the ramp and tighten the mount retaining bolts.Fit the battery holder/injection control unit assembly.Connect the injection control unit connections.Tighten the bolts securing the battery holder to the body.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	BATTERY SUPPORT/CAGE	M8	3

Position the earth lead on the control unit mount and tighten the nut.Secure the fuse boxes to the brackets, and do up the collars to secure the engine wiring.Position the collection tank in its seat on the cradle.Tighten the bolts and secure the air cleaner mounting bracket.Tighten the nut securing the earth lead to the gearbox.Connect the clutch release control cable to the lever and gearbox fitting. - 5530B10 battery - r+r - 1088B20 engine cooling radiator - r + r - 1088E10 radiator cooling fan - r + r - 1088D14 upper sleeve for coolant inlet to radiator - r + r - 1088D10 lower sleeve for coolant outlet from radiator - r + r - 1048A10 air cleaner filtering element - replace - 4450B10 Front WHEEL (one) - R.R.Remove the vehicle from the ramp.With the ignition key in stop position, connect the battery negative terminal.