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

2891348 - 1004B12 power unit with manual gearbox - r+r for versions with a/c

) - 5040A10 Air conditioning refrigerant CIRCUIT - Draining and Refilling - 7040A96 facia glove compartment flap (1) lh or rh - r r - 5050B32 windscreen wiper arm/s - r+r - 7055A18 Windscreen base TRIM - R.R.1. Disconnect electrical connection (1a), disconnect the electrical connections from injection control unit (1b).2. Disconnect the relays from the control unit mount.3. Unscrew bolt (3a) and disconnect earth lead (3b) from the right side pillar.

	Name	Connector
1a	Engine management ECU	M10

	Name	Connector
1b	Accelerator pedal potentiometer	K55

	Name	Connector
3b	Front earth right	C11

1. Unscrew retaining nuts (1a) and withdraw engine wiring (1b) from the passenger compartment. Place out of the way in the engine bay.

Place the car on a ramp. - 4450B12 front or rear wheels (two) - r+r - 1016A10 sound-proofing cover - r + r - 1048A10 air cleaner filtering element - replace - 5530B10 battery - r+r - 1048A41 sleeve from debimeter to turbocharger - r r - 1048B22 air delivery sleeve from heat exchanger to intake manifold - r + r - 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R. - 5550B30 l/h or r/h horn (one) - r+r - 5040A50 pipe from compressor to air conditioner condenser - r+r - 1048A12 air cleaner support - r r with air cleaner assembly removed - 5040A44 air conditioner dehydrating filter/accumulator - r+r - 1048B50 turbo charger intercooler - r + r - 5550C30 l/h or r/h front turn signal (one) - r+r - 7055B10 Front BUMPER - R.R. - 1088B32 engine cooling radiator support beam - r rPosition a suitable container for recovering the coolant.1. Undo the drain plug on the radiator and drain the engine coolant into the container.

1. Disconnect electrical connections (1a) and (1b) from the fan.2. Unscrew the retaining bolts.3. Disconnect both air conditioning lines from the evaporator.4. Disconnect pipe (4a) from its fitting on the thermostat and pipe (4b) from the rigid coolant pipe.5. Undo retaining bolts (5a) and remove radiator - fan - evaporator assembly (5b).

	Name	Connector
1a	Engine electric fan motor	N11

	Name	Connector
1b	Engine electric fan motor	N11

1. Disconnect the electrical connection for the speedometer.

	Name	Connector
1	Speedometer sensor	K84

2. Undo the adjustment nut (2a) and disconnect the release cable (2b) from the lever and from its engagement on the gearbox.3. Undo the nut (3a) and disconnect the earth lead from the gearbox (3b).4. Undo nuts (4a) and disconnect battery positive terminal leads (4b).

	Name	Connector
4b	Battery	A1

1. Disconnect the heater/air conditioner assembly water inlet/outlet pipes.2. Disconnect the brake servo pipe from the vacuum pump.3. Disconnect the vacuum pipe from the E.G.R. system.

1. Disconnect the glow plug preheating connection.

	Name	Connector
1	ABS control unit	M50

2. Disconnect the electrical connection from the E.G.R. valve.

	Name	Connector
2	EGR solenoid	L30

3. Disconnect the fuel lines from the fuel filter.4. Disconnect the water pipe from its fitting on the cylinder head.5. Disconnect the water hose from the rigid pipe.6. Disconnect the electrical connection to the compressor electromagnet coupling.

	Name	Connector
6	Air conditioning compressor electro-magnet	L20

7. Disconnect the fuel pipe from the return manifold.Use a syringe to draw off the power steering pump fluid from the reservoir.8. Disconnect the rubber oil delivery hose to the pump from the tank.

1. Remove the flexible transmission cable ends.2. Remove the retaining clips.3. Withdraw the two gear selection and engagement flexible transmission cables from the mounting bracket.

- 1008C10 power unit upper reaction link r r1. Disconnect power steering pump oil lines (1a) and (1b) from the power steering casing by unscrewing bolts (1c) and (1d).

1. Undo the bolts securing the suspension strut to the damper.2. Undo the bolts securing the drive shaft to the differential flange and place the drive shaft outside the working area.Repeat the above operation for the driveshaft on the intermediate shaft side.

- 1076B50 exhaust pipe attachment to engine - r + r - 1008B20 power unit intermediate mount flexible block - replace - 1008A44 rear rigid mount - r rLower the lift.Position a platform beneath the engine bay.1. Secure the metal cables (1a) provided to bracket (1b) on the gearbox and mount (1c) on the reaction rod motor.2. Secure the cables to a hydraulic hoist. Put the cables under tension by raising the hoist slightly.

1. Unscrew bolts (1a) securing the gearbox end flexible block to the body and bolt (1b) securing it to the rigid mount.2. Remove the flexible block.

1. Unscrew the bolts securing the flexible block on the camshaft end to the body and bolts (1b) securing it to the rigid mount.2. Remove the flexible block.

Lower the power unit slowly onto the underlying platform.Check that the electrical components, pipes and mechanical parts in the engine bay are not damaged duirng the engine removal operation.Raise the vehicle slowly and release the power unit from the engine bay.

Refitting ( Removing

) Place the power unit on a platform beneath the vehicle.Release the engine support cables and lower the lift to the point where the engine can be fitted into the engine bay.Secure the hydraulic hoist cables to the engine anchorage points.Raise the engine until the engine mounts are close to their anchorages on the body.Screw in the bolts securing the camshaft end flexible block to the body and to the rigid mount. Then tighten the fastenings to torque.

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

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT RUBBER MOUNTS	M8	3.5

Screw in the bolts securing the gearbox end flexible blocks to the body and the rigid mount. Then tighten the fastenings to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX SIDE RUBBER MOUNT	M12 x 1.25	8

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX SIDE RUBBER MOUNT	M8	3.5

Remove the support cables and place the hydraulic hoist outside the working area.Remove the platform. - 1008A44 rear rigid mount - r r - 1008B20 power unit intermediate mount flexible block - replace - 1076B50 exhaust pipe attachment to engine - r + rTighten the bolts securing the shaft to the differential flange to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M8	3

Tighten the bolts securing the suspension vertical link to the shock absorber to the specified torque.

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

Connect the oil pipes to the power steering pump. - 1008C10 power unit upper reaction link r rFit the two gear selection and engagement flexible transmission cables on the mounting bracket.Fit the flexible transmission cable ends.Fit the retaining clips.Connect the hose carrying oil to the pump to the tank.Connect the fuel pipe to the return manifoldConnect the electrical connection to the compressor electromagnet coupling.

	Name	Connector
-	Air conditioning compressor electro-magnet	L20

Connnect the water hose to the rigid pipe.Connect the water hose to the fitting on the cylinder head.Connect the fuel lines to the fuel filter.Connect the electrical connection to the E.G.R. valve.

	Name	Connector
-	EGR solenoid	L30

Connect the glow plug preheating connection.

	Name	Connector
-	ABS control unit	M50

Connect the EGR system vacuum pipe.Connect the brake servo pipe to the vacuump pump.Connect the heater/air conditioner unit water inlet and outlet pipes.Fit the leads to the battery negative terminal and tighten the retaining nuts.

	Name	Connector
-	Battery	A1

Connect the earth lead to the gearbox and secure by tightening the nut.Connect the release cable to the lever and the attachment on the gearbox.Tighten the adjustment nut.Connect the electrical connection for the speedometer sensor.

	Name	Connector
-	Speedometer sensor	K84

Fit the radiator - fan - evaporator assembly.Tighten the radiator - fan - evaporator assembly retaining bolts.Connect the fan electrical connections.Connect the water hoses to the thermostat and the rigid coolant pipe.Tighten the air conditioner fluid pipe retaining bolts. - 1088B32 engine cooling radiator support beam - r r - 7055B10 Front BUMPER - R.R. - 5550C30 l/h or r/h front turn signal (one) - r+r - 1048B50 turbo charger intercooler - r + r - 5040A44 air conditioner dehydrating filter/accumulator - r+r - 1048A12 air cleaner support - r r with air cleaner assembly removed - 5040A50 pipe from compressor to air conditioner condenser - r+r - 5550B30 l/h or r/h horn (one) - r+r - 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R. - 1048B22 air delivery sleeve from heat exchanger to intake manifold - r + r - 1048A41 sleeve from debimeter to turbocharger - r r - 5530B10 battery - r+r - 1048A10 air cleaner filtering element - replace - 1016A10 sound-proofing cover - r + r - 4450B12 front or rear wheels (two) - r+rFit the engine wiring into its seat and pull through to the injection control unit.Connect the electrical connections to the injection control unit.Fit the relays to the control unit mount.Tighten the bolts securing the wiring to the bulkhead.Connect the earth lead to the right side pillar.

	Name	Connector
-	Engine management ECU	M10

	Name	Connector
-	Accelerator pedal potentiometer	K55

	Name	Connector
-	Front earth right	C11

- 7055A18 Windscreen base TRIM - R.R. - 5050B32 windscreen wiper arm/s - r+r - 7040A96 facia glove compartment flap (1) lh or rh - r r - 5040A10 Air conditioning refrigerant CIRCUIT - Draining and RefillingRefill the power assisted steering system using appropriate fluid.Refill the engine coolant system with the required quantity of the specified fluid.