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

3362384 - 1004B12 POWER UNIT WITH MANUAL GEARBOX - R+R FOR VERSIONS WITH A/C

) Position the vehicle on a lift. 1016A10 COPERCHIO INSONORIZZANTE - S.R. Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. 7055B42 PASSARUOTA supplementare ANTERIORE (uno), sx o dx - S.R. 4450B10 RUOTA (una) anteriore - S.R. Op. 7210E10 R.R. FRONT BUMPERPosition a container underneath the engine to collect the engine coolant.1. Disconnect the bonnet release cable from the lock.

1. Disconnect the electrical connections for the front light clusters.

	Description	Connector
1	Right headlamp	F11

	Description	Connector
1	Left headlamp	F10

2. Loosen the bolt and the nuts (2a) fixing the front light clusters (2b) and move them towards the inside, radiator side.

1. Disconnect the electrical connection for the AIR BAG system first impact sensor secured to the fan.

	Description	Connector
1	Air Bag front sensor	K39

2. Disconnect the electrical connections for the fan resistor.

	Description	Connector
2	Engine fan adjustment resistance	O10

3. Disconnect the electrical connection for the engine fan.

	Description	Connector
3	FRONT ELECTRICALLY OPERATED WINDOW MECH	N11

Move the fan wiring away releasing it from the plastic bands.

1. Disconnect the lower pipe (1a) and the upper pipe (1b) from the radiator.

To disconnect the pipe from the radiator, press the spring manually and release the rapid connector for the pipe from the retainer on the radiator.

1. Disconnect the electrical connection for the horn.

	Description	Connector
1	Horn	P5

1. Disconnect the air pipes (1a) and (1b) from the heat exchanger.

Place a container to collect the oil beneath the oil sump.1. Unscrew the drain plug and collect the oil in the container.

The engine oil used contains substances that are harmful to the environment. Place these substances in containers designed for oil collection and disposal.

1. Undo the bolt (1a) and disconnect the engine oil supply pipe to the cooling radiator (1b).2. Undo the bolt (2a) and disconnect the engine oil return pipe from the cooling radiator (2b).

Collect the engine oil that comes out in a suitable container.

1. Undo the fixing nut (1a) and disconnect the air conditioning system pipes (1b) and (1c) from the lower coupling.2. Disconnect the electrical connection for the linear sensor.

	Description	Connector
2	Linear sensor	See K039 FRONT AIR BAG SENSOR

1. Disconnect the electrical connection for the air flow meter.

	Description	Connector
1	Air flow meter	See K41 AIR FLOW METER

2. Disconnect the turbocharger air intake pipe.3. Disconnect the air pipe from the resonator on the filter casing.

1. Disconnect the variable geometry solenoid valve vacuum pipes from the turbocharger.2. Disconnect the electrical connection for the solenoid valve.

	Description	Connector
2	Turbine variable geometry control solenoid	L36

3. Disconnect the variable geometry solenoid valve vacuum pipes.

1. Undo the bolts securing the reinforcement crossmember to the bodyshell struts.2. Undo the bolts securing the upper crossmember to the wings.3. Remove the crossmember/light cluster/radiator and fan assembly (front end).

Undo the positive battery terminal and separate the wiring.1. Disconnect the brake servo vacuum pipe from the vacuum pump.2. Release the pipe from the securing band.

1. Remove the air pipe from the heat exchanger to the turbocharger.

1. Undo the retaining bolts.2. Remove the rigid air intake pipe from the air heat exchanger to the throttle casing.

1. Disconnect the heater unit supply and return pipes (1a) and (1b) adjusting the tabs on the securing bands.2. Undo the fixing nut (2a) and disconnect the pipe (2b) from the expansion valve.

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

	Description	Connector
1	Heater plugs control unit	M15

1. Undo the nuts fixing the transmission cables mounting bracket.2. Release the two ends (2a) from the idler unit and move the gear selector and engagement transmission cables (2b) away from the work area complete with mounting bracket.

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

	Description	Connector
1b	Battery earth	C1

2. Lift up the spring (2a) and disconnect the oil pipe (2b) from the clutch release cylinder.

1. Disconnect the fuel pipes from the pressure pump and the return manifold.

Raise the vehicle.1. Undo the bolts fixing the steering knuckles to the shock absorbers.2. Undo the bolts fixing the left driveshaft to the flange on the differential.Repeat the same operation on the right driveshaft.

1. Undo the nuts fixing the first section of the exhaust pipe to the catalytic pre-converter.2. Undo the nuts fixing the first section of the exhaust pipe to the catalytic converter.3. Remove the first section of the exhaust pipe complete with gaskets.4. Undo the bolts fixing the lower reaction rods to the gearbox and to the engine.5. Undo the bolts fixing the rods to the suspension crossmember.Remove the two lower rods.

1. Disconnect the fuel supply pipe from the fuel tank.2. Undo the bolts fixing the fuel filter mounting bracket.3. Disconnect the electrical connections for the fuel filter.

	Description	Connector
3	Fuel temperature sensor	K81

	Description	Connector
3	Diesel pre-heating resistance	O20

	Description	Connector
-	Water in diesel filter sensor	K31

4. Remove the fuel filter complete with mounting bracket and pipes.

1. Disconnect the recirculation pipe from the engine coolant reservoir.2. Undo the retaining bolts.3. Disconnect the engine coolant pipe from the pump coolant filler pipe.4. Remove the pipe and tank assembly.

1. Undo the bolt fixing the compressor and position a bracket (1a) to allow the hook (1b) complete with chain for supporting the power unit to be fitted.

1. Undo the upper bolt fixing the alternator and fit a bracket (1a) to allow the shackle (1b) for supporting the power unit to be fitted.

1. Position a shackle complete with chain in the opening in the gearbox side engine support.

1. Prepare a hydraulic support and lifting device and secure the tool for supporting the power unit during the removal operation to it.

	Description	Code
1	Balance	1.871.001.700

Secure the chains to the hydraulic lifting device and tension the engine.Check that the engine is balance.2. If the engine is not balanced, adjust the nut on the tool and tighten or loosen it to make the centre part of the tool slide lengthwise until the balance is correct.

1. Undo the nuts fixing the timing side engine support to the pressure pump support.

1. Undo the nut securing the gearbox side flexible mounting to the support.

1. Manoeuvre the power unit, then adjust the hydraulic lift to move the power unit onto the platform.

Take the greatest care not to damage parts fitted to the vehicle during the removal of the engine.

Refitting ( Removing

) Support the power unit using the hydraulic lift fitted with suitable chains and the tool positioned previously and position the power unit in its compartment on the vehicle.

Take the greatest care not to damage parts fitted to the vehicle during engine installation.

Tighten the nut fixing the gearbox side flexible mounting to the rigid support.

	Fastening	Component	dia	Value(daNm)
-	Nut	GEARBOX SIDE RUBBER MOUNT	M12 X 1.25	10.5

Tighten the nuts fixing the rigid mount to the pressure pump mount to torque.

	Fastening	Component	dia	Value(daNm)
-	Nut	RIGID ENGINE MOUNT, TIMING SIDE	M12 X 1.25	(Engine side) 7.5

Remove the hooks, the chains and the hydraulic lift fitted with the special tool used for removing and positioning the power unit.

	Description	Code
-	Balance	1.871.001.700

Remove the brackets fitted on the alternator and on the compressor fixing bolt.Fit the engine coolant reservoir, complete with hoses and connect the coolant pipe using a new band.Connect the electrical connection for the water in the filter sensor.

	Description	Connector
-	Water in diesel filter sensor	K31

Fit the fuel filter complete with bracket and tighten the bolts fixing it to the bodyshell to torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	FUEL FILTER	M8	(Bodyshell) 2.5

Connect the supply pipe to the fuel tank.Connect the electrical connections for the fuel filter.

	Description	Connector
-	Fuel temperature sensor	K81

	Description	Connector
-	Diesel pre-heating resistance	O20

Raise the vehicle.Fit the two reaction rods from the housing on the suspension crossmember.Tighten the bolts fixing the rods to the gearbox and to the engine to torque.

	Fastening	Component	dia	Value(daNm)
-	Nut	LOWER LINK ON GEARBOX	M12 X 1.25	7.5

	Fastening	Component	dia	Value(daNm)
-	Nut	LOWER ROD ON ENGINE	M12 X 1.25	7.5

Tighten the bolts securing the lower reaction links to the suspension crossmember to torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	LOWER LINK ON GEARBOX	M12 X 1.25	13.5

	Fastening	Component	dia	Value(daNm)
-	Bolt	LOWER ROD ON ENGINE	M12 X 1.25	13.5

Position the exhaust pipe gaskets.Position the front section of the exhaust pipe.Secure the pins to the rubber mountings.Tighten the nuts fixing the pipe to the catalytic converter.

	Fastening	Component	dia	Value(daNm)
-	Nut	EXHAUST PIPE TO ENGINE	M8	(Catalyzer) 2.5

Tighten the nuts fixing the exhaust pipe to the catalytic pre-converter.

	Fastening	Component	dia	Value(daNm)
-	Bolt	EXHAUST PIPE TO ENGINE	M8	(Catalytic preconverter) 2.5

Place the driveshafts in contact with the differential internal driveshaft and with the intermediate driveshaft.Tighten the bolts fixing the driveshaft to the intermediate shaft and to the differrential internal shaft.

	Fastening	Component	dia	Value(daNm)
-	Bolt	DRIVESHAFT COMPLETE WITH JOINTS	M6	1

Tighten the bolts securing the steering knuckles to the shock absorbers to torque.

	Fastening	Component	dia	Value(daNm)
-	Nut	FRONT SHOCK ABSORBERS (S.M.)	M10 X 1.25	(Steering knuckle) 7

Lower the vehicle.Connect the rapid connectors for the fuel pipes from the pressure pump and the return manifold.Connect the fluid pipe to the clutch release cylinder.Connect the earth lead to the gearbox.

	Description	Connector
-	Battery earth	C1

Fit the gear selection and engagement flexible cables and press fit the ends on the fastening ball pins.Tighten the bolt fixing the mounting bracket for the flexible cables to the gearbox.Connect the electrical connection for the heater plugs control unit.

	Description	Connector
-	Heater plugs control unit	M15

Connect the pipe to the the expansion valve and tighten the fixing nut.Connect the delivery and return pipes to the heater unit.Fit the air pipe from the heat exchanger to the turbocharger.Fit the rigid air intake pipe from the heat exchanger to the throttle casing and tighten the fixing bolts on the throttle casing.Connect the brake servo vacuum pipe from the vacuum pump.Secure the pipe from the fastening band on the rigid air inletal pipe from the heat exchanger to the throttle casing.Fit the crossmember/light cluster/radiator and fan assembly (front end).Tighten the front end to the strut reinforcement crossmember to torque.

The bolts securing the front end to the struts should be tightened to a torque of 3 daNm

Tighten the bolts securing the front end to the upper crossmember.Connect the variable geometry solenoid valve vacuum pipes.Connect the electrical connection for the solenoid valve.

	Description	Connector
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