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

3362383 - 1004B10 power unit with manual gearbox - r + r

) Place the car on a lift. - 1016A40 ignition coil cover on cylinder head- r+r - 0010T84 coolant for air conditioning system dehydrate and recharge - 5530B56 BATTERY DRIP TRAY COVER - R.R.Disconnect the battery negative terminal.- 5530B10 battery - r+r - 1048A31 RIGID PIPE between air filter and intake manifold - R.R. - 5530B52 Battery DRIP TRAY/SUPPORT - R.R.1. Undo the nuts (1a) and (1b) and disconnect the supply leads (1c) for the starter motor and the alternator and the engine compartment junction unit supply lead.

1. Disconnect the electrical connections (1a) for the coupling for the front lead (1b) and the fan (1c) from the engine compartment junction unit.

	Name	Connector
1a	Engine compartment junction unit	B1A

	Name	Connector
1a	Engine compartment junction unit	B1B

	Name	Connector
1a	Engine compartment junction unit	B1C

	Name	Connector
1a	Engine compartment junction unit	B1D

	Name	Connector
1b	Front/engine connection	D4A

	Name	Connector
1c	Front coupling / air conditioner - with heating	D8A

Release fuel pressure through device attached to the valve at the end of the single fuel manifold pipe.

	Name	Country
-	Rapid connector	1.870.684.000

1. Disconnect the rapid attachment for the fuel supply pipe from the fuel manifold.2. Disconnect the anti-evaporation system pipe from the rapid attachment.3. Disconnect the recirculation pipe from the coolant reservoir.4. Disconnect the supply pipe from the reservoir to the pump rigid water inlet pipe from the rigid pipe.

Raise the vehicle on the lift. - 7055B54 under-engine guard - r r - 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R. (both sides) - 4450B12 front or rear wheels (two) - r+r - 7210E10 R.R. FRONT BUMPER1. Disconnect the electrical connection from the air flow meter.

	Name	Connector
1	Air flow meter	K41

2. Release the cold air intake from the fitting on the fan.3. Remove the air filter casing, complete with filter element and air flow meter, from the lower part of the engine compartment.

Position a suitable container to collect the coolant.1. Disconnect the lower pipe (1a) and the upper pipe (1b) from the radiator.

1. Disconnect the electrical connection for the horn.

	Name	Connector
1	Horn	P5

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.

	Name	Connector
2	Linear sensor for fans	K120

1. Undo the retaining bolts.2. Disconnect the bonnet release cable from the lock.3. Remove the lock complete with opening device.Release the fastenings at the front end and the bonnet release cable.

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

	Name	Connector
1	Right headlamp	F11

	Name	Connector
1	Left headlamp	F10

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

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

	Name	Connector
1	Air-Bag front sensor	K39

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

1. Unscrew the retaining bolts and nut.2. Remove the exhaust manifold heat shields.

1. Unscrew the nuts securing the catalytic preconverter to the manifold.2. Connect electrical connections for the Lambda sensors (2a) and (2b).

	Name	Connector
2a	Lambda sensor on pre-catalyzer	K15

	Name	Connector
2b	Lambda sensor on pre-catalyzer -2	K16

1. Undo the nuts fixing the flexible section to the catalytic converter.2. Undo the nuts fixing the reinforcement bracket for the flexible section.Remove the flexible mounting from the rubber pin fastened to the bodyshell.3. Remove the flexible section complete with catalytic pre-converter.

Position a suitable container to collect the transmission fluid.Drain the oil from the gearbox1. Remove the staking and undo the right hub nut.2. Undo the bolts securing the shock absorber strut.3. Undo the bolts (3a) and remove the right driveshaft (3b) complete with intermediate driveshaft (3c).

1. Undo the bolts securing the shock absorber strut.2. Release the inner driveshaft (2a) from the differential and move the right driveshaft (2b) outside of the work area.

1. Undo the nut (1a) and extract the bolt (1b) fixing the rod to the gearbox mounting bracket.2. Undo the bolt fixing the rod to the suspension crossmember.3. Remove the lower power unit rod.

1. Undo the retaining bolts.2. Remove the engine coolant reservoir.

1. Remve the fastening bands (1a) and (1b).2. Disconnect the heater supply (2a) and return pipes (2b) from the cylinder head and from the thermostat.Release the pipes from the fastening bands and place them outside of the work area.

1. Undo the bolt fixing the pipe flange to the compressor - air conditioner.2. Undo the fixing nut (2a) and remove the section (2b) of the air conditioning system pipe.

1. Position a hook on the engine support fastened to the engine on the timing side.2. Secure a hook fitted with a metal cable to the gearbox side support.3. Secure the cables to the hydraulic lifting device and tension the engine.

1. Lift the clip (1a) and release the hydraulic clutch release actuator pipe (1b).

Collect the fluid in a suitable container.

2. Undo the nut (2a) and disconnect the earth on the gearbox (2b).

1. Disconnect the pipe (1a) from the single-acting valve on the brake servo and release it from the retaining band (1b).

1. Disconnect the gear selector/engagement cables (1a) and (1b).2. Undo the fixing nuts (2a) then move the mounting bracket (2b) complete with gear engagement/selector cables.3. Open the fastening band (3a) and move the hydraulic clutch release actuator pipe (3b) outside of the work area.4. Undo the nut fixing the gearbox side flexible mounting to the rigid support.

1. Undo the bolts fixing the support to the bodyshell.2. Remove the rigid engine support complete with flexible mounting.

1. Manoeuvre the power unit tilting and rotating it, as appropriate, then, acting on the hydraulic lift, position the power unit on the support.

Take great care when rotating and removing the engine not to damage the components fitted on the vehicle.

Refitting ( Removing

) Support the power unit using a hydraulic hoist fitted with suitable chains and position the power unit in the special housing in the vehicle.

Take great care when fitting the engine not to damage the components fitted on the vehicle.

Tighten the nut securing the mounting to the gearbox side rigid mount to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	GEARBOX SIDE RUBBER MOUNT	M12	9

Fit the timing side rigid engine support.Tighten the bolts fixing the rigid support to the body to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ENGINE MOUNT TIMING SIDE	M10 x 1.25	(Bodyshell side) 5

Tighten the bolt fixing the rigid support to the flexible mounting to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ENGINE MOUNT TIMING SIDE	M12 x 1.25	(Engine side) 7.5

Remove the hooks, brackets and cables used for supporting the power unit.Move the hydraulic lift backwards and place it outside the working area.Fit the section of the air conditioning system pipe and tighten the nut fixing the pipe to the flange.Tighten the bolt fixing the low and high pressure pipes to the air conditioning compressor to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	A.C/ CONDENSER COMPRESSOR( PIPE..)	M10 x 1.25	3.5

Connect the heater supply and return pipes and secure them to the cylinder head and to the thermostat using the special bands.Position the hydraulic clutch release actuator pipe and secure it to the engine support using a special band.Connect the hydraulic clutch release actuator pipe and secure it using the special clip. Connect the earth to the gearbox and tighten the fixing nut.Position the mounting bracket, complete with gear engagement/selector cables, and tighten the fixing nuts.Connect the gear engagement/selector cables.Connect the pipe to the brake servo single-acting valve and secure it using the special fastening band.Fit the engine coolant reservoir and tighten the fixing bolts.Position the power unit lower reaction rod.Tighten the bolt fixing the rod to the frame to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	REACTION ROD	M12 x 1.25	13.5

Tighten the bolt fixing the reaction rod to the mounting bracket to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	REACTION ROD	M12 x 1.25	7.5

Position the driveshaft in the housing and fit the inner driveshaft in the differential housing.Tighten the bolts fixing the shock absorber to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	FRONT DAMPER	M10 x 1.25	(Steering knuckle) 7

Fit the right driveshaft complete with intermediate driveshaft.Tighten the bolts fixing the driveshaft to the support to torque.Position the driveshaft inside the wheel hub and tighten the fixing bolt.Tighten the bolts fixing the shock absorber to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	FRONT DAMPER	M10 x 1.25	(Steering knuckle) 7

Using a hammer and chisel, stake the nut securing the drive shaft to the wheel hub.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	TIMING COVER	M6	0.8 ÷ 1.0

Fit the flexible section complete with catalytic pre-converter.Secure the flexible mounting to the rubber pin fastened to the bodyshell.Tighten to torque the nuts securing the pipe to the catalytic converter.

	Fastening	Component	Ø	Value(daNm)
-	Nut	CATALYTIC CONVERTER (ONE)	M8	(To the flexible centre section) 2.5

Tighten to torque the nuts securing the exhaust pipe reinforcement bracket to the oil sump.

	Fastening	Component	Ø	Value(daNm)
-	Nut	PRE-CAT CONVERTOR/CAT CONVERTOR PIPE	M10 x 1.25	(Oil sump) 5

Tighten the nuts securing the catalytic converter to the central flexible section of the hose pipe.

	Fastening	Component	Ø	Value(daNm)
-	Nut	CATALYTIC PRE-CONVERTER	M8	2.5

Connect the lamba probe electrical connections.

	Name	Connector
-	Lambda sensor on pre-catalyzer	K15

	Name	Connector
-	Lambda sensor on pre-catalyzer -2	K16

Fit the top and bottom heat shields.Tighten the nuts and bolts fixing the upper and lower heat shields.Fit the crossmember/light cluster/radiator assembly and fan (front end).Tighten the bolts fixing the front end to the strut reinforcement crossmember to torque.

The bolts fixing the front end to the struts are tightened to a torque of 3 daNm.

Tighten the bolts fixing the front end to the upper crossmember.Connect the electrical connection for the AIR BAG system first impact sensor secured to the fan.

	Name	Connector
-	Air-Bag front sensor	K39

Place the two front lamps in the housing and tighten the fixing bolts.Connect the electrical connections for the front light clusters.

	Name	Connector
-	Right headlamp	F11

	Name	Connector
-	Left headlamp	F10

Secure the bonnet release cable to the front end fastenings.Fit the lock complete with opening device.Connect the bonnet release cable.Tighten the bolts fixing the bonnet lock to the front end.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	BONNET LID LOCK/S	M6	0.8

Connect the electrical connection for the linear sensor.

	Name	Connector
-	Linear sensor for fans	K120

Connect the air conditioning system pipes to the lower coupling and tighten the fixing nut.Connect the electrical connection for the horns.

	Name	Connector
-	Horn	P5

Connect the upper and lower radiator pipes.Fit the air cleaner casing complete with filter element fastening the lower pins.Secure the cold air pipe to the intake.Connect the electrical connection to the air flow meter.

	Name	Connector
-	Air flow meter	K41

- 7210E10 R.R. FRONT BUMPER - 4450B12 front or rear wheels (two) - r+r - 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R. (both sides) Connect the supply pipe from the pump rigid water inlet pipe to the rigid pipe.Connect the recirculation pipe to the coolant reservoir.Connect the anti-evaporation system pipe to the rapid connector.Connect the rapid attachment for the fuel supply pipe to the fuel manifold.Connect the electrical connections for the coupling for the front cable and the fan to the engine compartment junction unit.

	Name	Connector
-	Engine compartment junction unit	B1

	Name	Connector
-	Front/engine connection	D4A

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