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

) 1. Undo the bolts on the air conditioning pipes.2. Undo the bolt (2a) fixing the air conditioning pipe lower bracket (2b).

Position the vehicle on a lift. 1016A10 COPERCHIO INSONORIZZANTE - S.R. Op. 5530B56 BATTERY DRIP TRAY COVER - R.R. Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 1048A10 AIR FILTER ASSEMBLY - R.R. Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. 7055B42 PASSARUOTA supplementare ANTERIORE (uno), sx o dx - S.R. Op. 1072C16 EXHAUST MANIFOLD WITH CATALYTIC CONVERTER - R.R.Position a suitable container for collecting the coolant.1. Disconnect the radiator side upper hose (1a) and lower hose (1b) removing the retaining bands (1c).

1. Prise up the gear selection and engagement cable (1b) swivel heads (1a).

1. Unscrew the fixing bolts (1a) for the mounting bracket for the gear selection and engagement cables (1b).Place the cables complete with mounting bracket at the side.

1. Undo the fixing bolts (1a) and remove the clutch operating cylinder (1b).

1. Undo the bolt (1a) fixing the cam angle sensor.

1. Undo the fixing nut (1a) and disconnect the earth lead on the engine (1b) and disconnect the reversing lights electrical connector.

	Description	Connector
1b	Earth on engine	C40

	Description	Connector
-	Reversing lights switch	I20

1. Disconnect the vacuum valve from the brake servo.

1. Disconnect the heater coolant supply and return pipes (1a), heater side, using the clips on the couplings for the rapid connectors (1b).

1. Remove the protective cap (1a) from the fuel manifold breather valve (1b) and use the tool (1c) to discharge the fuel pressure.Collect the fuel in a suitable container.

	Description	Code
1c	Rapid attachment connector	1.870.684.000

Disconnect the pipe for the evaporation control system (1a) and the fuel supply pipe (1b) from the tank.

1. Tighten the nut fixing the steering box track rod end to the steering knuckle.2. Separate the front steering knuckle joint (2a) using the tool (2b).

	Description	Code
-	Extractor	1.847.038.000

3. Undo the upper bolt (3a) fixing the shock absorber to the front steering knuckle and loosen the lower bolt (3b) securing the shock absorber to the front steering knuckle.Carry out the same operations for both front steering knuckles.

1. Remove the band (1a) securing the sliding joint boot (1b) and move the driveshafts aside.Carry out the same operations on both driveshafts.

1. Undo the bolts (1a) fixing the lower reaction rod (1b) to the gearbox support.

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACELower the lift and place a support underneath the power unit.1. Secure the engine at points (1a), (1b) and (1c) using the chains and hooks. Secure the chains to the hydraulic lift and tension the engine making sure that the tension for the chains is the same.

Lift the power unit and place it on a suitable support using the hydraulic lift.

Refitting ( Removing

) Manouevre the hydraulic lift slowly and position the power unit in the engine compartment taking care not to damage the nearby components. Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACERemove the hydraulic lift used for removing the power unit and the brackets used for securing the hooks.Raise the lift and secure the reaction rod by tightening the bolt to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	POWER UNIT REACTION ROD	M12 X 1.25	12

Reposition the driveshafts and secure the band for the sliding joint boot.Tighten the upper and lower bolts securing the shock absorber to the front steering knuckle.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT HUB STRUT	M10 X 1.25	7.5

Fit the track rod end in the front steering knuckle and tighten the nut fixing the steering box track rod end to the steering knuckle.

	Fastening	Component	Ø	Value(daNm)
-	Nut	ADJUSTABLE STEERING LINKS	M8	3.2

Repeat the operation on both driveshafts.Connect the pipe for the evaporation control system and the fuel supply pipe to the tank.Connect the coolant delivery and return pipes to the heater.Connect the brake servo vacuum valve.Place the earth lead on the engine and tighten the fixing nut.

	Description	Connector
-	Earth on engine	C40

	Fastening	Component	Ø	Value(daNm)
-	Nut	POWER UNIT/BODY-SHELL EARTH CABLE	M8	2.4

Position the cam angle sensor and tighten the fixing bolt to torque.Place the clutch operating cylinder in position and tighten the fixing bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CLUTCH CONTROL HYDRAULIC ACTIVATOR	M8	1.8

Connect the electrical connection for the reversing light switch.

	Description	Connector
-	Reversing lights switch	I20

Position the gear selection and engagement flexible cables and tighten the cables mounting bracket.Fit the flexible cable track rod ends on the control levers.Reconnect the radiator side upper/lower hoses and secure them. Op. 1072C16 EXHAUST MANIFOLD WITH CATALYTIC CONVERTER - R.R. 7055B42 PASSARUOTA supplementare ANTERIORE (uno), sx o dx - S.R. Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. Op. 1048A10 AIR FILTER ASSEMBLY - R.R. Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 5530B56 BATTERY DRIP TRAY COVER - R.R. 1016A10 COPERCHIO INSONORIZZANTE - S.R. Op. 0010T20 ENGINE COOLANT - CHANGETighten the air conditioning pipe bolts on the compressor.Tighten the air conditioning pipe lower bracket fixing bolt.