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.- 5530B10 battery - r+r - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. - 5530B56 BATTERY DRIP TRAY COVER - R.R. - 4450B12 front or rear wheels (two) - r+r - 1048A10 air cleaner filtering element - replace - 7055B54 under-engine guard - r r - 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R. - 1072C44 exhaust manifold heat shield on bulkhead - r+r - 1072C16 exhaust manifold with catalytic converter - r rPosition a suitable container to collect the coolant.1. Disconnect upper sleeve (1a) and lower sleeve (1b) on the radiator side by removing collars (1c).

1. Remove the pivot joints (1a) for the gear selection and engagement flexible transmission cables (1b).

1. Unscrew bolts (1a) securing the bracket supporting gear selection and engagement cables (1b).Place the cables and bracket to one side.

1. Undo the bolts (1a) and move the clutch slave cylinder (1b).

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

1. Undo the nut (1a) and disconnect the engine earth lead (1b).2. Disconnect the electrical connection for the reversing lights.

	Name	Connector
1b	Earth on engine	C40

	Name	Connector
2	Reversing lights switch	I20

1. Disconnect the vacuum valve from the brake servo.

1. Disconnect the coolant supply/return pipes from the heater (1a), acting on the clips for the rapid connectors (1b).

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

	Name	Country
1c	Rapid connector	1.870.684.000

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

1. Undo the nut fixing the steering box beam ball joints to the front steering knuckle.2. Separate the ball joint (2a) from the front hub knuckle using the tool (2b).

	Name	Country
2b	Extractor	1.847.038.000

3. Undo the upper bolt (3a) fixing the shock absorber to the front hub steering knuckle and loosen the lower bolt (3b) fixing the shock absorber to the front hub steering knuckle. Carry out the same operation on the other front hub knuckle.

1. Remove collar (1a) securing the sliding coupling sleeve (1b) and move the half-axles aside.Carry out the same operations for both driveshafts.

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

- 1008B10 power unit front mount (timing side) flexible block - replace - 1008B30 gearbox side mount flexible block - replaceLower the lift and place a stand beneath the power unit.1. Secure the engine at point (1a), then position a special seal (1b) by the stud (1c) located underneath the air conditioning compressor and a seal (1d) on the bellhousing. Secure the chains to the hydraulic lifting device and tension the engine, making sure that the chains are evenly tensioned.

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

Refitting ( Removing

) Slowly manoeuvre the hydraulic lift to position the power unit inside the engine bay. Take care not to damage surrounding parts. - 1008B30 gearbox side mount flexible block - replace - 1008B10 power unit front mount (timing side) flexible block - replaceRemove the hdyraulic lift used to remove the power unit and the brackets used to anchor the hooks.Raise the lift and secure the reaction rod tightening the bolt to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	REACTION ROD	M12 x 1.25	12

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

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT HUB STEERING KNUCKLE.	M10 x 1.25	7.5

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

	Fastening	Component	Ø	Value(daNm)
-	Nut	ADJUSTABLE STEERING LINKS	M10 x 1.25	7

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

	Name	Connector
-	Earth on engine	C40

	Fastening	Component	Ø	Value(daNm)
-	Nut	POWER UNIT/BODY-SHELL EARTH CABLE	M8	(Engine) 2,4

Fit the cam angle sensor and tighten the retaining bolt.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 lights switch.

	Name	Connector
-	Reversing lights switch	I20

Position the gear selection and engagement cables and tighten the cable bracket bolts.Fit the flexible transmission cable ends to the control linkage.Reconnect the radiator side upper/lower hoses and secure them using the bands. - 1072C16 exhaust manifold with catalytic converter - r r - 1072C44 exhaust manifold heat shield on bulkhead - r+r - 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R. - 7055B54 under-engine guard - r r - 1048A10 air cleaner filtering element - replace - 4450B12 front or rear wheels (two) - r+r - 5530B52 Battery DRIP TRAY/SUPPORT - R.R.- 5530B10 battery - r+r - 5530B56 BATTERY DRIP TRAY COVER - R.R. - 0010T20 coolant change