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. 5530B56 BATTERY DRIP TRAY COVER - R.R.Remove the protective cover for the casing on the battery.1. Undo the nut (1a) and disconnect the starter motor electrical connection (1b).

	Description	Connector
1b	Battery	A1

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R 1048A32 MANICOTTO da filtro aria a collettore aspirazione - S.R. Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. 7055B42 PASSARUOTA supplementare ANTERIORE (uno), sx o dx - S.R.1. Disconnect the lower radiator coolant outlet hose.

Press the springs by hand and release the rapid connector to disconnect the hose.

Collect the coolant in a suitable container.

2. Undo the nuts (2a) and disconnect the connectors (2b).3. Disconnect the electrical connection for the climate control linear sensor.

	Description	Connector
3	Linear sensor for fans	K120

1. Using the retaining clips, disconnect the upper coolant inlet hose from the radiator.

1. Disconnect the electrical connection (1a) for the engine cooling fan (1b).

	Description	Connector
1a	FRONT ELECTRICALLY OPERATED WINDOW MECH	N11

Op. 7025A34 BONNET LID LOCK (ONE) - R+R OR REPAIR Op. 7210E10 R.R. FRONT BUMPER1. Disconnect the electrical connections for the light clusters.

	Description	Connector
1	Left headlamp	F10

	Description	Connector
1	Right headlamp	F11

2. Loosen the bolts and the nuts (2a) fixing the light clusters (2b) and move them towards the inside.

1. Disconnect the electrical connection for the horn.

	Description	Connector
1	Horn	P5

1. Disconnect the electrical connection for the Air Bag sensor.

	Description	Connector
1	Air Bag front sensor	K39

1. Undo the bolts fixing the wings.2. Undo the retaining bolts.3. Remove the crossmember/light cluster/radiator and fan assembly.

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

	Description	Connector
1b	Battery earth	C1

1. Undo bolts (1a) and move the clutch release cylinder (1b) to the side.

1. Disconnect the gear engagement/selector cables.2. Undo the fixing bolts (2a) and move the mounting bracket (2b) complete with gear engagement/selector cables.

1. Undo the nut (1a) and disconnect the connector (1b) from the expansion valve (1c).2. Use the retaining bands to disconnect the heater pipes.Disconnect the brake servo pipe from the one-way valve and release it from the retaining band.

1. Disconnect the rapid connector for the fuel supply pipe.Disconnect the electrical connection for the fuel vapour recovery solenoid valve.

	Description	Connector
-	Fuel vapour recovery solenoid valve	L10

2. Disconnect the fuel vapour recovery pipe (2a) from the air chamber and release it from the retaining band (2b).3. Undo the fixing bolts (3a) and move the coolant expansion tank (3b).

1. Undo the fixing nuts (1a) and disconnect the exhaust pipe (1b) from the manifold (1c).

Cut the bands retaining the driveshaft boots to the differential.1. Unscrew the nuts (1a) and disconnect the steering box rods (1b) from the front steering knuckles using the tool (1c).

	Description	Code
1c	Extractor	1.847.038.000

2. Undo the upper bolt securing the hub to the shock absorber.3. Loosen the lower bolt securing the hub to the shock absorber.Tilt the brake disc/hub assemblies towards the outside and disconnect the driveshafts from the differential releasing them from their seats.

Make sure that the driveshafts are in a fixed point on the vehicle so that they do not interfere with the operator''s movements.

Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.Lower the vehicle.1. Fit the bracket (1a) complete with hook (1b) on the alternator mounting bracket.2. Fit the bracket (2a) complete with hook (2b) on the gearbox.3. Position the hook (3a) on the intake manifold.Secure the chains to the hydraulic lifting device and tension the engine.

1. Undo the bolts (1a) fixing the timing side engine support (1b) to the strut and turret.

1. Undo the bolts (1a) fixing the gearbox side engine support (1b) to the strut.

Using a hydraulic lift, raise the power unit and place it on a suitable support.

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

Refitting ( Removing

) Adjust the hydraulic lift and place the engine in its housing.

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

Tighten the bolts fixing the gearbox side engine support to the strut to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX SIDE RUBBER MOUNT	M10 X 1.25	(Strut vertical wall) 4.5

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX SIDE RUBBER MOUNT	M12 X 1.25	(Strut horizontal wall) 8.5

Tighten the bolts fixing the timing side engine support to the strut and turret to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	RIGID ENGINE MOUNT, TIMING SIDE	M10 X 1.25	(Bodyshell/turret side) 5

Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.Remove the hooks and brackets used for securing the engine.Place the driveshafts in the special seats on the differential.Position the wheel hubs and tighten the upper and lower nuts fixing the hub to the shock absorber to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT SHOCK ABSORBERS (S.M.)	M10 X 1.25	(Shock absorber side) 7

Position the steering box rods on the front steering knuckles and tighten the fixing bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	ADJUSTABLE STEERINGI LINK JOINTS (C-S)	M10 X 1.25	7

Secure the driveshaft boots using new bands.Position the exhaust pipe on the manifold and tighten the fixing nuts to the recommended torque.

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

Position the coolant expansion tank and tighten the fixing bolts.Connect the rapid connector for the fuel vapour recovery pipe and secure it using the special band.Connect the electrical connection for the fuel vapour recovery solenoid valve.

	Description	Connector
-	Fuel vapour recovery solenoid valve	L10

Connect the rapid connector for the fuel supply pipe.Connect the heater pipes securing them using the special retaining bands.Position the air conditioning pipe and secure it using the special nut.Connect the brake servo pipe, brake servo side and secure it using the retaining band.Position the mounting bracket complete with gear engagement/selection cables and tighten the fixing bolts.Connect the gear engagement/selector cables.Fit the clutch release cylinder and tighten the fixing bolts.Position the battery earth lead on the gearbox and tighten the fixing bolt.

	Description	Connector
-	Battery earth	C1

Position the crossmember/light cluster/radiator and fan assembly on the vehicle.Tighten the fixing bolts on the wings to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ENGINE ASSEMBLY	M10 X 1.25	(Strut side) 3

Tighten the fixing bolts on the struts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ENGINE ASSEMBLY	M10 X 1.25	(Strut side) 3

Renew the electrical connection for the Air Bag sensor.

	Description	Connector
-	Air Bag front sensor	K39

Renew the electrical connection for the horn.

	Description	Connector
-	Horn	P5

Renew the electrical connection for the engine cooling fan.

	Description	Connector
-	FRONT ELECTRICALLY OPERATED WINDOW MECH	N11

Restore the correct position for the light clusters then tighten the nuts and the bolts.Restore the electrical connections for the light clusters.

	Description	Connector
-	Left headlamp	F10

	Description	Connector
-	Right headlamp	F11

Op. 7210E10 R.R. FRONT BUMPER Op. 7025A34 BONNET LID LOCK (ONE) - R+R OR REPAIRPosition the air conditioning pipe and secure it using the special nuts.Connect the electrical connection for the climate control linear sensor.

	Description	Connector
3	Linear sensor for fans	K120

Using the retaining clips, connect the radiator upper coolant inlet hose, radiator side.Using the retaining clips, connect the radiator lower coolant outlet hose, radiator side. 7055B42 PASSARUOTA supplementare ANTERIORE (uno), sx o dx - S.R. Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. Op. 4450B12 FRONT WHEELS (TWO) - R+R 1048A32 MANICOTTO da filtro aria a collettore aspirazione - S.R. Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.RRenew the starter motor electrical connection.

	Description	Connector
-	Starter motor	A20

Secure the wiring using retaining bands.Position the protective cover for the casing on the battery. Op. 5530B56 BATTERY DRIP TRAY COVER - R.R. 1016A10 COPERCHIO INSONORIZZANTE - S.R. Op. 0010T20 ENGINE COOLANT - CHANGERemove the vehicle from the lift.