1004E30 COMPONENTS TRANSFER FOR HALF-FINISHED ENGINE - Fiat - STILO - eLearn

3363568 - 1004E30 COMPONENTS TRANSFER for half-finished engine

) - 1004D40 engine - position on stand and remove1. Disconnect electrical connections (1a), (1b), (1c), (1d), (1e), (1f), (1g), (1h), (1i) and (1l).

	Name	Connector
1a	Integrated air temperature sensor	K43

	Name	Connector
1b	Integrated throttle body actuator	N75

	Name	Connector
1d	Engine temperature sender unit	K36

	Name	Connector
1e	Ignition coil	A30

	Name	Connector
1f	Injector	N70

	Name	Connector
1g	Alternator	A10

	Name	Connector
1h	Engine oil pressure sensor (switch)	K30

	Name	Connector
1i	RPM sensor	K46

	Name	Connector
1l	Detonation sensor	K50

2. Open the wiring duct (2a) and remove the engine wiring (2b).

1. Undo the belt plastic guard retaining bolts.2. Remove the power steering pump belt guard.3. Unscrew nut (3a) and adjustment screw (3b) to slacken belt tension. Then remove belt (3c).4. Undo the two bolts fixing the power assisted steering pump.5. Remove the power assisted steering pump (5a) complete with mounting brackets together with the drive belt (5b).

1. Disconnect the supply connections for the spark plugs.2. Undo the bolts fixing the ignition coils from the mounting bracket.3. Remove the ignition coils complete with spark plug high tension leads.

1. Undo the bolts (1a) fixing the oil filler pipe and the bolts (1b) fixing the oil dipstick.2. Disconnect the oil vapour inlet pipe.3. Remove the engine oil filler pipe.

1. Undo the fixing nuts (1a) and remove the protection (1b).2. Disconnect the flexible engine coolant pipe from the rigid section fixed to the butterfly casing.3. Undo the bolts fixing the air intake chamber to the inlet manifold.4. Undo the bolts (4a) fixing the intake chamber to the camshaft housing, then remove the intake chamber (4b).

1. Unscrew the retaining nuts.2. Remove the wiring duct.3. Undo the fixing bolts (3a) and remove the inlet manifold (3b) together with the oil dipstick.

1. Undo the retaining bolts.2. Remove the timing belt single shield.

1. Fit the engine flywheel retaining tool.

	Name	Country
1	Counter-torque	1.860.846.000

2. Undo the nut securing the crankshaft pulley.3. Remove the crankshaft pulley.

1. Unscrew the retaining nuts.2. Remove the exhaust manifold heat shield.3. Unscrew the retaining nuts.4. Remove the exhaust manifold (4a), together with the mounting bracket (4b) for the power assisted steering pump.Recover the exhaust manifold seal.

1. Undo the bolts fixing the water pump mounting to the cylinder block/crankcase.2. Remove the water pump complete with filler pipe.3. Undo the fixing bolts (3a) and remove the alternator mounting (3b).

1. Position the flywheel retainer.

	Name	Country
1	Counter-torque	1.860.846.000

2. Undo the retaining bolts.3. Remove the engine flywheel together with the flywheel lock positioned previously.

1. Undo and remove the minimum oil pressure warning light sensor.2. Undo the fixing bolt (2a) and remove the oil vapour separator (2b).3. Undo the fixing bolt (3a) and remove the detonation sensor (3b).

Refitting ( Removing

) Remove the half complete engine to be replaced from the overhauling stand.Remove the engine mounting brackets and transfer them to the new half complete engine.Using a suitable tool, lift the engine and fix it to the rotating stand to fit the missing component.Fit the detonation sensor on the cylinder block/crankcase.Position the vapour separator and fix it using the bolt.Fit the engine oil pressure sender unit/Position the flywheel retainer.

	Name	Country
-	Counter-torque	1.860.846.000

Fit the engine flywheel and tighten the fixing bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FLYWHEEL	M10	7.5 - 9.1

Fit the water pump complete with rigid pipe.Tighten the bolts securing the water pump to the crankcase to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	COOLANT PUMP	M8	2.3 ÷ 2.8

Fit the alternator mounting bracket and tighten the fixing bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ALTERNATOR SUPPORT	M10	4.5 ÷ 5.5

Fit the exhaust manifold to the cylinder head.Fit the power assisted steering pump mounting bracket on the exhaust manifold.Tighten the nuts fixing the exhaust manifold to the cylinder head .

	Fastening	Component	Ø	Value(daNm)
-	Nut	EXHAUST MANIFOLD/S	M8	2.3 ÷ 2.8

Fit the exhaust manifold heat shield.Tighten the nuts fixing the bulkhead.Fit the crankshaft pulley with its phonic wheel.Tighten the pulley retaining nut to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	CRANKSHAFT PULLEY	M20	18.0 - 20.0

Remove the flywheel lock.

	Name	Country
-	Counter-torque	1.860.846.000

Fit the timing belt single shield.Fit the oil dipstick at the same time as the inlet manifold.Fit the wiring duct on the inlet manifold.Tighten the lower bolt fixing the oil dipstick and the nuts fixing the inlet manifold.

	Fastening	Component	Ø	Value(daNm)
-	Nut	INLET MANIFOLD	M8	2.3 ÷ 2.8

Fit the air intake casing.Tighten the bolts and nuts securing the casing to the cylinder head extension.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	INLET AIR DUCT	M7	1.4 ÷ 1.7

Tighten the bolts and nuts to the intake manifold.Fit the shield and fix it using the nuts.Connect the coolant pipe.Fit the engine oil filler pipe.Tighten the fixing bolts and connect the oil vapour inlet pipe.Fit the ignition coils on the mounting bracket, tightening the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	IGNITION COIL/REEL	M6	0.8 - 1.0

Connect the supply connections for the coils to the spark plugs.Position the power assisted steering pump complete with supports.1. Fit the drive belt on the water pump and power assisted steering pump pullies.2. Acting on the adjustment nut and bolt, tension the power assisted steering pump drive belt.3. Using a dynamometer, check that the belt tension is correct.

	Name	Country
3	Torque wrench	1.895.762.000

	Measurement		Value
3	Power steering pump new belt tension (daN)		32 - 45

4. Tighten the bolts fixing the power assisted steering pump brackets to torque.

	Fastening	Component	Ø	Value(daNm)
4	Nut	POWER STEERING PUMP SUPPORT/BRACKET	M10	4.5 ÷ 5.5

Fit the pump plastic shield.

Position the electrical wiring.Connect the electrical connection for the detonation sensor.Connect the electrical connection for the rpm sensor.Connect the electrical connection to the brake fluid level sensor.Connect the electrical connection to the alternator.Connect the electrical connections to the injectors.Connect the electrical connections to the ignition coils.Connect the electrical connection to the engine coolant temperature sensor.Connect the electrical connection to the butterfly position sensor.Connect the electrical connection to the idle actuator.Connect the electrical connection to the integratd air temperature sensor.Position the part of the wiring concerned in the duct. - 1004D40 engine - position on stand and remove