1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, DISMANTLE AND REASSEMBLE - Fiat - CROMA - eLearn

194000228 - 1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, DISMANTLE AND REASSEMBLE

) 1. Undo the bolts (1a) and remove the intermediate driveshaft (1b).

- Open the access cover for the electrical connection.1. Undo the nuts (1a) and disconnect the electrical connections (1b) from the starter motor.

	Description	Connector
1b	Starter motor	See A020 STARTER MOTOR

2. Undo the bolts (2a) and remove the starter motor (2b).

1. Undo the bolts (1a) and remove the left side engine support flexible mounting (1b).

1. Undo the bolts (1a) and remove the bracket on the gearbox for the lower reaction rod (1b).

1. Undo the bolts (1a) and remove the manual gearbox and differential (1b).

1. Fit the flywheel lock.

Tool	Description	Function	Validity
1860846000	Counter-torque	Flywheel lock

2. Unscrew the three bolts spaced at 120° securing the clutch cradle.3. Fit the locating pin (3a) and the remaining part of tool (3b), tightening bolts (3c) into the sockets of the bolts removed previously.

Tool	Description	Function	Validity
1871003100	Extractor/Fitting tool	Clutch mechanism removal	2.2

4. Turn the tool handwheel until pins (4a) are in contact with disc (4b).5. Undo the remaining bolts securing the clutch cradle.6. Undo the tool handwheel to discharge the clutch mechanism diaphragm spring.- Remove the tool.

Tool	Description	Function	Validity
1871003100	Extractor/Fitting tool	Clutch mechanism removal	2.2

7. Remove the clutch tray.- Remove the clutch plate.

Refitting ( Removing

) 1. Fit the tool locating pin into the crankshaft.2. Refit the clutch mechanism in position.

It is not possible to replace the cltuch plate on its own. Instead the clutch plate/cradle assembly must be replaced.

When fitting the clutch plate the correct position is shown by the words "engine side" and "gearbox side".

Handle the clutch plate carefully. Do not touch the surfaces of the friction linings with your hands.

Clean any anti-corrosion protection or detergents from the friction surface of the clutch tray.

3. Fit the remaining part of tool (3a) for fitting the clutch device and tighten bolts (3b).4. Turn the tool handwheel until pins (4a) are in contact with disc (4b).5. Hand tighten the three free retaining bolts until the clutch device is packed together.6. Undo the tool handwheel to discharge the clutch mechanism diaphragm spring.- Remove the tool.

Tool	Description	Function	Validity
1871003100	Extractor/Fitting tool	Clutch mechanism removal	2.2

- Tighten the remaining clutch fixing bolts by hand.- Gradually tighten the bolts fixing the clutch diagonally until the recommended torque is reached.

Component	Fastening	dia	Value (daNm)	Validity
Clutch drip tray	Bolt	M8	(engine flywheel side) 2.3 - 2.8	2.2

7. Remove the flywheel lock.

Tool	Description	Function	Validity
1860846000	Counter-torque	Flywheel lock

1. Place the manual gearbox and differential unit (1a) in its housing and secure it tightening the bolts (1b) and (1c) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump	Bolt	-	(gearbox side) 4.0	2.2

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox	Bolt	M12	(engine crankcase side) 4.8 - 7.2	1.82.2

1. Refit the lower reaction rod bracket (1a) in its seat on the gearbox and secure it by tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Bracket on gearbox for lower reaction rod	Bolt	M12	(gearbox side) 7.5 - 8.5

1. Place the left side engine support flexible mounting (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Flexible mounting for left side engine support	Bolt	M12	(gearbox side) 7.5 - 8.5

1. Place the starter motor (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Starter motor	Bolt	M10 x 1.5	(gearbox side) 3.5 - 4.5	2.2

2. Connect the electrical connections (2a) to the starter motor and secure them using the nuts (2b).- Close the access cover for the electrical connection.

1. Place the intermediate drive shaft (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Intermediate driveshaft	Bolt	M8	(support side) 2.3 - 2.8	2.2