1004B10 POWER UNIT WITH MANUAL GEARBOX - R.R - Fiat - CROMA - eLearn

194000226 - 1004B10 POWER UNIT WITH MANUAL GEARBOX - R.R

) Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. Op. 1080B95 REAR LAMBDA SENSOR TO CATALYTIC CONVERTER - R.R Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R Op. 4410D10 FRONT SUSPENSION FRAME - R+R Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE Op. 0010T20 ENGINE COOLANT - CHANGE1. Disconnect the right driveshaft from the differential, move it to one side and secure it appropriately.2. Disconnect the left driveshaft from the differential, move it to one side and secure it appropriately.

1. Undo the nuts and remove the wiring for the alternator.

	Description	Connector
1	Alternator	See A10 ALTERNATOR

2. Undo the nuts and remove the wiring for the starter motor.

	Description	Connector
2	Starter motor	See A20 STARTER MOTOR

1. Disconnect the electrical connection for the coolant temperature sensor on the radiator.

	Description	Connector
1	Engine coolant temperature sensor/sender unit	See K036 ENGINE COOLANT TEMPERATURE SENSOR/SENDER UNIT

1. Undo the bolt fixing the flange for the air conditioning compressor inlet and supply pipes.

1. Disconnect the (rear) electrical connection for the injection control unit.

	Description	Connector
1	Engine management control unit	See M010 ENGINE MANAGEMENT CONTROL UNIT

2. Disconnect the engine coupling.3. Undo the injection control unit fixing nut and remove the earth lead.

	Description	Connector
3	Earth on engine	See C040 ENGINE EARTH

1. Disconnect the electrical connection for the reversing sensor.

	Description	Connector
1	Reversing lights switch	See I020 REVERSING LIGHTS SWITCH

2. Undo the bolt and remove the battery earth lead from the gearbox.- Move the cable loom to one side.

1. Remove the brake/clutch fluid reservoir cap and tighten the tool.

Tool	Description	Function	Validity
2000001400	Plug	Brake/clutch fluid reservoir cap

1. Lift up the retaining clip and disconnect the clutch fluid pipe from the three-way connector.

1. Disconnect the electrical connection for the air flow meter.

	Description	Connector
1	Air flow meter	See K041 AIR FLOW METER

1. Disconnect the electrical connection for the multilevel sensor.

	Description	Connector
1	Linear sensor for fans	See K120 LINEAR SENSOR FOR FANS

1. Loosen the bands and disconnect the two heater water supply and return pipes from the thermostat.

1. Loosen the band and disconnect the flexible water return pipe from the throttle body, intermediate connector side.

1. Loosen the band and disconnect the radiator upper hose, thermostat side.

1. Loosen the band and disconnect the lower radiator, water pump side.

- Disconnect the brake servo vacuum pipe, intake chamber side.1. Loosen the bands and remove the air hose between the flow meter and throttle body.

1. Loosen the band and remove the fuel vapour pipe from the solenoid valve.2. Disconnect the fuel pipe rapid connector from the rail.

1. Disconnect the gear selector and engagement cables.2. Adjust the retaining clips (2a) manually and remove the gear selection-engagement cables (2b) from the reaction bracket.

- Postion a suitable footboard beneath the power unit.1. Support the power unit using a hydraulic hoist (1a) and the tool (1b) connected to the brackets fitted previously.

Tool	Description	Function	Validity
1871001700	Balance	Removing-refitting power unit

1. Undo the bolts (1a) fixing the flexible mounting (1b) to the timing side rigid power unit support.

1. Undo the bolts (1a) fixing the flexible mounting (1b) to the gearbox side rigid power unit support.

- Slowly lower the power unit with the hydraulic hoist until it rests on the board positioned previously.

Refitting ( Removing

) - Connect the power unit to the support tools and, using a hydraulic hoist, place it in position in the engine compartment.- Place the gearbox side support flexible mounting in its housing and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side support flexible mounting	Bolt	M10	(support side) 5.0 - 6.0

- Place the flexible mounting in its housing and secure it to the timing side rigid power unit support tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support flexible mounting	Bolt	M10	(rigid support side) 5.0 - 6.0	1.82.21.9 JTD 16v1.9 JTD 8v

- Remove the hydraulic hoist and tool used for supporting the power unit.

Make sure that the gear lever is in neutral.

- Introduce the gear selection and engagement cables in the openings in the reaction bracket and secure them exerting manual pressure until they are properly attached.- Connect the ends of the cables to the gear selection and engagement levers on the gearbox.- Connect the fuel supply pipe rapid connector to the rail.- Connect the fuel vapour pipe to the solenoid valve and secure it using the band.- Place the air hose from the flow meter to the throttle body in its housing and tighten the bands.- Connect the brake servo vacuum pipe to the modular intake chamber.- Connect the lower radiator hose to the water pump and secure it using the band.- Connect the upper radiator hose to the thermostat and secure it using the band.- Connect the water return pipe from the throttle body to the intermediate connector and secure it using the band.- Connect the two passenger compartment heater supply and return pipes to the thermostat and secure them using the bands.- Connect the electrical connection to the multilevel sensor.- Connect the electrical connection for the air flow meter.- Connect the clutch fluid pipe to the three-way connector and secure it using the retaining clip.- Connect the battery earth lead to the gearbox and secure it using the bolts.- Connect the electrical connection for the reversing light sensor.- Connect the earth lead to the injection control unit and secure it using the nut.- Connect the engine coupling.- Connect the (rear) electrical connection for the injection control unit.- Connect the flanges for the air conditioning compressor inlet and supply pipes and secure them using the bolt.- Connect the electrical connection for the coolant temperature sensor on the radiator.- Connect the starter motor wiring and secure it using the nuts.- Connect the alternator wiring and secure it using the nuts.- Connect the left and right driveshafts to the differential. Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 5530B10 BATTERY - R+R Op. 4410D10 FRONT SUSPENSION FRAME - R+R Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R Op. 1080B95 REAR LAMBDA SENSOR TO CATALYTIC CONVERTER - R.R Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE Op. 0010T20 ENGINE COOLANT - CHANGE Op. 0010T64 BRAKE AND/OR CLUTCH FLUID CHECK LEVEL AND TOP UP AS NECESSARY Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR