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

199000400 - 1004B10 POWER UNIT WITH MANUAL GEARBOX - R.R

) - Position the vehicle on a lift. Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 1048A10 AIR FILTER ASSEMBLY - R.R. Op. 0010T20 ENGINE COOLANT - CHANGE Op. 0010T40 CHANGE MANUAL GEARBOX OIL Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R. Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R. Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R - Disconnect the exhaust pipe from the flange and from the flexible mountings, move it aside and secure it appropriately.1. Loosen the band and disconnect the air outlet pipe from the radiator.

1. Loosen the band and disconnect the radiator water inlet pipe.2. Loosen the band and disconnect the engine cooling system supply pipe.3. Loosen the band and disconnect the degassing pipe.

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

1. Disconnect the electrical connection for the reversing light switch.

	Description	Connector
1	Reversing lights switch	See I020 REVERSING LIGHTS SWITCH (GEARBOX BRIDGE)

2. Undo the bolts and move the clutch control actuator aside.3. Undo the nut and disconnect the earth lead.

	Description	Connector
3	Battery earth on engine	See C002 BATTERY EARTH ON ENGINE

1. Disconnect the gear selector and engagement cables.2. Move the locking bush (2a) backwards and remove the gear selector cable (2b).3. Move the locking bush (3a) backwards and remove the gear engagement cable (3b).

1. Connect the electrical connection for the injection control unit.

	Description	Connector
1	Engine management control unit	See M010 ENGINE MANAGEMENT ECU

2. Disconnect the engine coupling.

	Description	Connector
2	Engine cables/engine services cable coupling	See D029 ENGINE CABLES/ENGINE SERVICES CABLE COUPLING

1. Disconnect the single-acting valve from the brake servo.

1. Disconnect the fuel pipe rapid connector.

1. Disconnect the intermediate rapid connector for the fuel vapour pipe.

1. Undo the bolt (1a) and move the ABS sensor (1b) from the pillar.2. Undo the bolt securing the front suspension left track control arm to the steering knuckle3. Unscrew the nut (3a), fit the tool (3b) and disconnect the left steering link (3c) from the knuckle.

Tool	Description	Function	Validity
1871000700	Extractor	Extracting steering rod from strut

- Proceed in the same way for the right side.1. Disconnect the left driveshaft from the differential and secure it appropriately.

1. Disconnect the right driveshaft from the differential and secure it appropriately.

- Lower the lift and place a suitable support underneath the power unit.1. Fit the element (1a) on the hydraulic hoist (1b).

Tool	Description	Function	Validity
1871001700	Balance	Removing/ refitting power unit

2. Attach the power unit at the points shown in the diagram (2a), (2b) and (2c).- Gently raise the power unit and make sure that the chains have the same tension.

1. Undo the bolts fixing the flexible mounting to the timing side rigid support.

1. Undo the bolts fixing the flexible mounting to the gearbox side rigid power unit support.

- Lower the power unit until it rests on the board positioned previously.- Release the power unit from the support tools.

Refitting ( Removing

) - Fit the support tools to the power unit.- Place the power unit in its housing using the hydraulic hoist.- Tighten the bolts fixing the flexible mounting to the gearbox side rigid power unit support to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side support flexible mounting to rigid support	Bolt	M12	9.5 ÷ 10.5	1.2 8v1.4 8v1.4 16v1.3 Multijet

- Tighten the bolts fixing the flexible mounting to the timing side rigid power unit support.

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support flexible mounting to the body.	Bolt	M10	5.4 ÷ 6.6	1.2 8v1.4 8v1.4 16v

- Remove the hydraulic hoist and tool used for supporting the power unit safely.- Place the right driveshaft back in its housing.- Place the left driveshaft back in its housing.- Connect the left steering links to the knuckle and tighten the nut to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Steering rod to pillar	Nut	M10	3.6 ÷ 4.4

- Tighten the bolt securing the front suspension left track control arm to the steering knuckle

Component	Fastening	dia	Value (daNm)	Validity
Front suspension lower wishbone - strut side	Bolt	M10	5.4 ÷ 6.6

- Connect the ABS sensor to the knuckle and secure it using the bolt.- Proceed in the same way for the right side.- Connect the intermediate rapid connector for the fuel vapour pipe.- Connect the fuel pipe rapid connector to the rail.- Connect the single-acting valve to the brake servo.- Connect the engine coupling.- Connect the electrical connection for the injection control unit.- Place the gear selector and engagement cables complete with centering bushes back in their housings.- Connect the gear selector and engagement cables.- Connect the battery earth lead.- Place the hydraulic clutch actuator in position and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Hydraulic clutch actuator	Bolt	M8	1.8 ÷ 2.2	1.2 8v1.4 8v1.4 16v1.3 Multijet 75CV

- Connect the electrical connection for the reversing light switch.- Connect the heater water supply and return pipes and secure them using the bands.- Connect the degassing pipe and secure it using the band.- Connect the engine cooling system supply pipe and secure it using the band.- Connect the raidator coolant inlet pipe and secure it using the band.- Connect the raidator coolant outlet pipe and secure it using the band.- Connect the exhaust pipe to the flange and to the flexible mountings. Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R. Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R. Op. 0010T40 CHANGE MANUAL GEARBOX OIL Op. 0010T20 ENGINE COOLANT - CHANGE Op. 1048A10 AIR FILTER ASSEMBLY - R.R. Op. 0010T64 BRAKE AND/OR CLUTCH FLUID CHECK LEVEL AND TOP UP AS NECESSARY Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 5530B10 BATTERY - R+R - Remove the vehicle from the lift.