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

199000402 - 1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, DISMANTLE AND REASSEMBLE

) 1. Open the protective cover (1a), loosen the nut (1b) and disconnect the wiring (1c) from the starter motor.

	Description	Connector
1c	Starter motor	See A020 STARTER MOTOR

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

1. Unscrew bolt (1a), screws (1b) and (1c) and remove the reinforcement bracket (1d).

1. Undo the screws (1a), bolt (1b) and remove the flywheel side oil seal cover (1c).- Recover the exhaust manifold mounting bracket.2. Undo the nut fixing the gearbox to the cylinder block/crankcase.

1. Undo the remaining bolts fixing the gearbox to the engine block.- Remove the gearbox from the engine.

1. Fit the flywheel lock.

Tool	Description	Function	Validity
1860846000	Counter-torque	Flywheel lock

2. Undo the bolts (2a) and remove the clutch mechanism assembly (2b).

Refitting ( Removing

) - Refit the clutch mechanism assembly using the centring tool.

Tool	Description	Function	Validity
1875086000	Centring	Removing-refitting clutch plate/mechanism	1.2 8v1.4 8v

- Tighten the bolts securing the clutch mechanism to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Clutch mechanism	Bolt (to be replaced)	M6	1.2 ÷ 1.5	1.2 8v1.4 8v

- Remove the centring tool.

Tool	Description	Function	Validity
1875086000	Centring	Removing-refitting clutch plate/mechanism	1.2 8v1.4 8v

- Remove the flywheel lock.

Tool	Description	Function	Validity
1860846000	Counter-torque	Flywheel lock

- Place the manual gearbox in position and secure it tightening the bolts and nut to the recommended torque.

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

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox to engine - crankcase side	Nut	M12	4.8 ÷ 7.2

- Place the engine flywheel protective cover back in its housing and secure it using the bolts.- Refit the exhaust pipe bracket and secure by tightening the bolt to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Exhaust pipe mounting bracket	Bolt	M10	4.5 ÷ 5.5	1.2 8v1.4 8v

- Place the reinforcement pillar in its housing and secure it tightening the screws and bolt to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Bracket joining manual gearbox/differential to engine - differential side	Bolt	M8	2.2 ÷ 2.7	1.2 8v1.4 8v

Component	Fastening	dia	Value (daNm)	Validity
Bracket joining manual gearbox/differential to engine - gearbox side	Bolt	M12	5.0 ÷ 6.0	1.2 8v1.4 8v

Component	Fastening	dia	Value (daNm)	Validity
Bracket joining manual gearbox/differential to engine - gearbox side	Bolt	M10	3.6 ÷ 4.4	1.2 8v1.4 8v

- Place the starter motor in its housing and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Starter motor	Bolt	M8	2.25 ÷ 2.75

- Connect the starter motor electrical wiring, tighten the nut and close the protective cover. Op. 0010T40 CHANGE MANUAL GEARBOX OIL