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. 1016A10 SOUND-PROOFING COVER - R.R Op. 1048A10 AIR FILTER ASSEMBLY - R.R. Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. Op. 0010T20 ENGINE COOLANT - CHANGE Op. 0010T40 CHANGE MANUAL GEARBOX OIL Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R. Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R. Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 7210E10 R.R. FRONT BUMPER Op. 7210A18 R.R FRONT CROSSMEMBER Op. 5540B07 LEFT FRONT HEADLAMP - R.R Op. 5540B08 RIGHT FRONT HEADLAMP - R.R 1. Disconnect the vacuum pipe from the turbocharger actuator.

1. Loosen the band and disconnect the turbocharger air outlet hose.

1. Loosen the band and disconnect the intercooler air outlet hose.

1. Disconnect the electrical connection for the multi-stage valve.

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

1. Disconnect the electrical connections from the engine compartment junction unit.

	Description	Connector
1	Engine compartment junction unit	See B001 JUNCTION UNIT

2. Disconnect the rear dashboard junctions.

	Description	Connector
2	Rear junction/crossmember	See D106 REAR/CROSSMEMBER COUPLING

	Description	Connector
2	Rear dashboard/engine service junction	See D107 DASHBOARD-REAR/ENGINE SERVICES COUPLING

1. Undo the nut and disconnect the earth lead from the bodyshell.

	Description	Connector
1	Battery earth on bodyshell	See C003 BATTERY EARTH ON BODYSHELL

1. Disconnect the bonnet opening cable from the lock.

1. Loosen the collar and disconnect the sleeve from the coolant return pipe to the water pump.

1. Loosen the band and disconnect the coolant hose from the thermostat.

1. Loosen the band and disconnect the degassing pipe from the expansion tank.

1. Unscrew the bolts (1a) and remove the wing union assembly ring (1b).

1. Loosen the colllar and disconnect the oil vapour pipes from the cam cover.2. Disconnect the electrical connection for flow meter.

	Description	Connector
2	Air flow meter	See K041 AIR FLOW METER

3. Loosen the band, disconnect the turbocharger air outlet hose and remove.4. Disconnec the hose from the rigid vacuum pipe.

1. Unscrew the bolt, undo the clip and move the coolant pipes away from the air conditioner compressor.

- Disconnect the fan relay.

	Description	Connector
-	Engine fan switch relay	See J029 ENGINE FANS REMOTE CONTROL RELAY

1. Disconnect the electrical connection from the turbocharger vane position actuator solenoid valve.

	Description	Connector
1	Turbine variable geometry control solenoid	See L036 TURBINE VARIABLE GEOMETRY CONTROL SOLENOID VALVE

2. Unscrew the nuts and remove the turbocharger vane position actuator control solenoid bracket.

1. Disconnect the electrical connection for the Lambda sensor.

	Description	Connector
1	Lambda sensor on pre-catalyzer	See K015 LAMBDA SENSOR ON PRE-CATALYZER

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

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

3. Undo the bolt and release the earth lead from the gearbox.4. Withdraw clip (4a) and remove the clutch hose (4b) from the three-way fitting.

1. Undo the nut (1a) and disconnect the starter motor supply lead (1b) from the contact board.

	Description	Connector
1	Maxifuse casing on battery	See B099 MAXI FUSE BOX ON BATTERY

1. Disconnect the gear selector cable.2. Disconnect the gear engagement cable.

1. Open the clips (1a) and release the gear selector and engagement cables (1b) from the mounting bracket.

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 prewired junction.

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

1. Undo nut (1a), remove the glow plug preheating control unit (1b) and disconnect electrical connection (1c).

	Description	Connector
1c	Heater plugs control unit	See M015 PLUG PREHEATING CONTROL UNIT

1. Disconnect the water supply and return pipes to the heater.2. Disconnect the single-acting valve from the brake servo.

1. Disconnect pipe (1a) from the fuel return manifold and pipe (1b) from the pressure pump.

1. Undo the bolt (1a) and move the ABS sensor (1b) from the pillar.2. Unscrew the nut (2a), fit the tool (2b) and disconnect the left steering link (2c) from the knuckle.

Tool	Description	Function	Validity
1871000700	Extractor	Extracting steering rod from strut

3. Undo the bolts securing the left front shock absorber to the knuckle.

- Move back the left half-axle from the differential.- Proceed in the same way for the right side.1. Undo the bolts securing the intermediate driveshaft to the mount.2. Withdraw the right half-axle complete with intermediate driveshaft from the differential and secure to the steering box.

1. Support the power unit using a hydraulic hoist (1a) and the tool (1b) connected to the mounting brackets (1c).

Tool	Description	Function	Validity
1871001700	Balance	Removing/ refitting power unit

1. Undo the bolts (1a), (1b), then remove the power unit timing side front support flexible mounting (1c).

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

- Remove the power unit from the engine compartment and secure to a platform.- 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 gearbox side power unit flexible mounting block to the rigid support to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side support flexible mounting to rigid support	Bolt	M12	7.6 ÷ 8.4 + 45°	1.9 Multijet

- Place the power unit timing side front mount flexible mounting block in its housing and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit to rigid support flexible mounting	Bolt	M12	9.0 ÷ 11.0	1.3 Multijet1.9 Multijet

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit flexible mounting to body	Bolt	M10	5.4 ÷ 6.6

- Remove the hydraulic hoist and tool used for supporting the power unit safely.- Place the left half-axle back in its housing.- Tighten the bolts fixing the left front shock absorber to the steering knuckle to the recommended torque.

To tighten to torque, position the torque wrench on the nut and not on the bolt.

Component	Fastening	dia	Value (daNm)	Validity
Front shock absorber - strut side	Bolt (to be replaced)	M12	10.3 ÷ 12.6 + 45°

- 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

- Connect the ABS sensor to the knuckle and secure it using the bolt.- Proceed in the same way for the right side.- Tighten the bolts fixing the intermdiate driveshaft to the mounting to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Intermediate driveshaft - support side	Bolt	M6	0.6 ÷ 1.0	1.9 Multijet

- Connect the pipe to the fuel return manifold and the pipe to the pressure pump.- Connect the single-acting valve to the brake servo.- Connect the water supply and return pipes to the heater.- Place the heater plug control unit in position, secure it using the nut and connect the electrical connection.- Connect the engine prewired junction.- Connect the electrical connection for the injection control unit.- Fasten the gear selection and engagement cables to the mounting bracket securing them using the clips.- Connect the gear engagement cable.- Connect the gear selector cable.- Connect the starter motor earth lead to the contact board and secure it using the nut.- Connect the clutch fluid hose to the three-way fitting and do up the clip.- Connect the earth lead to the gearbox and secure it using the nut.- Connect the electrical connection for the reversing light switch.- Connect the electrical connection for the Lambda sensor.- Refit the turbocharger vane position actuator control solenoid valve bracket in its seat and secure with nuts.- Connect the electrical connection from the turbocharger vane position actuator solenoid valve.- Connect the fan relay.- Refit the coolant pipes to the air conditioner compressor in their seats, do up the clip and tighten the bolt.- Connect the hose to the rigid vacuum pipe.- Place the air outllet hose from the turbocharger back in its housing and secure it using the band.- Connect the electrical connection for flow meter.- Connect the oil vapour pipe to the cam cover and secure with the band.- Refit the wing union assembly ring in its seat and secure with the bolts.- Connect the degassing pipe to the expansion tank nd secure it using the band.- Connect the coolant pipe to the thermostat and secure it using the band.- Connect the hose to the coolant return pipe to the water pump and secure it using the band.- Connect the bonnet opening cable to the lock.- Connect the earth lead to the bodyshell.- Connect the rear dashboard junctions.- Connect the electrical connection for the multi-stage valve.- Connect the air outlet hose from the intercooler and secure with the band.- Connect the air outlet pipe to the turbocharger and secure it using the band.- Connect the vacuum pipe to the turbocharger actuator. Op. 5540B08 RIGHT FRONT HEADLAMP - R.R Op. 5540B07 LEFT FRONT HEADLAMP - R.R Op. 7210A18 R.R FRONT CROSSMEMBER Op. 7210E10 R.R. FRONT BUMPER Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R. Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R. Op. 0010T40 CHANGE MANUAL GEARBOX OIL Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. Op. 1048A10 AIR FILTER ASSEMBLY - R.R. Op. 1016A10 SOUND-PROOFING COVER - 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 Op. 0010T20 ENGINE COOLANT - CHANGE - Remove the vehicle from the lift.