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

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

) Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 1048A10 AIR FILTER ASSEMBLY - R.R. Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R + R Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R Op. 1072C16 EXHAUST MANIFOLD WITH CATALYTIC CONVERTER - R.R. Op. 0010T20 ENGINE COOLANT - CHANGE Op. 0010T40 CHANGE MANUAL GEARBOX OIL Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R. Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R. Op. 4450B12 FRONT WHEELS (TWO) - R+R 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 switch.

	Description	Connector
1	Reversing light 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

- Undo the nut and disconnect the starter motor supply lead from the contact board.1. Disconnect the gear selector and engagement cables.2. Move the locking cursor (2a) backwards and remove the gear selector cable (2b).3. Move the locking cursor (3a) backwards and remove the gear engagement cable (3b).

1. Disconnect the electrical connection for the injection/ignition control unit.

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

1. Disconnect the engine front coupling.

	Description	Connector
2	Front/engine coupling	See D004 FRONT/ENGINE COUPLING

1. Disconnect the single-acting valve from the brake servo and move it to one side.

1. Disconnect the fuel pipe rapid connector from the rail.

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.

1. Disconnect the rapid connector for the air conditioning coolant supply pipe.

1. Disconnect the rapid connector for the air conditioning coolant return pipe.

- 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 to the recommended torque.

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.- Connect the rapid connector for the air conditioning coolant pipes.- 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 to the recommended torque.

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 front coupling.- Connect the electrical connection for the injection/ignition control unit.- Working in the engine compartment, introduce the two quick-fits for the gear selector and engagement cables in the openings in the bracket keeping the cursors retracted and inserting them fully into the seats using manual pressure until they are attached. Release the cursors.- Using manual pressure, connect the ends of the gear selection and engagement cables to the ball joints for the levers on the gearbox.- Connect the starter motor earth lead to the contact board and secure it using the nut.- Connect the battery earth lead and tighten the nut.- Place the clutch control actuator in its housing 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 switch.- Connect the heater water supply and return pipes and secure them using the bands.- Connect the degassing pipe to the engine coolant radiator and secure it using the band.- Connect the system supply pipe to the engine coolant radiator and secure it using the band.- Connect the raidator coolant inlet pipe and secure it using the band.- Connect the radiator coolant outlet pipe and secure it using the band. 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. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE Op. 0010T40 CHANGE MANUAL GEARBOX OIL Op. 0010T20 ENGINE COOLANT - CHANGE Op. 1072C16 EXHAUST MANIFOLD WITH CATALYTIC CONVERTER - R.R. Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R + R Op. 1048A10 AIR FILTER ASSEMBLY - R.R. Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 5530B10 BATTERY - R+R