2584151 - 1004B12 power unit with manual gearbox - r+r for versions with a/c
Removing
(
Refitting
)
- Position the vehicle on a lift.- Turn the ignition key to the OFF position.- Disconnect the negative battery terminal. Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R. Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND RECHARGE Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R. Op. 0010T20 ENGINE COOLANT - CHANGE Op. 0010T40 CHANGE MANUAL GEARBOX OIL Op. 4450B12 FRONT WHEELS (TWO) - R.R.Position a suitable container underneath the vehicle to collect the engine coolant.1. Using the special tool, remove the band (1a) and disconnect the coolant outlet pipe from the radiator (1b). Collect the coolant that comes out in a suitable container.
1. Compress the clips at the point shown by the arrow and remove the cold air intake hose, releasing it from the mounting.2. Undo the fixing bolts (2a) and detach the air filter (2b).
1. Lift up the air filter, loosen the band (1a) and disconnect the engine oil vapour pipe (1b) and the pipe (1c) from the air filter.2. Remove the air filter assembly from the engine compartment.
1. Using the special tool, remove the band (1a) and disconnect the intermediate coupling for the coolant supply pipe to the water pump from the expansion tank.
1. Using the special tool, remove the band (1a) and disconnect the coolant return pipe from the expansion tank.
1. Using the special tool, remove the bands (1a) securing the coolant return pipe to the water pump and the coolant return pipe from the passenger compartment heater.2. Release the branch of the return pipe from the passenger compartment heater from the mountings. 3. Scollegare la tubazione di ritorno liquido di raffreddamento dal raccordo del riscaldatore abitacolo e dal tubo di ritorno alla pompa e rimuoverla dalla vettura. Collect the remaining coolant that comes out in a suitable container.
1. Using the special tool, remove the bands (1a), thermostat side and (1b), radiator side and disconnect the coolant supply pipe to the radiator.
1. Using the special tool, remove the band (1a), thermostat side and disconnect the coolant supply pipe to the passenger compartment heater.
1. Disconnect the electrical connection for the reversing light switch.2. Undo the bolts and move the clutch control actuator aside.3. Undo the nut and disconnect the earth lead.
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.2. Disconnect the engine coupling.
1. Lift up the retaining clip (1a) and release the fuel supply pipe (1b) to the distribution manifold.2. Open the retaining clip (2a) and release the fuel vapour recovery pipe then, adjusting the connector (2b), disconnect the fuel supply pipe from the solenoid valve. | Seal the ends of the pipes to protect them from any impurities. |
1. Disconnect the electrical connection from the fuel vapour solenoid valve.2. Disconnect the fuel pipe from the rail.
1. Disconnect the electrical connection from the throttle casing.
1. Disconnect the single-acting valve from the brake servo.
1. Undo the bolts (1a) and disconnect the pipes (1b) and (1c) for the refrigerant from the air conditioning system compressor (1d). | Seal the ends of the pipes and the housings in the compressor to protect them from any impurities. |
1. Disconnect the electrical connections of the lambda sensors upstream and downstream of the catalytic converter.
1. Undo the fixing nuts (1a) and disconnect the exhaust pipe from the manifold/catalytic converter (1b).
1. Unscrew the fixing bolt (1a) and the bolt (1b), then remove the lower reaction link (1c) from the vehicle.
1. Undo the nut (1a) and disconnect the steering links (1b) using the tool (1c).2. Unscrew the bolts securing the front stub axles to their shock absorbers. | Code | Description | Function |
|---|
| 1c | 1871000700 | Extractor | Steering link extraction |
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). | Code | Description | Function |
|---|
| 1c | 1871001700 | Balance | Removing-refitting 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 fixing bolts (1a), then remove the engine coolant expansion tank (1b), complete with flexible pipe and bracket (1c).2. Loosen the bolt (2a) and the nut fixing the bracket. Move the power steering fluid reservoir (2b) complete with bracket aside without disconnecting the pipe.3. Undo the nuts securing the flexible mounting to the bodyshell.4. Undo the fixing nuts and remove the power unit rigid support flexible mounting from the vehicle.
1. Undo the nut (1a) securing the power unit gearbox side rigid support to the flexible mounting block (1b).
- Lower the power unit until it rests on the board positioned previously.- Release the power unit from the support tools.
1. Undo the nut (1a) securing the power unit gearbox side rigid support to the flexible mounting block (1b).
Refitting
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Removing
)
- Fit the support tools to the power unit.- Place the power unit in its housing using the hydraulic hoist.- Tighten the nut fixing the flexible mounting to the gearbox side rigid power unit support to the recommended torque. | Value daNm | Fastening | Component | dia |
|---|
| - | 8.1 ÷ 9.9 | Nut | Gearbox side support flexible mounting to rigid support | M12 |
1. Position the flexible mounting for the timing side power unit rigid support and tighten the nuts fixing it to the engine support and to the bodyshell to the recommended torque. | Value daNm | Fastening | Component | dia |
|---|
| - | (Rigid support side) 4.5 - 5.5 | Nut | Timing side power unit rigid support flexible mounting | M12 |
| Value daNm | Fastening | Component | dia |
|---|
| - | (Bodyshell side) 4.1 - 5.0 1.4 8v | Nut | Timing side power unit rigid support flexible mounting | M12 |
- Remove the hydraulic hoist and tool used for supporting the power unit safely.- Connect the driveshafts and tighten the protective boot retaining bands.- Tighten the bolts fixing the front hub steering knuckles to the shock absorbers to the recommended torque. | Value daNm | Fastening | Component | dia |
|---|
| - | (Shock absorber side) 12 | Bolt | FRONT HUB STEERING KNUCKLE | M10 |
- Connect the steering links to the front steering knuckles and tighten the nuts to the specified torque. | Value daNm | Fastening | Component | dia |
|---|
| - | (Steering knuckle) 4.9 | Nut | STEERING LINKS | M8 |
- Secure the lower reaction link to the suspension crossmember and to the gearbox tightening it to the recommended torque. | Value daNm | Fastening | Component | dia |
|---|
| - | (Front suspension crossmember side) 11.4 - 12 | Bolt | LOWER ROD ON ENGINE | M12 |
| Value daNm | Fastening | Component | dia |
|---|
| - | (Gearbox side) 7.2 - 8.3 | Bolt | LOWER ROD ON ENGINE | M12 |
- Connect the exhaust pipe to the manifold - catalytic converter unit and tighten the nuts to the specified torque. | Always replace the gasket with a new one. |
| Value daNm | Fastening | Component | dia |
|---|
| - | 4.5 | Nut | EXHAUST MANIFOLD/CATALYTIC CONVERTER | M10 |
- Connect the electrical connections to the two catalytic converter Lambda sensors.- Connect the coolant inlet and outlet pipes to the air conditioner compressor and secure by tightening the bolts to the specified torque. | Always replace the gasket with a new one. |
| Value daNm | Fastening | Component | dia |
|---|
| - | 4.5 ÷ 5.5 | Bolt | PIPE COMPRESSOR/CONDENSER (A.C.) | M6 |
- Fit the power assisted steering fluid reservoir complete with bracket and tighten the fixing bolt and nut.- Position the engine coolant expansion tank, complete with flexible pipe and bracket, and tighten the fixing bolts.- Connect the fuel vapour recovery pipe, chamber side and secure it to the clip.- Fit the one-way valve on the brake servo.- Connect the electrical connection to the throttle casing.- Connect the fuel pipe to the rail and secure it to the clip.- Connect the electrical connection to the fuel vapour solenoid valve.- Connect the electrical connection for the front engine coupling.
- Connect the electrical connection for the engine wiring to the injection control unit.- Connect the gear selector and engagement cables.- Connect the earth lead to the gearbox.- Place the clutch operating cylinder in its housing and tighten the fixing bolts to the recommended torque. | Value daNm | Fastening | Component | dia |
|---|
| - | 1.8 ÷ 2.2 | Bolt | CLUTCH SLAVE CYLINDER | M8 |
- Connect the electrical connection to the reversing light switch.- Connect the coolant supply pipe to the passenger compartment heater to the thermostat and secure it using a new band.- Connect the upper coolant supply pipe to the thermostat and to the heater and secure it using new bands.- Connect the coolant outlet pipe to the radiator and secure it using a new band. Connect the branch of the coolant return pipe from the passenger compartment heater and the return pipe to the water pump then secure using a new band.- Connect the supply pipe to the water pump from the expansion tank and secure using a new band.- Connect the intermediate coolant return pipe to the expansion tank and secure using a new band.- Connect the engine oil vapour recovery pipes to the air filter and secure using a new band.- Position the air filter assembly on the engine and secure it using the bolts. Op. 4450B12 FRONT WHEELS (TWO) - R.R. Op. 0010T40 CHANGE MANUAL GEARBOX OIL Op. 0010T20 ENGINE COOLANT - CHANGE Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND RECHARGE 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.
