1004B12 POWER UNIT WITH MANUAL GEARBOX - R+R FOR VERSIONS WITH A/C - Fiat - DOBLO - eLearn

2584151 - 1004B12 power unit with manual gearbox - r+r for versions with a/c

) Position the vehicle on a lift. Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R. Op. 5040A10 AIR CONDITIONING REFRIGERANT CIRCUIT - DRYING AND REPRESSURIZING Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R. Op. 4450B12 FRONT WHEELS (TWO) - R.R. Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R.R.1. Undo the bolts (1a) fixing the mounting bracket, disconnect the electrical connection (1b) for the built in throttle casing actuator, disconnect the cold air intake pipe (1c) from the filter casing and also disconnect the vacuum intake pipe (1d) from the connector on the shutter valve.

	Description	Connector
1b	Throttle body solenoid valve	See L62 BUTTERFLY CASING SOLENOID VALVE ( ENGINE )

2. Remove the filter casing.

Have a suitable container for collecting the engine coolant ready.1. Disconnect the lower engine pipe from the radiator (1a), from the thermostat (1b) and from the connector (1c) on the rigid section of the pump water intake pipe.2. Remove the lower pipe from the engine compartment.

1. Disconnect the upper engine pipe from the radiator (1a) and from the thermostat (1b).2. Remove the upper pipe from the engine compartment.Then remove the container used for collecting the engine coolant.

1. Disconnect the pipe (1a) and the heater unit water supply and return pipe (1b) from the thermostat.2. Disconnect the vacuum air pipe from the brake servo.

1. Lift up the fuse box protective cover.2. Disconnect the electrical connections (2a) and release the fuse box (2b).

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

3. Undo the nut and disconnect the positive terminal lead from the fuse box.4. Turn the fuse box over and disconnect the reed connection from the junction unit.

	Description	Connector
4	Engine compartment junction unit	See B001 JUNCTION UNIT

1. Undo the retaining bolts.2. Move the operating cylinder out of the work area.3. Undo the bolt (3a) and disconnect the earth lead (3b) from the gearbox.

	Description	Connector
3b	Battery earth	See C1 BATTERY EARTH ( BATTERY NEGATIVE )

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

	Description	Connector
4	Reversing lights switch	See I20 REVERSING LIGHTS SWITCH ( FRONT )

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

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

2. Undo the nut (2a) and move the heater plugs control unit (2b) onto the engine.3. Undo the fixing nut (3a) and disconnect the injection earth lead (3b) from the engine compartment bulkhead.

1. Disconnect the two injection pump supply (1a) and return (1b) pipes from the fuel filter.

1. Release the ends of the gear selection and engagement cables from the idler unit.2. Release the two retaining clips.3. Release the two flexible cables from the mounting bracket.

1. Disconnect the two engine coolant pipes (1a) and (1b) from the rigid pipe and from the rigid section of the recirculation pipe.2. Undo the retaining bolts.3. Remove the engine coolant reservoir.

Raise the lift.Position a suitable container for collecting the power steering pump fluid.1. Disconnect the rapid connector (1a), separate the two oil pipes (1b) and drain the fluid into the special container.

After having completely drained the power assisted steering system fluid, reconnect the rapid connector.

Lower the vehicle.1. Undo the bolts fixing the power assisted steering fluid reservoir.2. Disconnect the two pipes (2a) and (2b) from the reservoir.3. Remove the power steering pump fluid reservoir.

1. Disconnect the oil supply pipe from the power steering pump to the steering box.

1. Disconnect the engine oil vapour recovery pipe from the tappet cover.2. Undo the bolts fixing the exhaust gas supply pipe to the E.G.R. valve.3. Undo the retaining bolts.4. Remove the tappet cover with built-in intake ducts.Recover the underlying gasket.

1. Undo the retaining bolts.2. Disconnect the air conditioning system two high pressure and low pressure pipes from the compressor.

Raise the vehicle.1. Remove the staking and then undo the nuts fixing the driveshafts to the wheel hubs on both sides.2. Undo the bolts fixing the steering knuckles to the shock absorbers.3. Undo the nuts (3a) and release the steering track rod ends from the steering knuckles using the tool (3b).4. Then release the driveshafts from the hubs, securing them to the power unit using suitable cords.

	Description	Code
3b	Head extractor	1.847.035.000

1. Undo the nuts fixing the reinforcement bracket to the oil sump.2. Remove the reinforcement bracket.3. Undo the nuts fixing the exhaust pipe to the manifold.4. Undo the nuts fixing the pipe to the catalytic converter.5. Undo the fixing bolt and release the rubber mounting complete with bodyshell pin.6. Remove the front section of the exhaust pipe.

Position a hydraulic lift under the gearbox to work safely.1. Undo the centre bolt fixing the reaction rod to the bodyshell.

Position a hydraulic jack underneath the engine to support it.1. Undo the three nuts securing the support to the bodyshell.2. Undo the two nuts fixing the support to the engine.3. Remove the timing side engine support.

Position the hydraulic jack so that after having removed the engine support there is sufficient space to position the hoist for the subsequent operation of removing the engine.

1. Position the brackets on the support for the injection pump andon the gearbox to support the power unit.2. Secure the metal cables to the brackets positioned previously.3. Position a hydraulic lift and secure the metal cables for supporting the engine during the removal operation to it.Tension the metal cables and remove the hydraulic jack from underneath the vehicle.4. Undo the nut fixing the mounting to the gearbox side engine support, lower the lift and remove the power unit.

Lower and carefully manoeuvre the hydraulic lift, then remove the power unit from the lower part of the engine compartment taking care not to damage the surrounding components.Rest the power unit on a support.Release the hooks from the brackets, raise the liift, resecure the hooks for the hydraulic lift and place the power unit away from the vehicle.

Refitting ( Removing

) Take the power unit from the support and place it under the engine compartment.Release the hydraulic lift from the power unit and lower the vehicle in order to centre the actual power unit.Secure the hydraulic lift to the power unit again and raise it until the power unit supports can be fastened to the bodyshell.Tighten the nut fixing the gearbox side engine mounting to torque.

	Fastening	Component	dia	Value(daNm)
-	Nut	POWER UNIT GEARBOX SIDE RIGID SUPPORT	M10	5

Position a hydraulic jack underneath the oil sump to support the engine.Remove the mounting brackets and the cables secured to them.Fit the rigid engine support, complete with flexible mounting.Tighten the nuts fixing the rigid support to the bodyshell to torque.

	Fastening	Component	dia	Value(daNm)
-	Nut	RIGID ENGINE MOUNT, TIMING SIDE	M10 X 1.25	(Bodyshell side) 4.3

Tighten the nuts fixing the rigid support to the engine to torque.

	Fastening	Component	dia	Value(daNm)
-	Nut	RIGID ENGINE MOUNT, TIMING SIDE	M10 X 1.25	(Engine side) 5

Fit the power steering fluid reservoir mounting bracket and tighten the two fixing bolts.Position the engine coolant expansion tanke and tighten the fixing bolts.Tighten the centre bolt fixing the reaction rod to the bodyshell to torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	POWER UNIT REACTION ROD	M12 X 1.25	12

Fit the front section of the exhaust pipe.Tighten the nuts fixing the exhaust pipe to the manifold to torque.

	Fastening	Component	dia	Value(daNm)
-	Nut	EXHAUST PIPE TO ENGINE	M8	(Exhaust manifold) 3

Tighten the nuts fixing the pipe to the catalytic converter to torque.

	Fastening	Component	dia	Value(daNm)
-	Nut	EXHAUST PIPE TO ENGINE	M8	(catalytic converter) 3

Tighten the bolt fixing the rubber mounting complete with pin to the bodyshell.Tighten the nuts fixing the reinforcement bracket on the oil sump.Tighten the bolts securing the steering knuckle to the shock absorber to torque.

	Fastening	Component	dia	Value(daNm)
-	Nut	FRONT HUB STRUT	M12 X 1.25	12

Place the steering track rod end pin in position.Tighten the fixing nut to the recommended torque.

	Fastening	Component	dia	Value(daNm)
-	Nut	ADJUSTABLE STEERINGI LINK JOINTS (C-S)	M10 X 1.25	4.9

Tighten the wheel hub fixing nut to torque.

	Fastening	Component	dia	Value(daNm)
-	Nut	FRONT HUBS COMPLETE WITH BEARING	M22	7 + 55°

1. Proceed with staking the nut following the illustration below.

Lower the lift.Connect the two high and low pressure pipes to the air conditioning compressor.

	Fastening	Component	dia	Value(daNm)
-	Bolt	COMPRESSOR INLET PIPE	M6	0.85

	Fastening	Component	dia	Value(daNm)
-	Bolt	PIPES FROM COMPRESSOR TO CONDENSOR	M6	0.85

Fit the new gasket on the tappet cover.Fit the tappet cover with built-in intake ducts tightening the bolts to torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	CAM COVER	M6	1

Connect the engine oil vapour pipe to the tappet cover.Tighten the bolts fixing the exhaust gas supply pipe to the E.G.R. valve to torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	EGR VALVE PIPE	M8	(EGR valve) 2.5

Connect the oil supply pipe from the power steering pump to the steering box.Connect the two power steering system fluid pipes to the fluid reservoir.Fit the power assisted steering fluid reservoir on the mounting bracket tightening the fixing bolts.Secure the power steering fluid pipe fastening the retaining bracket to the bodyshell.Connect the recirculation pipe from the engine coolant reservoir to the rigid section secured to the head.Connect the pipe connecting the engine coolant reservoir to the pump rigid water inlet pipe.Place the two flexible gear control cables on the mounting bracket.Secure the two flexible cables to the bracket attaching the two clips.Fit the ends of the gear selection and engagement cables on the idler unit.Connect the two supply and return pipes from the injection pump to the fuel filter.Connect the electrical connection for the injection control unit.

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

Fit the heater plugs control unit on the engine compartment bulkhead and secure it using the nut.Tighten the fixing nut and connect the injection earth lead to the engine compartment bulkhead.Connect the electrical connection for the reversing light switch.

	Description	Connector
-	Reversing lights switch	See I20 REVERSING LIGHTS SWITCH ( FRONT )

Connect the earth lead to the gearbox.

	Description	Connector
-	Battery earth	See C1 BATTERY EARTH ( BATTERY NEGATIVE )

Fit the operating cylinder in the special housing on the gearbox and tighten the fixing bolts to torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	CLUTCH CONTROL HYDRAULIC ACTIVATOR	M8	2.8

Turn the fuse box over and connect the connections disconnected previously.

	Description	Connector
-	Engine compartment junction unit	See B001 JUNCTION UNIT

Connect the positive terminal lead to the fuse box.Position the fuse box protective cover.Connect the vacuum air pipe from the brake servo.Connect the heater coolant supply and return pipes to the thermostat.Position the upper pipe in the engine compartment.Connect the upper engine pipe to the radiator and to the thermostat.Position the lower pipe in the engine compartment.Connect the lower engine pipe to the radiator, to the thermostat and to the rigid section of the pump water inlet pipe.Fit the air filter casing assembly.Connect the vacuum pipe for the built in throttle casing actuator.Tighten the bolts fixing the filter mounting bracket and connect the cold air intake pipe to the casing.Connect the electrical connection for the integrated throttle casing actuator.

	Description	Connector
2b	Throttle body solenoid valve	See L62 BUTTERFLY CASING SOLENOID VALVE ( ENGINE )

Top up the power steering system fluid level.

	Type	Component	Description	Qty.
-	Oil [l]	POWER ASSISTED STEERING CIRCUIT	TUTELA GI/A	-

Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R.R. Op. 4450B12 FRONT WHEELS (TWO) - R.R. Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R. Op. 5530B10 BATTERY - R+R Op. 0010T20 ENGINE COOLANT - CHANGE Op. 5040A10 AIR CONDITIONING REFRIGERANT CIRCUIT - DRYING AND REPRESSURIZING Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R.Remove the vehicle from the lift.