1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, REMOVE AND RE-BUILD - Fiat - DOBLO - eLearn

2584153 - 1004d10 power unit (manual gearbox), removed, remove and re-build

) 1. With the engine on a stand and secured to the hydraulic lift, unscrew nuts (1a) retaining wiring of starter motor (1b).

	Name	Connector
-	Starter'' motor	See A020 STARTER MOTOR

2. Undo the starter motor bolts on the engine and gearbox sides.3. Remove the starter motor.

1. Unscrew the retaining bolts and nut.2. Remove the bracket joining the gearbox to the engine.

1. Unscrew the retaining boltsRaise the engine slightly.2. Remove the engine flywheel guard.

Lower the engine onto the stand.1. Disconnect the electrical connection for the speedometer sensor.

	Name	Connector
1	Speedometer sensor	See K84 SPEEDOMETER SENSOR ( ENGINE )

2. Unscrew the fastenings securing the gearbox to the engine.3. Remove the gearbox and differential unit with drive shafts.

Refitting ( Removing

) Position the gearbox and differential unit and centre onto the locating pins.Tighten the bolts and nuts securing the gearbox to the engine to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MANUAL GEARBOX	M12 x 1.25	(Lower) 8

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MANUAL GEARBOX	M12 x 1.25	(Upper) 8

	Fastening	Component	Ø	Value(daNm)
-	Nut	MANUAL GEARBOX	M12 x 1.25	8

Connect the electrical connection of the speedometer sensor.

	Name	Connector
-	Speedometer sensor	See K84 SPEEDOMETER SENSOR ( ENGINE )

Slightly raise the power unit and position the engine flywheel guard.Tighten the flywheel guard retaining bolts.Fit the bracket securing the gearbox assembly to the engine and tighten the retaining bolts and nut to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX/ENGINE COUPLING BRACKET	M12 x 1.25	8

	Fastening	Component	Ø	Value(daNm)
-	Bolt	STARTER MOTOR	M8	2.7

Fit the starter motor and secure with bolts.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	STARTER MOTOR	M8	2.7

Connect the electrical connections to the starter motor and secure by tightening the nuts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	BATTERY/MOTOR LEAD	M8	(Motor side) 2.4

	Name	Connector
-	Starter'' motor	See A020 STARTER MOTOR