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 the lift.1. Undo the fixing bolts (1a) and release the filter casing retaining clips (1b).2. Release the cold ir intake (2a) from the retaining band (2b).3. Lift up the air filter casing complete with cold air intake releasing it from the oil vapour recovery hose (3a), then remove the assembly (3b).

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. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R.Position a suitable container underneath the vheicle to collect the engine coolant.1. Disconnect the lower pipe from the radiator, draining the coolant into the container.2. Disconnect the pipe from the connector on the engine coolant reservoir (2a), from the rigid pipe (2b) and from the heater (2c), then remove the pipe assembly (2d).

1. Disconnect the upper pipe from the connector on the radiator (1a) and from the thermostat (1b).2. Remove the pipe from the engine compartment.Remove the container for collecting the coolant from underneath the vehicle.

1. Disconnect the water return pipe from the connector on the heater.

1. Lift up the clip (1a), release the cable from the connector (1b) on the throttle and from the bracket 91c), the place the accelerator control cable (1d) at the side.

Working the securing tabs, remove the protective cover for the junction unit in the engine compartment.1. Disconnect the electrical connections (1a), (1b) and (1c), releasing the wiring from the retaining clips.

	Description	Connector
1a	Engine compartment junction unit	See B001 JUNCTION UNIT

	Description	Connector
1b	Engine compartment junction unit	See B001 JUNCTION UNIT

	Description	Connector
1c	Engine compartment junction unit	See B001 JUNCTION UNIT

2. Undo the fixing nut (2a) and disconnect the earth lead (2b) from the housing on the junction unit.

1. Undo the nut (1a) and release the earth lead (1b) on the gearbox.2. Disconnect the electrical connection for the reversing lights.3. Undo the adjustment nut (3a) and release the clutch release cable (3b) from the connector on the gearbox (3c) and place it outside the work area.

	Description	Connector
1b	Earth on engine	See C040 ENGINE EARTH

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

1. Remove the two fastening clips (1a) and release the two ends of the flexible gear engagement and selection cables (1b).2. Release the two gear selection and engagement cables from the bracket and place them outside the work area.

1. Undo the fuel manifold breather valve (1b) plug (1a) and place the tool (1c) on the fuel manifold and discharge any fuel pressure that has formed inside the actual manifold.

	Description	Code
1c	Rapid attachment connector	1.870.684.000

1. Disconnect the brake servo vacuum pipe (1a) and the evaporation control system pipe (1b) from the throttle casing.2. Disconnect the single fuel supply pipe from the manifold.

Position a suitable container for collecting the power assisted steering fluid from the reservoir and the pipes.1. Using the band (1a), disconnect the supply pipe (1b) from the reservoir to the power steering pump.2. Undo the connector (2a) and disconnect the return pipe (2b) to the power assisted steering box.

1. Undo the fixing bolt (1a) and move the return pipe (1b) to the power steering box outside the work area.

1. Undo the fixing bolt (1a) and disconnect the air conditioning system high pressure pipe from the compressor.2. Undo the fixing nut (2a) and disconnect the air conditioning system low pressure pipe from the coupling (2b).

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
3a	Head extractor	1.847.035.000

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD R+R Op. 1072C16 EXHAUST MANIFOLD WITH CATALYTIC CONVERTER - R R Op. 1008C10 POWER UNIT UPPER SUPPORT - R R1. Fit the service bracket (1a) on the gearbox (1b), on the cylinder head (1c) and on the engine block complete with shackle as illustrated.2. Secure the chains fitted with hooks to the hydraulic lifting device and to the brackets using the hooks.

1. Disconnect the coolant recirculation pipe from the reservoir.2. Undo the nuts fixing the rigid power unit support to the engine.

1. Undo the nut securing the flexible mounting to the gearbox side rigid support.

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 vehicle, 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 nuts fixing the timing side power unit rigid support to the engine to torque.

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

Tighten the nuts to a pre-torque of about 50% of the recommended figure, starting the tightening with the nuts near the flexible mounting and continuing with the nuts on the engine side; when the pre-torque is reached, then tighten to the recommended torque without changing the tightening order.

Tighten the nut fixing the flexible mounting to the gearbox side rigid support.

	Fastening	Component	dia	Value(daNm)
-	Nut	POWER UNIT GEARBOX SIDE RIGID SUPPORT	M12 X 1.25	(Flexible mounting side) 9

Connect the coolant recirculation pipe from the reservoir.Remove the brackets positioned previously for supporting the power unit. Op. 1008C10 POWER UNIT UPPER SUPPORT - R R Op. 1072C16 EXHAUST MANIFOLD WITH CATALYTIC CONVERTER - R R Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD R+RFit the driveshafts on the wheel hubs.Fit the track rod ends in the steering knuckle and tighten the fixing nuts to torque.

	Fastening	Component	dia	Value(daNm)
-	Nut	ADJUSTABLE STEERING LINKS	M10 X 1.25	4.9

Tighten the bolts securing the steering knuckles to the shock absorbers to torque.

	Fastening	Component	dia	Value(daNm)
-	Nut	FRONT SHOCK ABSORBERS (S.M.)	M10 X 1.25	(Steering knuckle) 12

Tighten the nuts fixing the driveshafts to the wheel hubs on both wheels to torque.

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

1. Stake the nuts fixing the driveshafts to the wheel hubs on both sides working as illustrated.

Lower the vehicle.Connect the air conditioning system high pressure pipe to the compressor.Connect the air conditioning system low pressure pipe to the coupling.Connect the supply pipe from the reservoir to the power assisted steering pump.Connect the return pipe to the power steering box.Connect the brake servo vacuum pipe and the evaporation control system pipe to the throttle casing.Connect the single fuel supply pipe from the manifold.Place the two gear selection and engagement cables on the bracket.Fasten the two ends of the gear selection and engagement cables to the ball joints and secure them to the bracket using the two clips.Connect the clutch release cable to the gearbox and to the lever and tighten the adjustment nut.Connect the electrical connection for the reversing lights.Connect the earth lead on the gearbox.

	Description	Connector
-	Earth on engine	See C040 ENGINE EARTH

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

Connect the earth lead on the junction unit.Connect the electrical connections to the junction unit and secure the wiring to the retaining clips.

	Description	Connector
-	Engine compartment junction unit	See B001 JUNCTION UNIT

	Description	Connector
-	Engine compartment junction unit	See B001 JUNCTION UNIT

	Description	Connector
-	Engine compartment junction unit	See B001 JUNCTION UNIT

Fit the engine compartment junction unit protective cover.Position the accelerator control cable on the mounting bracket and fit it to the throttle valve control.Connect the water return pipe to the heater.Fit the upper pipe and connect it to the thermostat and to the radiator.Fit the lower water pipe and connect it to the engine coolant reservoir, to the rigid pipe, to the radiator and to the heater. Op. 4450B12 FRONT WHEELS (TWO) - R.R. Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R. Op. 5530B10 BATTERY - R+RFit the air filter assembly and secure it using the bolts taking care to engage the rubber engine oil vapour pipe in the special housing in the filter casing.Secure the air intake pipe to the retaining clip.Attach the retaining clip to the filter casing. Op. 0010T21 COOLANT - CHECK DENSITY AND TOP UP IF NECESSARY Op. 1068A10 ACCELERATOR PEDAL CONTROL - CHECK, ADJUST IF NECESSARY AND LUBRICATE Op. 5040A10 AIR CONDITIONING REFRIGERANT CIRCUIT - DRYING AND REPRESSURIZING Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R.Remove the vehicle from the lift