1004B10 POWER UNIT WITH MANUAL GEARBOX - R + R - Fiat - DUCATO - eLearn

244000619 - 1004B10 POWER UNIT WITH MANUAL GEARBOX - R + R

) - Position the vehicle on a lift.1. Disconnect the windscreen washer jet pipe.2. Undo the bolts fixing the bonnet lid hinges to the bodyshell.3. Remove the bonnet lid, with the help of a second mechanic, and place it on a surface taking care over the paintwork.

Op. 7055B54 UNDER-ENGINE GUARD - R R Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R Op. 7055B64 LH OR RH REFLECTOR(ONE) ON REAR BUMPERS - R R- [From both sides] Op. 7210E10 R.R. FRONT BUMPER1. Undo the fixing bolts.2. Remove the crossmember.

- Using a syringe, draw off the power assisted steering fluid from the reservoir.1. Undo the bolts securing the power steering fluid reservoir to the mounting bracket.2. Disconnect the fluid pipes from the reservoir.3. Remove the power steering fluid reservoir.

1. Disconnect cold air intake hose from the air filter casing and from the cold air intake.2. Remove the intake sleeve assembly from the engine bay.

1. Undo the retaining nuts.2. Disconnect the bonnet lid opening cable.3. Remove the bonnet lid catch.- Release the cable from the retaining collars in the engine bay.

- Disconnect the left and right front light cluster electrical connection.

	Description	Connector
.	Left headlamp	F010

	Description	Connector
.	Right headlamp	F011

1. Unscrew the upper light cluster retaining bolt.2. Use a suitable tool (2a) to prise light cluster from its seat, while releasing the pin from the opening in the wing.3. Undo the nuts fixing the hinges for the left light cluster (3a) and remove the left front light cluster (3b).- Repeat the same operation on the right front light cluster.

	Description	Code	Function
2	Knife	1.078.077.000	Prise light cluster out of beam

1. Undo the upper retaining bolts for the radiator/fan assembly.2. Unscrew the nuts and bolts securing the upper beam located inside the light cluster seats.3. Remove the upper beam from the engine bay complete with front light clusters.

- Arrange a container beneath the engine to recover the engine coolant.1. Disconnect bands (1a) and disconnect the lower radiator pipe from rigid section (1b).

1. Disconnect the uppper radiator pipe.2. Disconnect the pipes from the thermotat.3. Remove the upper radiator pipe.

1. Undo the bolt securing the plastic side guard.2. Disconnect the recirculation pipe to the tank from the radiator.3. Disconnect the fan electrical connections.

	Description	Connector
3	Fan motor	N011

	Description	Connector
3	Engine fan motor 2	N012

4. Remove the radiator unit with fans.

1. Disconnect the right front wheel ABS sensor electrical connection.

	Description	Connector
1	Right front wheel sensor for ABS	K071

2. Undo bolt (2a) and disconnect earth lead (2b) from the body.

1. Remove the protective caps, unscrew retaining nuts (1a) and disconnect alternator electrical wiring (1b).

	Description	Connector
1b	Alternator	A010A

	Description	Connector
1b	Alternator	A010B

1. Remove the protective boot, undo the fixing nuts (1a) and disconnect the electrical wiring for the starter mtor (1b).

	Description	Connector
1b	Starter motor	A020A

	Description	Connector
1b	Starter motor	A020B

- Release the electrical wiring from the bands on the radiator beam and place to one side outside the working area.

- Partly raise the lift.1. Undo the fixing bolts.2. Remove the radiator supporting crossmember.

1. Disconnect the band retaining the coolant pipe to the cylinder head.2. Undo the nuts securing the reservoir to the bodyshell.3. Disconnect sleeve (3a) from the rigid pipe and remove expansion tank (3b).

1. Undo the fixing bolts (1a) and remove the protective cover (1b) for the heater plugs control unit.

1. Undo the bolts securing both EGR and turbocharging control solenoids to the support beam.

1. Disconnect the electrical connection for the heater plugs control unit.

	Description	Connector
1	Heater plugs control unit	M015C

2. Undo the nut securing the glow plug control unit to the bracket.- Release the wiring from the bands and replace the control unit on the engine.3. Undo the retaining nuts.4. Remove the bracket from the engine compartment.

1. Disconnect the single-acting valve from the brake servo.

1. Remove the turbocharger intake manifold rigid delivery hose.

1. Open retaining clips (1a) and remove protective cover (1b) from the filter element.2. Remove the filter element from the filter casing.

1. Disconnect the electrical connection for the air flow meter.

	Description	Connector
1	Air flow meter	K041

2. Undo the nuts securing the filter casing to the bracket.3. Disconnect the band securing the air flow meter to the air delivery pipe to the turbo.4. Remove the air filter casing.

1. Disconnect the lower radiator sleeve from the thermostat.2. Undo the bolts securing the rigid section of the pipe to the gearbox.3. Remove the lower radiator pipe.

1. Undo bolts (1a) and remove the clutch release cylinder (1b) from its housing.

1. Disconnect the engine management unit electrical connections.

	Description	Connector
1	Engine management control unit	M010A

	Description	Connector
1	Engine management control unit	M010B

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

	Description	Connector
1	Reversing lights switch	I020

1. Disconnect the electrical connection for the speedometer sensor.

	Description	Connector
1	Speedometer sensor	K084

1. Undo the retaining bolt.2. Remove the engine bay junction unit protective cover.

1. Release the junction unit from its seat in the mount and disconnect electrical connections (1a) and (1b).

	Description	Connector
1a	Engine compartment junction unit	B001C

	Description	Connector
1b	Front/facia coupling	D001A

1. Undo bolt (1a) and remove gearbox earth lead (1b) from the body.

1. Disconnect the fuel pipe from the return manifold by releasing from the retaining bands.

1. Undo connector (1a) and disconnect oil delivery pipe (1b) to the power assisted steering box.

1. Disconnect the engine coolant return pipe from the heater.2. Disconnect the engine coolant delivery pipe to the supplementary radiator from the rigid exhaust gas recirculation pipe.

- Have a suitable container for collecting the transmission fluid ready.1. Undo the plug, using a suitable spanner, and drain the transmission fluid.

	Description	Code	Function
.	Spanner	1.850.182.000	Wrench for slackening/tightening differential fluid plug

1. Disconnect the electrical connection for the left front brake pad wear sensor.

	Description	Connector
1	Left brake pad wear sensor (switch)	K020

2. Undo the bolts fixing the brake caliper to the bracket and move it aside without disconnecting the oil pipe.

- Position a hydraulic column lift under the track control arm to work safely.1. Undo the nut fixing the track rod end to the steering knuckle.2. Extract the track rod end (2b) from the housing in the steering knuckle using the tool (2a).

	Description	Code	Function
2a	Head extractor	1.847.038.000	Ball joint removal

1. Undo the bolts fixing the steering knuckle to the shock absorber.2. Undo the retaining bolt.3. Remove the left ABS sensor from the housing and place it outside the work area.

1. Undo the bolts fixing the stub axle to the steering knuckle.

1. Prise up the internal drive shaft (1a) from its seat on the differential, then remove the drive shaft - strut - brake disc assembly (1b).

	Description	Code	Function
1a	Head extractor	1.847.038.000	Ball joint removal

1. Undo the bolts fixing the brake caliper to the bracket and move it aside without disconnecting the oil pipe.

1. Undo the bolts fixing the steering knuckle to the shock absorber.2. Undo the retaining bolt.3. Remove the right ABS sensor from the housing and place it outside the work area.

1. Undo the bolts fixing the stub axle to the steering knuckle.

1. Undo the bolts securing the intermediate driveshaft to the mount.2. Remove the intermediate drive shaft - right drive shaft assembly with strut and brake disc.

1. Release the two ends (1a), move the two gear selector and engagement flexible cables (1b) out of the slot in the bracket (1c) and place them outside of the work area.

1. Undo nuts (1a) and separate the exhaust pipe from the flange (1b) for the turbocharger hose.2. Undo the bolts securing the rear flange (2a) and remove the exhaust pipe attachment to the engine (2b).

1. Undo the clip and disconnect the oil vapour recovery pipe from the cam cover.2. Undo the retaining nuts.3. Remove the throttle body from the intake manifold.

1. Undo the bolt securing the lower reaction rod to the suspension crossmember.2. Undo the bolt securing the lower reaction rod to the mounting bracket on the gearbox.3. Remove the lower reaction link.

1. Position the tool and secure with hooks to the brackets on the engine.2. Secure the tool to a hydraulic lift for supporting and removing the power unit.

	Description	Code	Function
1	Crossmember	1.860.851.003	Power unit anchorage beam

- Place a support under the power unit to rest the power unit on later on.1. Undo the bolts fixing the flexible mounting to the timing side rigid power unit support.

1. Undo the nuts fixing the gearbox side flexible mounting to the rigid support.

1. Manoeuvre the power unit acting on the hydraulic lift and lower it slowly until it is resting on the support.- Raise the vehicle and extract the support placing it away from the actual vehicle.

Take the greatest care not to damage parts fitted to the vehicle during the removal of the engine.

Refitting ( Removing

) - Support the power unit by means of a hydraulic lift with chains and position the power unit in its compartment on the vehicle.

Take the greatest care not to damage parts fitted to the vehicle during engine installation.

- Tighten the nuts fixing the gearbox side flexible mounting to the rigid support.

	Value - daNm	Fastening	Component	Ø
.	(Rigid mount) 5	Nuts	GEARBOX SIDE RUBBER MOUNT	M10

- Tighten the nut and the two bolts fixing the flexible mounting to the timing side rigid power unit support to torque.

	Value - daNm	Fastening	Component	Ø
.	(Rigid mount on engine) 5	Bolt	FRONT FLEXIBLE MOUNTING BLOCKS, POWER UNIT	M10

	Value - daNm	Fastening	Component	Ø
.	(Rigid mount on engine) 8	Nut	FRONT FLEXIBLE MOUNTING BLOCKS, POWER UNIT	M12

- Remove the tool and hydraulic lift for supporting and removing the power unit.

	Description	Code	Function
.	Crossmember	1.860.851.000	Power unit anchorage beam

- Fit the throttle body with built-in pneumatic valve and tighten the retaining nuts.- Fit the lower reaction rod in the housing and tighten the bolt fixing the suspension crossmember to torque.- Tighten the nut fixing the reaction rod to the gearbox to torque.- Fit the rigid middle section of the exhaust pipe and tighten the bolts securing it to the rear section to torque.

	Value - daNm	Fastening	Component	Ø
.	(Front section flange) 2.6	Bolts	REAR SILENCER EXHAUST	M8

- Tighten the nuts securing the front section of the exhaust pipe to the turbocharger to torque.

	Value - daNm	Fastening	Component	Ø
.	(Flange on turbocharger) 2.6	Nut	REAR SILENCER EXHAUST	M8

- Connect the oil vapour recovery pipe to the cam cover.- Connect both ends of the gear selection and engagement cables and secure them to the mounting bracket.- Fit the intermediate drive shaft - right drive shaft assembly with strut and brake disc.- Tighten the nuts fixing the intermediate driveshaft to the support to torque.- Tighten the bolts securing the stub axle to the hub to torque.- Fit the right ABS sensor in its housing and tighten the retaining bolt.- Tighten the bolts fixing the steering knuckle to the shock absorber to torque.

	Value - daNm	Fastening	Component	Ø
.	(damper strut) 19	Bolts	FRONT HUB STRUT	-

- Fit the brake caliper - bracket assembly and tighten the bolts fixing the bracket to the left disc to torque.

	Value - daNm	Fastening	Component	Ø
.	21	Bolt	FRONT BRAKE CALIPER BRACKET	M16

- Tighten the nut fixing the ball joint to the steering rod to torque.

	Value - daNm	Fastening	Component	Ø
.	6.9	Nut	ADJUSTABLE LINK BALL JOINTS	M16

- Fit the left driveshaft assembly and press fit the inner driveshaft in the housing on the left differential.- Tighten the bolts fixing the stub axle to the left hub to torque.- Fit the right ABS sensor in its housing and tighten the retaining bolt.- Tighten the bolts fixing the steering knuckle to the shock absorber to torque.

	Value - daNm	Fastening	Component	Ø
.	(damper strut) 19	Bolt	FRONT HUB STRUT	M16

- Tighten the nut fixing the ball joint to the steering rod to torque.

	Value - daNm	Fastening	Component	Ø
.	6.9	Nut	ADJUSTABLE LINK BALL JOINTS	M16

- Fit the brake caliper - bracket assembly and tighten the bolts fixing the bracket to the left disc to torque.

	Value - daNm	Fastening	Component	Ø
.	21	Bolt	FRONT BRAKE CALIPER BRACKET	M16

- Connect the engine coolant return pipe to the heater.- Connect the engine coolant delivery pipe to the supplementary radiator to the rigid exhaust gas recirculation pipe.- Connect the fluid supply pipe to the power assisted steering box and tighten the connector.- Connect the fuel pipes to the return manifold, securing them to the retaining bands.- Connect the gearbox earth lead to the bodyshell.- Connect the electrical connections and reposition the junction unit in the casing.

	Description	Connector
.	Engine compartment junction unit	B001C

	Description	Connector
.	Front/facia coupling	D001A

- Fit the engine compartment junction unit protective cover and tighten the fixing bolt.- Connect the electrical connection for the speedometer sensor.

	Description	Connector
.	Speedometer sensor	K084

- Connect the electrical connection for the reversing light switch.

	Description	Connector
.	Reversing lights switch	I020

- Connect the electrical connections for the engine management control unit.

	Description	Connector
.	Engine management control unit	M010A

	Description	Connector
.	Engine management control unit	M010B

- Place the clutch release cylinder in the housing and tighten the fixing bolts.- Fit the lower radiator pipe, tighten the bolts fixing it to the bellhousing and connect the hose to the thermostat.- Fit the air filter casing.- Connect the band securing the air flow meter to the air delivery pipe to the turbo.- Tighten the nuts fixing the filter casing to the mounting bracket.- Connect the electrical connection for the air flow meter.

	Description	Connector
.	Air flow meter	K041

- Fit the filter element in the filter casing and fit the protective cover securing it using the fastenings.- Fit the turbocharger intake manifold rigid delivery hose.- Connect the single-acting valve to the brake servo.- Fit the junctiton unit and solenoid valve mounting bracket and tighten the fixing nuts.- Fit the glow plug control unit to the bracket and tighten the retaining nut.- Connect the electrical connection for the heater plugs control unit.

	Description	Connector
.	Heater plugs control unit	M015C

- Fit both EGR and turbo control solenoids to the bracket and tighten the retaining bolts.- Fit the glow plug and solenoid unit control unit protective cover.- Fit the engine coolant reservoir and connect the coolant hoses.- Tighten the nuts securing the reservoir to the bodyshell.- Fit the radiator supporting crossmember and tighten the fixing bolts to torque.

	Value - daNm	Fastening	Component	Ø
.	8.5	Bolt	COOLANT RADIATOR SUPPORT BEAM	M12

- Connect the electrical wiring for the starter motor.

	Description	Connector
.	Starter motor	A020A

	Description	Connector
.	Starter motor	A020B

- Connect the alternator electrical wiring.

	Description	Connector
.	Alternator	A010A

	Description	Connector
.	Alternator	A010B

- Connect the electrical connection for the right front wheel A.B.S. sensor.

	Description	Connector
.	Right front wheel sensor for ABS	K071

- Tighten the fixing bolt and connect the earth lead to the bodyshell.- Fit the radiator assembly complete with fans.- Connect the electrical connections for the fans.

	Description	Connector
.	Fan motor	N011

	Description	Connector
.	Engine fan motor 2	N012

- Tighten the bolt fixing the side plastic shield.- Fit the upper radiator pipe and connect it to the thermostat and to the radiator.- Connect the lower radiator hose to the rigid section of the pipe.- Fit the upper crossmember in the engine bay complete with front light clusters.- Tighten the retaining bolts and nuts to torque.

	Value - daNm	Fastening	Component	Ø
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