1004B12 POWER UNIT WITH MANUAL GEARBOX - R+R FOR VERSIONS WITH A/C - Fiat - NUOVA 500 - eLearn

312000268 - 1004B12 POWER UNIT WITH MANUAL GEARBOX - R+R FOR VERSIONS WITH A/C

) Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE Op. 0010T20 ENGINE COOLANT - CHANGE Op. 0010T40 CHANGE MANUAL GEARBOX OIL Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 4410D22 BRACKET FIXING FRONT SUSPENSION CROSSMEMBER TO BODYSHELL (ONE), LEFT OR RIGHT - R.R. Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 5540B70 LEFT FRONT LIGHT CLUSTER WITH DIRECTION INDICATOR - R.R. Op. 5540B71 RIGHT FRONT LIGHT CLUSTER WITH DIRECTION INDICATOR - R.R. Op. 5040A50 PIPE FROM AIR CONDITIONING COMPRESSOR TO CONDENSER - R+R Op. 7210A02 FRONT END ASSEMBLY - R.R. Op. 5520C20 HEATER PLUGS CONTROL UNIT - R.R Op. 1048B20 AIR SUPPLY HOSE FROM HEAT EXCHANGER TO RIGID PIPE - REPLACE Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R. 1. Unscrew bolts (1a) and disconnect high and low pressure pipes (1b) from the air conditioner system, compressor side.

1. Adjust quick coupling (1a), disconnect the water supply pipe to heater (1b), heater side.2. Open band (2a) and disconnect the water return pipe to heater (2b), heater side.

1. Undo nut (1a) and disconnect gearbox earth lead (1b).

	Description	Connector
1b	BATTERY EARTH ON BODY	See C3 BATTERY EARTH ON BODYSHELL

2. Disconnect reversing switch electrical connection (2a) and release the associated wiring from retaining bracket (2b).

	Description	Connector
2a	REVERSING LIGHTS SWITCH	See I020 REVERSING LIGHTS SWITCH

1. Unscrew stroke adjustment device (1a) and disconnect clutch cable (1b) from lever (1c).

- Remove the fuse box casing cover. 1. Undo nut (1a) and disconnect positive cable (1b), engine compartment junction unit side.

	Description	Connector
1b	ENGINE COMPARTMENT JUNCTION UNIT	See B001 JUNCTION UNIT

Op. 1076B20 REAR EXHAUST SILENCER - R + R Op. 1076B40 CENTRE EXHAUST PIPE - R.R. Op. 1008C30 POWER UNIT LOWER REACTION LINK - R.R. 1. Prise up the head of the gear selector cable.2. Prise up the head of the gear engagement cable.3. Undo retaining bolts (3a) on the gearbox from gear selection-engagement cables mounting bracket (3b).

1. Undo nut (1a) and disconnect reaction rod (1b), wheel strut side.2. Undo the bolts securing the wheel strut to the suspension.3. Release brake system (3a) pipe and wheel rpm sensor (3b) electrical wiring from the retaining clips.- Carry out the same operation for the remaining side.

1. Undo the nut securing the steering rod head to the wheel hub.

1. Using tool (1a) prise up steering rod (1b) from wheel hub (1c).

Tool	Description	Function	Validity
1.871.000.700	Extractor	Separation of steering track rod end from wheel hub	all versions

- Carry out the same operation for the remaining side.

1. Using a special tool, adjust the sliding joint to prise up the driveshaft from its housing on the gearbox.- Carry out the same operation for the remaining side.

1. Disconnect the electrical connection for Lambda sensor (1a) and release the wiring from retaining bands (1b).

	Description	Connector
1a	LAMBDA SENSOR	See K040 LAMBDA SENSOR

- Disconnect the junction between the front wiring and engine wiring.

	Description	Connector
-	FRONT/ENGINE COUPLING	See D004 FRONT/ENGINE COUPLING

1. Disconnect the brake servo quick coupling, vacuum pump side.

1. Fit rocker (1a) on a hydraulic lift and anchor the power unit to brackets provided (1b).

Anchor the engine using support hooks and brackets/chains, taking the greatest care to find the engine balance point to prevent it tipping over in any way.

Tool	Description	Function	Validity
1.871.001.700	Balance	Removing-refitting power unit	all versions

1. Undo the bolt securing the engine support to the flexible block, gearbox side.

1. Undo retaining bolts (1a) and remove engine support (1b), gearbox side.

1. Undo nuts (1a) on body and (1b) on engine mount and remove flexible block (1c), gearbox side.

- Remove the engine from its housing with the help of a second mechanic.- Whilst moving the engine, take care not to damage part of the bodywork and/or neighbouring parts.- Once removed, place the engine on a suitable footboard and secure it.

Refitting ( Removing

) - Place the engine in position. 1. Position the flexible block (1a), engine side, and tighten nuts (1b) to the recommended torque on body and (1c) on engine mounting.

Component	Fastening	dia	Value (daNm)	Validity
Engine side flexible block (on body)	Nut	M10x1.25	5.0	T.i.T

Component	Fastening	dia	Value (daNm)	Validity
Engine side flexible block (on engine)	Nut	M10x1.25	5.0	T.i.T

1. Place engine mounting (1a) in position, gearbox side, and tighten retaining bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side engine mounting (on gearbox)	Bolt	M10x1.25	5.0	T.i.T

1. Tighten the retaining bolt securing the flexible block to the engine support, gearbox side, to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side flexible block (on mounting)	Bolt	M12x1.25	8.0	T.i.T

- Release the engine from the retaining hooks used for removal.- Connect the brake servo quick coupling, vacuum pump side. 1. Connect electrical connection (1a) for the Lambda sensor and secure the wiring to retaining bands (1b).

	Description	Connector
1a	LAMBDA SENSOR	See K040 LAMBDA SENSOR

- Connect the junction between the front wiring and engine wiring.

	Description	Connector
-	FRONT/ENGINE COUPLING	See D004 FRONT/ENGINE COUPLING

- Position the driveshaft, right and left, in its housing on the gearbox.- Fit the steering rod to the wheel hub.- Carry out the same operation for the remaining side. 1. Tighten the nut securing the steering rod head to the wheel hub to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Steering track rod end to steering knuckle	Nut	M10x1.25	4.0	all versions

1. Connect reaction rod (1a) to the wheel strut and tighten nut (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Reaction rod (on front shock absorber)	Nut	M10x1.25	5.0	all versions

2. Tighten the main retaining bolts securing the front wheel strut the suspension to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Shock absorber (on steering knuckle)	Nut	M10x1.25	7.5	all versions

3. Connect brake system (3a) pipe and wheel rpm sensor (3b) electrical wiring to the retaining clips.- Carry out the same operation for the remaining side.

1. Position the gear selector cable head.2. Position the gear engagement cable head.3. Tighten retaining bolts (3a) on the gearbox from the gear selection-engagement cables mounting bracket (3b), to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox earth	Nut	M8	1.5	all versions

Op. 1008C30 POWER UNIT LOWER REACTION LINK - R.R. Op. 1076B40 CENTRE EXHAUST PIPE - R.R. Op. 1076B20 REAR EXHAUST SILENCER - R + R 1. Connect positive cable (1a), engine compartment junction unit side and tighten nut (1b).

	Description	Connector
1a	ENGINE COMPARTMENT JUNCTION UNIT	See B001 JUNCTION UNIT

- Fit the fuse box cover.- Position the clutch cable on the levers and screw in the stroke adjustment device. 1. Position the engine earth braid on gearbox (1a) and tighten nut (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox earth	Nut	M8	1.5	all versions

2. Connect reversing switch (2a) and release the associated wiring from retaining bracket (2b).

	Description	Connector
2a	REVERSING LIGHTS SWITCH	See I020 REVERSING LIGHTS SWITCH

- Connect the water return pipe to the heater and secure it using a new retaining band.- Working on quick coupling, connect water supply pipe to heater. 1. Connect the climate control system high and low pressure pipes (1a), compressor side, and tighten bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Return pipe from evaporator to compressor (on compressor)	Bolt	M6	0.9	all versions

Component	Fastening	dia	Value (daNm)	Validity
Supply pipe from compressor to condenser (on compressor)	Bolt	M6	0.9	all versions

Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R. Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE Op. 1048B20 AIR SUPPLY HOSE FROM HEAT EXCHANGER TO RIGID PIPE - REPLACE Op. 5520C20 HEATER PLUGS CONTROL UNIT - R.R Op. 7210A02 FRONT END ASSEMBLY - R.R. Op. 5040A50 PIPE FROM AIR CONDITIONING COMPRESSOR TO CONDENSER - R+R Op. 5540B71 RIGHT FRONT LIGHT CLUSTER WITH DIRECTION INDICATOR - R.R. Op. 5540B70 LEFT FRONT LIGHT CLUSTER WITH DIRECTION INDICATOR - R.R. Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 5530B10 BATTERY - R+R Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. Op. 4410D22 BRACKET FIXING FRONT SUSPENSION CROSSMEMBER TO BODYSHELL (ONE), LEFT OR RIGHT - R.R. 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 REPRESSURIZE - Remove the vehicle from the lift.