Fiat barchetta Engine

Removing-refitting power unit

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REMOVING-REFITTING POWER
UNIT
Start up vehicle engine and leave running
with air conditioner activated for at least 10
minutes, then open bonnet lid and discon-
nect battery leads.
1. Remove anti-resonance duct by discon-
necting rubber fitting and unscrewing
both screws indicated.
2. Connect quick-release fittings of Cleaner
134 device to air conditioning system nee-
dle valves and discharge-:
3. Working from inside the passenger com-
partment, remove guard located beneath
facia glove compartment.
4. Unscrew retaining screws and remove
junction unit from body.
5. Remove earth lead located on the top of
the ECU and disconnect the four connec-
P3WO1AXO3
tors.

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CoDvriaht Fiat Auto 1

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Engine Fiat barchetta
Removing-refitting power unit

3 1. Push rubber gasket on body aside in order

~ to allow wiring to be taken into the engine
bay. When fitting, it is advisable to lubri-
cate gasket to facilitate installation.

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2. Position the vehicle on a stand and, work-
ing from the engine bay, remove the air in-
take pipe by unscrewing both screws and
loosening collar fastening pipe to the air
cleaner.
~ 3. Remove the car alarm ECU, together with
mount, by unscrewing both nuts indicat-
ed.
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4. Disconnect the three connectors located
,I on the car alarm ECU after removing pro-
tection indicated.
5. Remove battery from mount after un-
screwing nuts and screw indicated.

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2 Publication no. 506.586

Fiat barchetta Engine
Removing-refitting power unit

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1. Remove air sleeve connecting debimeter

to butterfly valve case by loosening the
two collars and pipe indicated.
2. Remove the battery mount after releasing
electrical wiring from the rear and un-
screwing the screws indicated.
3. Unscrew the nuts and bolt indicated by
white arrows located on the top of the air
cleaner and release connector indicated
by the black arrow.
4. Unscrew the retaining bolts on the top
part of the fan and disconnect the connec-
tor located close to the right hand light
cluster.
5. Remove protection on exhaust manifold
by unscrewing the three bolts indicated.

Copyright Fiat Auto 3

Engine Fiat barchetta
Removing-refittingpower unit

1. Raise vehicle and loosen bolt indicated by

white arrow, which fastens left-hand end
of lower beam to body in order to facilitate
removal of air cleaner plastic pin (A) from
seat (indicated by black arrow) on body
mount.
2. Push air cleaner upward in order to release
plastic pin A, then move toward power
unit and lower. Open collar B retaining
both air conditioner pipes and take air
cleaner out from rear of vehicle.
3. Unscrew lower fan retaining bolts and
bolts retaining air conditioning system to
the beam.
4. Remove fan from the engine bay.
5. Disconnect lambda probe connector indi-
cated in the figure.

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4 Publication no. 506.586

Fiat barchetta Engine
Removing-refitting power unit

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P3WO5AXO1 P3WO5AXO2

1. Unscrew bolts on first exhaust pipe sec-

tion to catalytic converter.
/ 2. Unscrew bolts retaining first exhaust pipe
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/ section to exhaust manifold.
/ 3, Remove front exhaust pipe section after
/ unscrewing nuts retaining mount bracket
II to oil sump.
4. Loosen collar retaining lower coolant
sleeve to radiator.
5. Loosen power steering pipe fitting located
on steering box. Lower lift, remove lower
radiator sleeve and power steering system
fitting in order to allow coolant to drain
from the cooling systems.

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P3WO5AXO3

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Copyright Fiat Auto 5

 Engine Fiat barchetta
Removing-refitting power unit

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P3WO6AXO1
A: compressorend
B: compressorend

1. Disconnect both pipes from compressor

and remove pipe leading to evaporator.
2. Disconnect delivery and return pipes from
fuel manifold.
3. Disconnect fuel vapour recovery pipe
from intake manifold.
4. Remove coolant expansion tank after dis-
connecting return and delivery pipes.
5. Draw off lluid from the power steering
tank using a syringe; unscrew bolts retain-
ing unit to body, remove pipes and remove
from engine bay.

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6 Publication no. 506.586

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Fiat barchetta Engine
Removing-refitting power unit
1.0.
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P3WO7AXO1

1. the
Remove top coolant
two collars sleeve by taking
indicated. .
off

2. Unscrewscrews retaining relay protection

in engine bay and remove.
3. Unscrew both nuts retaining relay carrier
plate to body and disconnect connectors
A and B indicated in figure.
4. Remove accelerator sheath and cable from
butterfly valve case.
5. Disconnectvalve from brakeservo.

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P3WO7AXO5

Copyright Fiat Auto 7

 Engine Fiat barchetta
Removing-refitting power unit

1. Removecoolant delivery and return lines

from radiator.
2. Releasecable and sheathfrom clutch link-
age.
3. Releasereaction rod by unscrewing nut
indicated. Remove gear engagementca-
ble by disengaging gear selection ball
joint from mount bracket, after removing
clip A. Withdraw cable from mount.
4. Disconnect engine injection supply lead
connector.
5. Remove gearbox earth and disconnect re-
versing light connector.

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P3WO8AX04

8 Publication no. 506.586

Fiat barchetta Engine
Removin~.refitting power unit

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1. Loosen bolts retaining front wheels.

2. Raise vehicle and remove front wheels.
3
Unscrew bolts retaining passenger end
cf} wheel-arch protection and remove from
~ vehicle.
~ """"'-- 3. Remove left-hand half-axle by unscrew-
ing bolts indicated by white arrows (fas-
tening axle to differential flange) and re-
lease left-hand stub axle from damper af-
ter unscrewing bolts indicated by black
arrows, which join the two parts.
4. Position left-hand half-axle as shown in
c figure and tie in place in order to facilitate
F removal of the power unit from the engine
bay.
c 5. Remove passenger side constant velocity
joint and wheel hub from damper.
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PJWO9AXOJ

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Copyright Fiat Auto 9

 Engine Fiat barchetta
Removing-refitting power unit

P3"\N10AXO2

1. Open collar indicated from the catalytic

converter end in order to release the pow-
er steering pipe.
2. Unscrew bolts indicated from gearbox.
3. Position profiled bracket of tool
1860859000 on power unit using bolts
removed previously (although note that
reaction bracket bolt must be replaced).
4. Raise hydraulic jack (to an appropriate
height) with tool 1860860000 installed to
bring bracket on jack and bracket on pow-
er unit into contact, then fasten with the
aid of the bolts supplied.
5. Position U-bracket on tool 1860860000
as shown in the figure to allow correct in-
stallation to passenger end engine mount.

P3W10AXO3

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10 Publication no. 506.586

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 Fiat barchetta Engine
Removing-refitting power unit

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1. Unscrew central power unit reaction

bracket and loosen the others.
2. Loosen nut retaining bracket to flexible
power unit mount (driver's end). Carry out
the same operation for the passenger's
end.
3. Unscrew bolts retaining driver's end flexi-
ble power unit mount to the body. Carry
out the same operation for the passenger
end.
4. Lower hydraulic jack slowly until passen-
ger end half-axle can be removed in order
to secure to damper, as for driver's end.
Withdraw electrical wiring from inside ve-
hicle. Wiring must be installed by inserting
into access hole to passenger compart-
ment (figure 1 page 2) when wire is long
enough. This operation is impossible with
the power unit fitted.

P3W11 AXO2

Copyright Fiat Auto 1

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Engine
Removing-refitting power unit

1. Lower hydraulic jack slowly until power

unit is fully outside engine bay.
2. Hook sling onto power unit and put links
under tension.
3. Unscrew bolts indicated retaining profiled
bracket to tool 1860859000.
4. Raise the power unit and remove profiled
bracket.
5. Before placing power unit on platform,
unscrew lower bolt joining gearbox to en-
gine.

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12 Publication no. 506.586

Fiat barchetta Engine
Removing-refitting power unit

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P3W13AXO1

SEPARATING ENGINE AND GEARBOX

1. After postioning power unit on platform,
remove intermediate drive shaft by un-
screwing the three bolts indicated.
2. Disconnect mileometer pulse generator
connector and release wiring on bracket
located on butterfly valve case.
3. Remove protective boots located on
starter motor electrical connections.
4. Remove starter motor electrical connec-
tions.
5. Unscrew bolts located on starter motor
flange.

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Copyriqht Fiat Auto 13

Engine Fiat barchetta
Removing-refitting power unit
1.0.

Disconnect flexible mounts from

power unit and position on body
without tightening retaining bolts in
order to facilitate refitting on vehi-
cle.

14 Publication no. 506.586

Fiat barchetta Engine
Cooling system

P3W15AXO1

REMOVING-REFITTING RADIATOR

1. Remove resonator by unscrewing bolts

indicated in figure.
2. Remove air shroud by undorng collar and
fastenings shown in figure.
3. Remove nuts securing ECUjcar alarm
siren, then place on one side of the engine
bay without disconnecting electrical con-
nectors.
4. Remove bracket securing battery to hold-
er, then remove battery from engine bay.
5. Disconnect battery holder by undoing fas-
teners shown in figure.

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P3W15AX04

Copyright Fiat Auto 15

Engine Fiat barchetta
Cooling system

P3W16AXO1

1. Remove air intake duct by undoing fastenings

shown in figure.
2. Remove air cleaner assembly mount bracket re-
taining bolts and nut retaining pipe connecting
compressorto evaporator.
3. Raise lift and work on lower part of engine bay.
Loosen bolt (1) retaining radiator unit support
beamto lower beamslightly so that air cleaner as-
sembly may be removed after releasing electric
leads froh1 unit.
4. Remove both bolts retaining pipe connecting
compressor to evaporator from radiator support
beam.
5. Remove lower fan retaining bolts, disconnect
electrical connector, and loosen collar (1) on
lower coolant sleeve.

16 Publication no. 506.586