3237440 - 1004D10 power unit (manual gearbox), removed, remove and re-build

Dismantling ( Reassembling ) Position the power unit on a suitable workbench.1. Undo the nuts (1a) and remove the right cylinder head exhaust manifold (1b).Remove the seal.
1. Disconnect the electrical connections from the starter motor.2. Undo the bolts (2a) and remove the starter motor (2b).

NameConnector
2bStarter' motor  A20 
1. Undo the bolts (1a) and remove the intermediate shaft (1b).
1. Undo the bolts (1a) and remove the gearbox-differential unit (1b) from the engine.
Undo the bolts and remove the clutch cover.Remove the clutch disc.1. Remove the clutch release bearing (1a) from the clutch cover using the tool (1b).

NameCountry
1bExtractor1.821.215.000
Reassembling ( Dismantling ) Fit the clutch disc and clutch cover, centring them using the tool.

NameCountry
-Centering1.820.124.000
Tighten the clutch cover bolts to the specified torques.

FasteningComponentØValue(daNm)
-BoltCLUTCH ASSEMBLYM8(Engine flywheel side) 2.6 - 3.0
1. Lift up the plastic tapered seal (1a) for the thrust bearing until the spring (1b) is covered.2. Fit the thrust bearing (2a) on the main shaft and attach it to the fork bearing (2b).
Fit the gearbox-differential unit and secure it tightening the bolts to the recommended torque.

FasteningComponentØValue(daNm)
-BoltMANUAL GEARBOXM10(Engine side) 5.0 ÷ 6.1
Fit the intermediate shaft and ensure it fits properly into the differential. Then tighten the retaining bolts to torque.

FasteningComponentØValue(daNm)
-BoltINTERMEDIATE DRIVE SHAFTM82.5 - 2.8
Fit the starter motor and fix it tightening the bolts to the recommended torque.

FasteningComponentØValue(daNm)
-BoltSTARTER MOTORM8(Manual gearbox side) 2.4 ÷ 3.0
Connect the electrical connections to the starter motor.Fit the right cylinder head exhaust manifold complete with gasket and fix it tightening the nuts to the recommended torque.

FasteningComponentØValue(daNm)
-NutEXHAUST MANIFOLD/SM81.9 - 2.3