3237722 - 1004B10 power unit with manual gearbox - r + r

Removing ( Refitting ) Position the vehicle on the ramp. Drain the air conditioner coolant circuit - 0010T84 coolant for air conditioning system dehydrate and recharge . Proceed with removal  - 1016A10  sound-proofing cover - r + r . Proceed with removal  - 5530B10  battery - r+r . Proceed with removal  - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. . Proceed with removal  - 4450B12  front or rear wheels (two) - r+r . Proceed with removal  - 7055B54  under-engine guard - r r . Proceed with removal - 7055B66 Engine compartment DUST SHIELD protection in right front wheel arch - R.R. . Proceed with removal - 7055B91 Right front WHEEL ARCH LINER - R.R. . Proceed with removal - 7055B90 Left front WHEEL ARCH LINER - R.R. . Proceed with removal  - 1048A50  air inlet pipe to turbo charger - r + r . 1. Undo the fixing bolt (1a) and disconnect the lower steering control shaft (1b) from the power steering box.

The bolt is pre-treated with sealant and so a new one should be fitted whenever it is replaced.

1. Disconnect the rapid connector and disconnect the lower radiator coolant outlet hose from the radiator, radiator side.

Recover the coolant using a suitable container.

1. Disconnect the rapid connectors on the power steering fluid inlet and outlet pipes, heat exchanger pipe side.

Recover the power steering fluid in a suitable container.

2. Loosen the band and disconnect the air supply hose between the turbocharger and the heat exchanger, heat exchanger side. 1. Loosen the band, disconnect the air supply hose between turbocharger and heat exchanger, turbocharger side, and remove it. 2. Disconnect the vacuum pipe from the turbocharger variable geometry control actuator. 1. Disconnect the electrical connection from the air flow meter.

	Name	Connector
1	Air flow meter	K41

2. Remove the air filter (2a) complete with air flow meter (2b) after releasing it from the cold air intake. 1. Undo the bolt (1a) and disconnect the pipe from the intermediate connector to the air conditioning compressor (1b), air conditioning compressor side.2. Undo the bolt (2a) and disconnect the pipe from the air conditioning compressor to the intermediate connector (2b), compressor side.

Seal the disconnected connectors, using suitable plugs, to prevent humidity and impurities from entering the system.

1. Undo the nut (1a) and disconnect the pipe from the intermediate connector to the air conditioner compressor (1b), intermediate connector side and move it aside.2. Undo the nut (2a) and disconnect the pipe from the air conditioning compressor to the intermediate connector (2b), intermediate connector side.3. Remove the pipe from the air conditioning compressor to the intermediate connector, after releasing it from the fastening bands.

Seal the disconnected connectors, using suitable plugs, to prevent humidity and impurities from entering the system.

1. Loosen the band and disconnect the air supply hose from the heat exchanger to the inlet manifold, inlet manifold side. 2. Connect the electrical connections to the diesel electronic injection control unit.

	Name	Connector
2	Engine management ECU	M10

1. Disconnect the electrical connection from the reversing lights switch.

	Name	Connector
1	Reversing lights switch	I20

2. Disconnect the gear selector and engagement cables.3. Remove the cap on the bleed valve.4. Connect the collection system (pipe and reservoir) to the bleed valve on the hydraulic clutch actuator. 5. Lift the retaining clip (5a) and extract the bleed device as much as necessary (5b).Let the hydraulic clutch system drain completely.6. Lift the retaining clip (6a) and disconnect the pipe (6b) from the clutch hydraulic control actuator and move it aside after releasing it from the bands (6c). 1. Undo the bolts securing the power steering fluid reservoir.2. Lift the power steering fluid reservoir as much as necessary and disconnect the rapid connectors on the power steering fluid supply and return pipes.3. Remove the power steering fluid reservoir. 1. Undo the nut (1a), move the plug preheating control unit (1b) as much as necessary to disconnect the electrical connections (1c), then remove it.

	Name	Connector
1c	Plug preheating control unit	M15

1. Disconnect the quick-release connector for the front fuel supply pipe, fuel filter side.2. Disconnect the rapid attachment on the fuel return pipe to the fuel return manifold pipe, fuel filter side.3. Disconnect the quick-release connector for the fuel supply pipe to the pressure pump, fuel filter side.

Recover the fuel which comes out in a suitable container.

4. Disconnect the electrical connection from the fuel temperature sensor.

	Name	Connector
4	Fuel temperature sensor	K81

5. Disconnect the electrical connection from the fuel pre-heating device.

	Name	Connector
5	Fuel temperature sensor	K81

1. Undo the nuts (1a), raise the fuel filter sufficiently to disconnect the electrical connection from the water presence sensor in the fuel filter (1b).

	Name	Connector
1b	Water in diesel filter sensor	K31

2. Remove the complete fuel filter. 1. Disconnect the single-acting valve from the brake servo. 1. Disconnect the front engine coupling.

	Name	Connector
1	Front/engine connection	D4

2. Loosen the band and disconnect the flexible coolant return pipe from the rigid coolant return pipe to the engine coolant reservoir. 3. Disconnect the rapid attachment for the fuel return pipe to the tank, fuel return manifold pipe side. 1. Loosen the band and disconnect the system supply pipe from the water pump rigid inlet pipe. 1. Disconnect the vacuum pipe from the solenoid valve for the turbocharger vanes actuator. 1. Remove the stops (1a) and release the front brake caliper hoses (1b) from the mounting brackets.2. Remove the clips fixing the brake calipers to the brackets.3. Remove the protective plugs (3a), undo the bolts (3b) and move aside the front brake calipers (3c) complete with pads and secure them as appropriate. 1. Undo nuts (1a) and disconnect upper track control arms (1b) from the steering knuckles using tool (1c).

	Name	Country
1c	Extractor	1.821.169.000

1. Undo the bolts securing the lower forks to the lower track control arms. 1. Undo the nuts (1a) and disconnect the front anti-roll bar joints (1b), lower forks side. 2. Loosen the bands securing the gaiters and disconnect the front driveshafts. 1. Loosen the bands and disconnect the coolant supply and return pipes to the climate control system heater.2. Disconnect the electrical connection from the temperature sensor for additional heater.

	Name	Connector
2	Additional heater temperature sensor	K80

1. Undo the bolts (1a) and disconnect the oil supply and return pipes (1b), engine oil heat exchanger side.

Recover the engine oil which comes out in a suitable container.

1. Undo bolt (1a) and disconnect battery earth lead (1b) from the power unit gearbox end rigid mount.

	Name	Connector
1b	Battery earth	C1

Proceed with removal  - 1076B70  exhaust pipe between pre-catalytic converter and catalytic converter - r r . Proceed with removal  - 1080B62  catalytic converter - r + r . Proceed with removal  - 1008A44  rear rigid mount - r r . Proceed with removal  - 2125C70  gearbox/brake lever mount - r r . 1. Undo the bolts (1a) and remove the flexible mounting for the power unit rigid rear support (1b). 1. Undo the connector and disconnect the delivery pipe from pump to power steering box, steering box side.Release the supply pipe from the pump to the power steering box from the retaining bands on the power steering box. 1. Support the front suspension crossmember using a hydraulic jack (1a) and the tool (1b).

	Name	Country
1b	Flange	1.860.978.000

2. Undo the bolts fixing the front suspension crossmember to the bodyshell. 1. Lower the hydraulic jack and remove the front suspension crossmember complete with accessories. Proceed with removal  - 1008C10  power unit upper reaction link r r . Position a suitable support under the power unit.1. Fit a suitable bracket (1a) on the bracket on the engine for the reaction rod and secure it with the bolt (1b).2. Support the power unit using a hydraulic crane fitted with suitable chains connected to the bracket mounted previously and to the rod of the power unit support, gearbox side. 1. Undo the bolt securing the timing side power unit rigid support to the flexible mounting. 1. Undo the bolt fixing the gearbox side power unit rigid support to the flexible mounting. Slowly lift the car on the ramp, then place the power unit on the platform using the hydraulic crane. Refitting ( Removing ) Refit the power unit in its seating, slowly lowering the car on the eramp and manoeuvring the hydraulic crane as appropriate.1. Tighten the bolt securing the gearbox side rigid power unit support to the flexible mounting to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	-	-	-	-

1. Tighten the bolt fixing the timing side rigid power unit support to the flexible mounting to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	ENGINE MOUNT TIMING SIDE	M12	(Flexible mounting side) 7.9 ÷ 9.7

Remove the hydraulic hoist fitted with suitable chains used for safely supporting the power unit.Undo the bolt and remove the bracket from the bracket on the engine for the reaction rod.Remove the platform from under the power unit. Proceed with refitting  - 1008C10  power unit upper reaction link r r . Using the hydraulic jack, refit the front suspension crossmember complete with accessories in its seating.1. Tighten the bolts securing the front suspension crossmember to the bodyshell to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Side bolt	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 ÷ 13.2

	Fastening	Component	Ø	Value(daNm)
1	Rear bolts	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 ÷ 13.2

	Fastening	Component	Ø	Value(daNm)
1	Rear bolt	ENGINE OR ROD ANCHORAGE BEAM	M10	(Bodyshell side) 8.1 ÷ 9.9

2. Remove the hydraulic jack (2a) and tool (2b) used for supporting the front suspension crossmember.

	Name	Country
2b	Flange	1.860.978.000

1. Refit the flexible mounting for the power unit rear rigid support (1a) in its seating and tighten the bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	INTERM RUBBER MOUNT	M8	(Front suspension crossmember side) 3.3 ÷ 3.9

Proceed with refitting  - 2125C70  gearbox/brake lever mount - r r . Proceed with refitting  - 1008A44  rear rigid mount - r r . Proceed with refitting  - 1080B62  catalytic converter - r + r . Proceed with refitting  - 1076B70  exhaust pipe between pre-catalytic converter and catalytic converter - r r . Connect the battery earth lead to the gearbox side rigid power unit support and fix it using the bolt. Connect the oil supply and return pipes, engine oil heat exchanger side, and secure it with the bolts.Secure the supply pipe from the pump to the power steering box to the retaining bands on the power steering box. 1. Connect the supply pipe from pump to the power steering pump, power steering box side and tighten the connector to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Connector	PIPE BTWN PUMP + POWER STEERING BOX	M14	(Power assisted steering box side) 3.6 ÷ 4.4

Connect the electrical connection to the temperature sensor for the additional heater.Connect the coolant supply and return pipes to the climate control heater and tighten the bands.1. Connect the front drive shafts and tighten the gaiter bands.2. Connect the front suspension anti-roll bar joints, lower forks side, and tighten the nuts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2	Nut	FRONT ANTI-ROLL BAR JOINTS	M10	4.5 ÷ 5.5

1. Tighten the bolts securing the lower forks to the lower track control arms to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	FRONT DAMPER FORK ON WISHBONE	M12	(Lower track control arm side) 10.8 ÷ 13.2

1. Connect the upper track control arms (1a) to the steering knuckles and tighten the nuts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	FRONT SUSPENSION TOP LEVER	M10	(Wheel damper side) 4.3 - 4.7

1. Refit the front brake calipers (1a) in their seats complete with pads and tighten the bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FRONT BRAKE CALIPER ASSEMBLY	M10	(Bracket side) 4.8 - 5.2

2. Refit the plugs in their housings.3. Refit in their seats the clips securing the brake calipers to their mounting brackets.4. Secure the front brake caliper hoses (4a) to their mounting brackets and lock them with their stops (4b). Connect the vacuum pipe to the solenoid valve for the turbocharger vanes actuator. Connect the system supply pipe to the water pump rigid inlet pipe and tighten the band.Connect the rapid attachment for the fuel return pipe to the tank, fuel return manifold pipe side.Connect the flexible pipe to the coolant return pipe to the engine coolant reservoir and tighten the band. Connect the front engine coupling.Connect the electrical connection to the water-in-fuel filter sensor, then refit it in its seating and secure it with the nuts.Connect the electrical connection to the fuel pre-heating device.Connect the electrical connection to the fuel temperature sensor.Connect the quick-release connector for the fuel supply pipe to the pressure pump, fuel filter side. Connect the rapid attachment of the front fuel return pipe to the fuel return manifold pipe, fuel filter side.Connect the quick-release connector for the front fuel supply pipe, fuel filter side. Connect the electrical connections to the plug preheating control unit, then refit it in its seating and secure it with the nut. Connect the one-way valve to the brake servo.Connect the rapid connectors for the power steering fluid supply and return pipes to the power steering fluid reservoir, then place it in its seating and secure it with the bolts.Connect the clutch hydraulic actuator pipe and secure it with its clip.Connect the gear selector and engagement cables.Connect the electrical connection to the reversing lights switch. Connect the electrical connection to the diesel electronic injection control unit.Connect the air supply hose from the heat exchanger to the inlet manifold, inlet manifold side, and tighten the band. Replace the pipe from the air conditioning compressor to the intermediate connector in its seating and secure it with its attachments.Connect the pipe from the air conditioning compressor to the intermediate connector, intermediate connector side, and tighten the nut to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	COOLANT SYSTEM FITTINGS	M6	0.7 ÷ 1.1

Connect the pipe from the intermediate connector to the air conditioning comrpessor, intermediate connector side, and tighten the nut to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	COOLANT SYSTEM FITTINGS	M6	0.7 ÷ 1.1

Connect the pipe from air conditioning compressor to the intermediate connector, compressor side, and tighten the bolt to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	COOLANT SYSTEM FITTINGS	M6	0.7 ÷ 1.1

Connect the pipe from the intermediate connector to the air conditioning compressor, air conditioning side, and tighten the bolt to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	COOLANT SYSTEM FITTINGS	M6	0.7 ÷ 1.1

Replace the O-rings for the connectors using green coloured seals only, resistant to R134a refrigerant fluid. Lubricate the thread of the connectors using anti-freeze. .

Place the air filter, complete with air flow meter, back in its housing and connect it to the cold air intake.Connect the electrical connection to the air flow meter.Connect the vacuum pipe from the turbocharger variable geometry control actuator.Refit in its seating the air supply duct between turbocharger and heat exchanger and tighten the bands. Connect the rapid connectors of the power steering fluid inlet and outlet pipes, heat exchanger pipe side.Connect the rapid attachment for the lower coolant outlet hose from the radiator, radiator side.1. Connect the lower steering control shaft (1a) to the power steering box and tighten a new one (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	-	-	-	-

Proceed with refitting  - 1048A50  air inlet pipe to turbo charger - r + r . Proceed with refitting - 7055B90 Left front WHEEL ARCH LINER - R.R. . Proceed with refitting - 7055B91 Right front WHEEL ARCH LINER - R.R. . Proceed with refitting - 7055B66 Engine compartment DUST SHIELD protection in right front wheel arch - R.R. . Proceed with refitting  - 4450B12  front or rear wheels (two) - r+r . Refill the engine oil lubrication system - 0010T11 engine oil check level and top up . Refill the manual gearbox and differential - 0010T41 MANUAL GEARBOX OIL - Check level and top up, if necessary . Proceed with refitting - 0010T64 brake and or clutch fluid check level and top up as necessary . Proceed with refitting  - 0010T67  hydraulic clutch system bleed air . Proceed with refitting  - 0010T71  power steering fluid check level and top up if necessary . Refill the engine cooling system with coolant  - 0010T20  coolant change . Fill the air conditioner coolant circuit - 0010T84 coolant for air conditioning system dehydrate and recharge . Proceed with refitting  - 7055B54  under-engine guard - r r . Proceed with refitting  - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. . Proceed with refitting  - 5530B10  battery - r+r . Proceed with refitting  - 1016A10  sound-proofing cover - r + r . Remove the car from the ramps.