125000864 - 1004B10 POWER UNIT WITH MANUAL GEARBOX - R + R

Removing ( Refitting ) Position the vehicle on a lift.Drain the air conditioning refrigerant circuit    Op. 5040A10 EXPANSION/CONNECTION PIPE - R R.Proceed with the removal    Op. 1048A48 THROTTLE HEATER SLEEVE - R R.Proceed with the removal    Op. 5530B10 BATTERY - R+R.Proceed with the removal    Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R..Proceed with the removal    Op. 1048A10 AIR CLEANER FILTERING ELEMENT - REPLACE.Proceed with the removal    Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R.Proceed with the removal    Op. 7055B54 UNDER-ENGINE GUARD - R R.Proceed with the removal    Op. 7055B64 LH OR RH REFLECTOR(ONE) ON REAR BUMPERS - R R.Proceed with the removal    Op. 7055B42 LH OR RH REFLECTOR(ONE) ON REAR BUMPERS - R R.Proceed with the removal    Op. 7210E10 R.R. FRONT BUMPER.Proceed with the removal    Op. 5540B76 FRONT LIGHT CLUSTER WITH FOGLAMP ONE LH OR RH R R WITH INTERFERING PARTS REMOVED(Right and left sides).Proceed with the removal    Op. 7025A34 BONNET LID LOCK (ONE) - R+R OR REPAIR.Proceed with removal - 7210A15 R&R FRONT WING/HEADLAMP HOUSING CROSSMEMBER .Proceed with the removal    Op. 1088B20 ENGINE COOLING RADIATOR - R + R.1. Loosen the band and disconnect the radiator upper coolant inlet hose, thermostat side and remove it.2. Loosen the band and disconnect the radiator lower coolant inlet hose, radiator side.3. Loosen the band and disconnect the intermediate coupling for the engine cooling system supply pipe. 1. Undo the bolts (1a) and remove the lower radiator crossmember (1b) complete with engine cooling system pipes (1c). 1. Undo the nut (1a) and disconnect the earth lead (1b) from the gearbox side power unit rigid support.

	Description	Connector
1b	Battery earth	See C1 BATTERY EARTH

2. Loosen the bands and disconnect the flexible power assisted steering fluid supply and return pipes to the radiator, rigid pipe side.

Collect the power assisted steering hydraulic circuit fluid that comes out in a suitable container.

1. Undo the nuts (1a) and remove the power assisted steering system fluid cooling radiator mounting bracket (1b) complete with radiator (1c), duct (1d) and piping (1e). 1. Undo the bolt (1a) and remove the cold air intake for the air filter (1b). 1. Undo the connector (1a) and disconnect the supply pipe from the pump to the power assisted steering box (1b), power assisted steering box side. 1. Loosen the band and disconnect the intermediate coupling for the return pipe from the power assisted steering box to the radiator. Proceed with the removal    Op. 1076B82 LEFT EXHASUST PIPE BETWEEN CATALYTIC PRECONVERTER AND CONVERTER R R.1. Undo the bolts (1a) and disconnect the engine oil inlet and outlet pipes (1b), engine oil cooling radiator side.

Collect the engine oil in a suitable container.

2. Undo the nuts (2a) and remove the engine oil cooling radiator (2b). 1. Undo the nut (1a) and disconnect the starter motor electrical connection (1b) from the maxi fuse box. 1. Disconnect the electrical connection from the reversing light switch.

	Description	Connector
1	Reversing lights switch	See I20 REVERSING LIGHTS SWITCH

2. Disconnect the gear selector and engagement cables. 1. Loosen the collar and disconnec the coolant delivery pipe to the climate control system heater, connector side.2. Loosen the band and disconnect the coolant return pipe from the climate control system heater, thermostat side. Remove the protective cap from the bleed valve on the clutch operating cyliner.Connect the recovery device (pipe and reservoir) to the bleed valve on the operating cylinder.Operate the clutch pedal until the brake/clutch reservoir is drained.1. Remove the split pin (1a) and disconnect the pipe from the vibration damper to the clutch operating cylinder (1b), damper side. 1. Disconnect the rapid connector for the fuel vapour recirculation pipe from the air chamber.2. Loosen the band and disconnect the brake servo vacuum intake pipe from the air chamber.3. Disconnect the electrical connection from the injection/ignition control unit.

	Description	Connector
3	Engine management control unit	See M10 ENGINE MANAGEMENT ECU

4. Open the electrical connection holder case.5. Disconnect the engine coupling.6. Disconnect the electrical connections (6a) and (6b) securing the rear Lambda sensors to the catalytic converter.

	Description	Connector
6a	Lambda sensor on catalyzer	See K17 LAMBDA SENSOR ON CATALYZER ( CONNECTORS )

	Description	Connector
6b	Lambda sensor on catalyzer - 2	See K18 LAMBDA SENSOR ON CATALYZER 2 ( CONNECTORS )

1. Undo the bolts (1a) and remove the electrical connections box (1b). 1. Loosen the coolar and disconnect the coolant return pipe from the engine coolant reservoir.2. Undo the bolts (2a) and remove the power unit reaction rod (2b). Discharge the fuel supply pressure.1. Disconnect the fuel supply pipe rapid connector. 1. Undo the bolts (1a) and disconnect the right driveshaft (1b) from the intermediate driveshaft. 1. Undo the bolts (1a) and disconnect the left driveshaft (1b) from the differential internal shaft. Proceed with the removal    Op. 1008A44 REAR RIGID MOUNT - R R.Postion a suitable footboard beneath the power unit.1. Fit a suitable bracket on the left cylinder head for supporting the power unit. 1. Fit a suitable bracket on the right cylinder head for supporting the power unit. 1. Using a hydraulic hoist (1a) fitted with suitable chains (1b) connected to the brackets fitted previously and to the bracket (1c) already on the gearbox, support the power unit. 1. Unscrew the bolt securing the power unit rigid mount to the flexible block. 1. Loosen the nut fixing the timing side rigid engine support to the flexible mounting. Move the power unit foward to prevent interference with the front suspension crossmember, then slowly lower the power unit using the hydraulic hoist until it is resting on the support positioned previously. Refitting ( Removing ) Replace the power unit in the engine compartment using a hydraulic hoist.1. Tighten the nut fixing the timing side rigid engine support to the flexible mounting.

	Fastening	Component	Ø	Value(daNm)
1	Nut	RIGID ENGINE MOUNT, TIMING SIDE	M10	(Flexible mounting side) 4.5 - 5.5

1. Tighten the bolt securing the gearbox side power unit rigid support to the flexible mounting.

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

Remove the hydraulic hoist with the chains used to support the power unit.Remove the brackets fitted for supporting the power unit.Remove the support positioned previously underneath the power unit.Proceed with the refitting    Op. 1008A44 REAR RIGID MOUNT - R R.1. Connect the left driveshaft (1a) to the differential internal shaft and secure it tightening the bolts (1b) to the recommended torque.

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

1. Connect the right driveshaft (1a) to the intermediate driveshaft and secure it tightening the bolts (1b) to the recommended torque.

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

Connect the fuel supply pipe rapid connector.1. Place the power unit reaction rod (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT REACTION ROD	M10	4.5 ÷ 5.5

2. Connect the coolant return pipe to the engine coolant reservoir to the coolant reservoir and tighten the band. Place the electrical connections box in its housing and secure it using the bolts.Connect the electrical connections for the rear Lambda sensors to the catalytic converter.Connect the engine coupling.Close the electrical connection holder case.Connect the electrical connection to the injection/ignition control unit.Connect the brake servo vacuum intake pipe to the air chamber and tighten the band.Connect the rapid connector for the fuel vapour recirculation pipe to the air chamber.Connect the pipe from the vibration damper to the clutch operating cylinder, damper side and secure it using the split pin.Connect the coolant return pipe from the climate control system heater, thermostat side, and tighten the band.Connect the coolant supply pipe to the climate control system heater, connector side, and tighten the band.Connect the gear selector and engagement cables.Connect the electrical connection to the reversing light switch.Connect the starter motor electrical connection to the maxi fuse box and tighten the nut.Place the engine oil cooling radiator back in its housing and tighten the nuts.Connect the engine oil inlet and outlet pipes, engine cooling radiator side and tighten the bolts.Proceed with the refitting    Op. 1076B82 LEFT EXHASUST PIPE BETWEEN CATALYTIC PRECONVERTER AND CONVERTER R R.Connect the intermediate coupling for the return pipe from the power assisted steering box to the radiator and tighten the band.1. Connect the supply pipe from the pump to the power assisted steering box (1a), power assisted steering box side and tighten the connector (1b) to the recommended torque.

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

Place the cold air intake for the air filter back in its housing and secure it using the bolt.Place the power assisted steering system fluid cooling radiator mounting bracket in position complete with radiator, duct and piping and secure it using the nuts.Connect the flexible power assisted steering fluid supply and return pipes to the radiator, rigid pipe side and tighten the bands.Connect the earth lead to the power unit gearbox side rigid support and secure it using the nut.Place the lower radiator crossmember in position complee with engine cooling system pipes and secure it using the bolts.Connect the intermediate coupling for the engine cooling system supply pipe and tighten the band.Connect the radiator lower coolant inlet hose, thermostat side, and tighten the band.Place the radiator upper coolant inlet hose in position, connect it to the thermostat and tighten the band.Proceed with the refitting    Op. 1088B20 ENGINE COOLING RADIATOR - R + R.Proceed with refitting - 7210A15 R&R FRONT WING/HEADLAMP HOUSING CROSSMEMBER .Proceed with the refitting    Op. 7025A34 BONNET LID LOCK (ONE) - R+R OR REPAIR.Proceed with the refitting    Op. 5540B76 FRONT LIGHT CLUSTER WITH FOGLAMP ONE LH OR RH R R WITH INTERFERING PARTS REMOVED(Right and left sides).Proceed with the refitting    Op. 7210E10 R.R. FRONT BUMPER.Proceed with the refitting    Op. 7055B42 LH OR RH REFLECTOR(ONE) ON REAR BUMPERS - R R.Proceed with the refitting    Op. 7055B64 LH OR RH REFLECTOR(ONE) ON REAR BUMPERS - R R.Proceed with the refitting    Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R.Proceed with the refitting    Op. 1048A10 AIR CLEANER FILTERING ELEMENT - REPLACE.Proceed with the refitting    Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R..Proceed with the refitting    Op. 5530B10 BATTERY - R+R.Proceed with the refitting    Op. 1048A48 THROTTLE HEATER SLEEVE - R R.Refill the engine oil lubrication system    Op. 0010T11 ENGINE OIL CHECK LEVEL AND TOP UP.Refill the engine cooling system    Op. 0010T20 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY.Bleed the air and top up the hydraulic clutch release system    Op. 0010T67 HYDRAULIC CLUTCH SYSTEM BLEED AIR.Refill the air conditioning refrigerant circuit    Op. 5040A10 EXPANSION/CONNECTION PIPE - R R.Refill the power assisted steering circuit with the recommended fluid.

	Type	Component	Description	Qty.
-	Fluid [I]	POWER STEERING HYDRAULIC SYSTEM	TUTELA GI/A	1.2

The table shows the total quantity of fluid present in the power steering circuit.

Proceed with bleeding the air from the power assisted steering system following the instructions given below.With the front wheels raised off the ground and the engine switched off, carry out 4 or 5 complete rotations of the steering wheel (left and right).Check the level of the fluid in the reservoir and top up if necessary.Remove the vehicle from the lift.Start the engine and carry out 4 - 5 complete steering wheel rotation cycles (left and right).Top up the fluid level in the reservoir.Proceed with the refitting    Op. 7055B54 UNDER-ENGINE GUARD - R R.