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

Removing ( Refitting )

• Position the vehicle on a lift.
• Op. 5530B10 BATTERIA - S.R.

During the removal of the battery, take care to also disconnect the starter motor supply cable, shown in the diagram, from the maxi fuse box.

• Op. 5530B52 SUPPORTO/CESTELLO BATTERIA - S.R.

1. Disconnect the earth lead from the power unit gearbox side rigid support.

	Description	Connector
1	Earth on engine	Vedere C40 MASSA SU MOTORE

2. Disconnect the electrical connection from the reversing light switch.

	Description	Connector
2	Reversing lights switch	Vedere I20 INTERRUTTORE LUCI RETROMARCIA

1. Disconnect the electrical connection from the air flow meter.

	Description	Connector
1	Air flow meter	Vedere K41 MISURATORE PORTATA D''ARIA

• Release the electrical wiring for the air flow meter from the fastening on the air intake hose.

2. Disconnect the oil vapour recirculation pipe from the air intake hose.3. Disconnect the air intake hose from the throttle casing.

• Remove the air filter assembly and intake hose complete with air flow meter after having released it from the resonator unit.

• Move the rubber protection aside to access the coupling for the clutch hydraulic actuator pipe.
• Completely release the flexible clip retaining the pipe to the actuator body.
• Disconnect the flexible pipe from the vibration damper to the clutch hydraulic actuator, hydraulic actuator side and secure it.

Collect the clutch fluid that comes out in a suitable container, then seal the pipe and place it at the side.

1. Disconnect the gear selector and engagement cables.

To disconnect the gear selector cable, press the release tabs illustrated and retract the actual cable.

2. Remove the plates (2a) and release the gear selector and engagement cables from the mounting bracket (2b).

• Disconnect the brake servo single-acting valve, brake servo side.

1. Disconnect the electrical connection from the injection/ignition control unit.

	Description	Connector
1	Engine management control unit	Vedere M10 CENTRALINA CONTROLLO MOTORE

2. Disconnect the engine front coupling.

	Description	Connector
2	Front/engine coupling	Vedere D4 GIUNZIONE ANTERIORE/MOTORE

3. Disconnect the electrical connection for the Lambda sensor.

	Description	Connector
3	Lambda sensor on pre-catalyzer	Vedere K15 SONDA LAMBDA SUL PRE-CATALIZZATORE

• Disconnect the rapid connectors and remove the fuel vapour recovery pipe.

Seal the fuel vapour recovery system pipes.

• Undo the bolt (1a), bolt (1b) and remove the power unit reaction rod (1c).

• Draw off the power assisted steering fluid from the reservoir using a suitable syringe.

• Undo and remove the engine oil filler plug.
• Undo the bolts (2a) and remove the ignition coils cover (2b).

• Place the engine oil filler cap in its housing.

• Discharge the fuel supply pressure with the tool connected to the special valve located at the side of the fuel manifold pipe.

	Description	Code
-	Connector	1.870.684.000

• Disconnect the rapid connector for the front fuel supply pipe, fuel manifold pipe side.

Seal the front fuel supply pipe and place it at the side.

• Disconnect the coupling for the coolant return pipe from the engine coolant reservoir.

Seal the disconnected pipes to prevent impurities from getting into the system.

•     Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE

• Undo the bolt (1a) and disconnect the coolant inlet/outlet pipes flange (1b) from the air conditioning compressor.
• Undo the nut (2a) and disconnect the flange (2b) for the pipe from the air conditioning condenser to the intermediate connector, intermdiate connector side.

Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.

• Op. 4450B12 RUOTE (DUE) ANTERIORI - S.R.
•     Op. 7055B65 ENGINGE BAY DUSTGUARD PROTECTION IN LEFT FRONT WHEEL ARCH R R
•     Op. 7055B66 ENGINE COMPARTMENT DUST SHIELD PROTECTION IN RIGHT FRONT WHEEL ARCH - R.R.
•     Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.
•     Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

• Disconnect the lower coolant outlet hose from the radiator and drain the engine cooling system.

Manually press the clips and release the hose rapid connector.

Collect the coolant in a suitable container.

• Disconnect the radiator upper coolant inlet hose.

Manually press the clips and release the hose rapid connector.

• Release the electrical wiring from the fastening on the engine cooling system supply pipe.
• Disconnect the engine cooling system supply pipe, water pump rigid inlet pipe side.

• Disconnect the climate control system heater coolant supply pipe, thermostat side.
• Disconnect the coolant return pipe from the climate control system heater, water pump rigid inlet pipe side.

•     Op. 7210E10 R.R. FRONT BUMPER

• Unscrew the bolts securing the lower radiator crossmember to the bodyshell.
• Remove the engine cooling radiator complete with fan, air conditioning condenser and pipes and lower crossmember.

Take care to release the fan upper pin from the mounting bracket.

• Undo the nuts (1a) and the bolts (1b), then remove the exhaust manifold heat shield (1c).

• Disconnect the electrical connection for the right Lambda sensor and release the electrical wiring from the fastenings.

	Description	Code
1	Lambda sensor	Vedere K40 SONDA LAMBDA

• Disconnect the electrical connection for the left Lambda sensor and release the wiring from the fastenings.

	Description	Code
1	Lambda sensor - 2	See K39 LAMBDA SENSOR - 2

• Undo the nuts fixing the catalytic preconverter to the exhaust manifold.
• Undo the nuts fixing the catalytic preconverter to the catalytic converter.
• Undo the bolts fixing the catalytic preconverter bracket to the engine block.
• Undo the bolt fixing the catalytic preconverter flexible mounting to the front suspension crossmember.
• Remove the catalytic preconverter complete with Lambda sensors.

• Remove the seals.

• Disconnect the return pipe from the heat exchanger to the power assisted steering fluid reservoir, reservoir side.

• Undo the connector (1a) and disconnect the supply pipe from the pump to the power assisted steering box (1b), pump side.

• Loosen the bolts fixing the driveshafts to the differential internal driveshaft/intermediate driveshaft.
• Release the front brake caliper flexible pipes, the electrical wiring for the pad wear sensors and the A.B.S. sensors electrical wiring from the fastenings.

• Undo the nuts (1a) and disconnect the upper front track control arms (1b) from the steering knuckles using the tool (1c).

	Description	Code
1c	Extractor	1.821.169.000

• Move the driveshafts away from the differential internal driveshaft/intermediate driveshaft.

• Position a hydraulic jack under the power unit rigid rear support.
• Unscrew the bolt securing the power unit rigid rear support to the flexible mounting.

• Slowly lower the hydraulic jack and remove it.

• Postion a suitable footboard beneath the power unit.

• Position suitable brackets on the power unit as illustrated in the diagram.

• Support the power unit using a hydraulic hoist (1a) and the tool (1b) connected to the brackets fitted previously.

	Description	Code
1b	Balance	1.871.001.700

• Unscrew the bolt securing the power unit rigid mount to the flexible block.

• Loosen the bolt fixing the timing side rigid engine support to the flexible mounting.

• Slowly lower the power unit with the hydraulic hoist until it rests on the floor.
• Release the hydraulic hoist chains from the power unit.
• Raise the vehicle on the lift.

• Using a hydraulic hoist fitted with suitable chains as described previously, place the power unit on a suitable support.

Refitting ( Removing )

• Using a hydraulic hoist fitted with a suitable tool as described previously, position the power unit under the vehicle.
• Release the hydraulic hoist chains from the power unit.
• Lower the vehicle on the lift.
• Via the engine compartment, support the power unit using the hydraulic hoist and the special equipment.
• Slowly raise the power unit using the hydraulic hoist until it is positioned back in its housing in the engine compartment.

• Tighten the bolt securing the timing side rigid engine support to the flexible mounting to the recommended torque.

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

• Tighten the bolt securing the power unit gearbox side rigid support to the flexible mounting to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
1	Bolt	GEARBOX SIDE RIGID SUPPORT FOR POWER UNIT	M10	(Flexible mounting side) 4.2 - 5.1

• Remove the tools used for refitting the power unit and put them away.

• Position a hydraulic jack under the power unit rigid rear support and raise it slowly until it is in contact with the flexible mounting.
• Tighten the bolt securing the power unit side rigid rear support to the flexible mounting to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
2	Bolt	POWER UNIT REAR RIGID MOUNT	M12	(Flexible mounting side) 7.5 - 9.2

• Remove the hydraulic jack.

• Place the driveshafts in their housings in contact with the differential internal driveshaft/intermediate driveshaft.

• Connect the upper track control arms (1a) to the steering knuckles and secure them tightening the nuts (1b) to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
1b	Nut	UPPER FRONT TRACK CONTROL ARMS	M10	(Steering knuckle) 4.3 - 4.7

1. Tighten the bolts fixing the driveshafts to the differential internal driveshaft/intermediate driveshaft to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
1	Bolt	DRIVESHAFT	M8	(Differential internal driveshaft/intermediate driveshaft side) 3.5 - 4.3

2. Fasten the front brake caliper flexible pipes, the electrical wiring for the pad wear sensors and the A.B.S. sensors electrical wiring.

• Connect the supply pipe from the pump to the power assisted steering box (1a), pump side and tighten the connector (1b) to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
1b	Connector	PIPE BTWN PUMP + POWER STEERING BOX	M16	(Power assisted steering pump side) 4.5 - 5.5

• Connect the return pipe from the heat exchanger to the power assisted steering fluid reservoir, reservoir side.

1. Place the catalytic preconverter back in its housing complete with Lambda sensors and seals.2. Tighten the bolt fixing the catalytic preconverter flexible mounting to the front suspension crossmember.3. Tighten the bolts fixing the catalytic preconverter bracket to the engine block.4. Tighten the nuts fixing the catalytic preconverter to the catalytic converter to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
4	Nut	CATALYTIC PRE-CONVERTER	M8	(Catalytic converter side) 2.7 - 3.3

5. Tighten the nuts fixing the catalytic preconverter to the exhaust manifold to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
5	Nut	CATALYTIC PRE-CONVERTER	M8	(Manifold side) 2.7 - 3.3

• Connect the electrical connection for the left and right Lambda sensors, then fasten the electrical wiring.
• Place the exhaust manifold heat shield back in its housing and secure it using the nuts and bolts.
• Place the engine cooling radiator complete with fan, air conditioning condenser and pipes and lower crossmember in position.

Check that the fan upper pin is correctly inserted in the mounting bracket.

• Tighten the bolts securing the lower radiator crossmember to the bodyshell.
•     Op. 7210E10 R.R. FRONT BUMPER
• Connect the coolant return pipe from the climate control system heater, water pump rigid inlet pipe side.
• Connect the climate control system heater coolant supply pipe, thermostat side.
• Connect the engine cooling system supply pipe, water pump rigid inlet pipe side.
• Connect the upper coolant inlet hose to the radiator.
• Connect the lower radiator coolant outlet hose.
•     Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.
•     Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.
•     Op. 7055B65 ENGINGE BAY DUSTGUARD PROTECTION IN LEFT FRONT WHEEL ARCH R R
•     Op. 7055B66 ENGINE COMPARTMENT DUST SHIELD PROTECTION IN RIGHT FRONT WHEEL ARCH - R.R.
•     Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R

1. Connect the flange for the pipe from the air conditioning condenser to the intermesdiate connector (1a) intermediate connector side and tighten the nut (1b) to the recommended torque.

Replace the O rings for the connectors. Only use green coloured seals that are resistant to R134a refrigerant fluid. Lubricate the connector threads using anti-freeze.

	Fastening	Component	Ø	Value (daNm)
1b	Nut	COOLANT CIRCUIT CONNECTORS	M6	0.7 ÷ 1.1

2. Connect the flange (2a) for the air conditioning compressor inlet/supply pipes and secure it by tightening the bolt (2b) to the recommended torque.

	Fastening	Component	Ø	Value (daNm)
2b	Bolt	COMPRESSOR PIPE CONNECTOR	M10	(Air conditioning compressor side) 2.8 - 4.2

• Connect the coupling for the coolant return pipe from the engine coolant reservoir.
• Connect the rapid connector for the front fuel supply pipe, fuel manifold pipe side.
• Remove the engine oil filler plug.
• Place the ignition coil cover back in its housing and secure it using the bolts.
• Place the engine oil filler cap in its housing.

• Place the power unit reaction link (1a) back in its housing, then secure it by tightening the bolt (1b) and the bolt (1c) to the specified torque.

	Fastening	Component	Ø	Value (daNm)
1b	Bolt	POWER UNIT REACTION ROD	M10	(Engine support side) 4.5 - 5.5

	Fastening	Component	Ø	Value (daNm)
1c	Bolt	POWER UNIT REACTION ROD	M10	(Bodyshell support side) 4.5 - 5.5

• Place the fuel vapour recovery pipe in position and connect the rapid connectors.
• Connect the electrical connection for the Lambda sensor.
• Connect the engine front coupling.
• Connect the electrical connection to the injection/ignition control unit.
• Connect the brake servo single-acting valve, brake servo side.
• Place the gear selection and engagement cables on the mounting bracket and fasten them using the plates.
• Connect the gear selector and engagement cables.

1. Position the flexible clip as illustrated, i.e. not fully fitted.

Make sure that the housing in the hydraulic actuator for the O-ring and the connector on the pipe is thoroughly clean and in good condition.Lubricate the O ring with brake fluid, if necessary, to facilitate the fitting of the pipe.Do not use detergents or mineral lubricants that are not compatible with the materials for the brake fluid.

2. Fully introduce the flexible pipe from the vibration damper to the clutch hydraulic actuator into the clutch hydraulic actuator.

• Insert the flexible clip completely to lock the pipe.
• Place the rubber protection back in its housing.

• Place the air filter assembly and intake hose complete with air flow meter in position and connect it to the resonator unit.
• Connect the air intake hose to the throttle casing.
• Connect the oil vapour recirculation pipe to the air intake hose.
• Connect the electrical connection to the air flow meter and secure the electrical wiring to the air intake hose using the band.
• Connect the electrical connection to the reversing light switch.
• Connect the earth lead to the power unit gearbox side rigid support.
•     Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R.
•     Op. 5530B10 BATTERY - R+R

Take care to also connect the starter motor supply lead to the maxi fuse box.

•     Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE
•     Op. 0010T20 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY
•     Op. 0010T67 HYDRAULIC CLUTCH SYSTEM BLEED AIR
•     Op. 0010T71 POWER STEERING FLUID CHECK LEVEL AND TOP UP IF NECESSARY
• Top up the fluid level in the reservoir.