2400050 - 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  - 4450B12  front or rear wheels (two) - 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  - 5530B10  battery - r+r Proceed with removal  - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. Proceed with removal  - 1048A10  air cleaner filtering element - replace1. Loosen the collar and disconnect the engine oil vapour intake pipe from the tappet cover.2. Disconnect the engine oil vapour inlet pipe from the intake manifold.3. Loosen the band, disconnect the hose from the air filter to the intake manifold, intake manifold side and remove it.4. Loosen band and disconnect the upper coolant inlet hose to the radiator, thermostat side.

Recover the coolant which comes out in a suitable container.

1. Loosen the band and disconnect the lower radiator coolant outlet hose from the radiator, radiator side. 1. Undo the bolt securing the coolant pipe mounting bracket to the air conditioner compressor.2. Undo the bolt (2a) and disconnect the coolant fluid inlet and outlet pipes (2b) from the air conditioning compressor and move aside.3. Undo the protective plug (3a) for the fuel manifold and use tool (3b) to drain the pressure from the fuel system.

Recover the fuel which comes out in a suitable container.

	Name	Country
3b	Rapid connector	1.870.684.000

4. Disconnect the rapid connector for the fuel vapour recirculation pipe from the air chamber.5. Disconnect the rapid attachment for the fuel supply pipe (5a) from the fuel manifold and release from collar (5b). 1. Undo the bolts (1a) and move the clutch operating cylinder (1b) aside without disconnecting the pipe.2. Undo the nut and disconnect the battery earth lead from the gearbox.

	Name	Connector
2	Battery earth	C1

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

	Name	Connector
3	Reversing lights switch	I20

1. Disconnect the brake servo single-acting valve from the brake servo.2. Release the vacuum pipe for the brake servo (2a) from the retaining band (2b). 1. Undo the bolts (1a) fixing the gear selector and engagement cables mounting bracket (1b).2. Press the release button (2a) and disconnect the gear selector cable (2b). 3. Disconnect the gear engagement cable.Move the gear selector and engagement cables, complete with mounting bracket, sideways. 1. Loosen the band and disconnect the coolant return pipe to the climate control heater, thermostat side.2. Loosen the band and disconnect the coolant return pipe from the climate control heater, water pump rigid inlet pipe side. 3. Release the coolatn return pipe from the climate control system heater from its bands. Proceed with removal  - 1072C44  exhaust manifold heat shield on bulkhead - r+r Proceed with removal  - 1072C16  exhaust manifold with catalytic converter - r r1. Undo the nuts (1a) and disconnect the track rods (1b) from the steering knuckles usiing the tool (1c).

	Name	Country
1c	Extractor	1.871.000.700

2. Undo the bolts fixing the front hub steering knuckle to the front shock absorbers. 1. Loosen the bands (1a) and disconnect the driveshafts (1b ).

Secure the drive shafts.

1. Undo the bolt fixing the air conditioning pipe mounting bracket to the alternator. Position a hydraulic jack under the gearbox.1. Undo the bolt (1a) and the bolt (1b) and remove the power unit lower reaction rod (1c).Remove the hydraulic jack from under the gearbox. Lower the lift and place a suitable stand beneath the power unit.1. Position a suitable bracket (1a) by the stud (1b) under the air conditioning compressor and a special bracket (1c) on the bellhousing. 2. Secure the engine at points (2a), (2b) and (2c) near the seals positioned previously using a hydraulic lift fitted with special chains and hooks. Lift the power unit slightly so that all cables are under the same strain. 1. Undo the nuts fixing the timing side power unit support flexible mounting to the support. 1. Undo the nut fixing the power unit gearbox side rigid support to the flexible mounting. Slowly lower the power unit with the hydraulic hoist until it is resting on the support positioned previously. Refitting ( Removing ) Place the power unit back in the engine compartment using the hydraulic hoist.1. Undo the nut fixing the gearbox side rigid power unit support to the flexbile mounting to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M12	(Flexible mounting side) 8.1 ÷ 9.9

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

	Fastening	Component	Ø	Value(daNm)
1	Nut	FRONT RUBBER MOUNTS	M10	(Rigid support side) 4.5 ÷ 5.5

Remove the hydraulic hoist fitted with suitable chains and the brackets used for supporting the power unit.Position a hydraulic jack under the gearbox.1. Place the power unit reaction rod (1a) back in its housing, then fasten by tightening bolts (1b) and (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	LOWER ROD ON ENGINE	M12	(Gearbox side) 7.2 ÷ 8.8

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	LOWER ROD ON ENGINE	M12	(Front suspension crossmember side) 11.4 ÷ 12.6

Remove the hydraulic jack from under the gearbox. Tighten the bolt fixing the air conditioning pipe mounting bracket to the alternator.Connect the driveshafts and tighten the bands.1. Tighten the front wheel hub fastening bolts to the front shock absorbers to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	FRONT HUB STEERING KNUCKLE.	M10	(Shock absorber side) 6.2 ÷ 6.8

2. Connect the steering rods (2a) to the front steering knuckles and tighten the nut (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	EXHAUST PIPE MOUNTS/FASTENERS	M10 x 1.25	(centre) 5

Proceed with refitting  - 1072C16  exhaust manifold with catalytic converter - r r . Proceed with refitting  - 1072C44  exhaust manifold heat shield on bulkhead - r+r . Connect the coolant return hose from the climate control heater on the side of the rigid inlet pipe to the water pump and do up the band. Connect the engine coolant return pipe from the climate control system heater, thermostat side, and tighten the band.Place the gear selector and engagement cables, complete with mounting bracket, back in their housings.Connect the gear selector cable.Connect the gear engagement cable.Tighten the bolts fixing the gear selector and engagement mounting bracket.Secure the vacuum pipe for the brake servo using the band.Connect the brake servo one-way valve to the brake servo.Connect the electrical connection to the reversing lights switch. Connect the battery earth lead and tighten the nut.Replace the clutch operating cylinder, then fix it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CLUTCH SLAVE CYLINDER	M8	(Gearbox side) 1.8 - 2.2

Connect the rapid attachment for the fuel supply pipe to the fuel manifold pipe and secure with the band.Connect the rapid connector for the fuel vapour recirculation pipe to the air chamber.Connect the coolant inlet and outlet pipes to the air conditioning compressor and secure by tightening the bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	PIPES FROM COMPRESSOR TO CONDENSOR	M6	0.7 ÷ 1.1

	Fastening	Component	Ø	Value(daNm)
-	Bolt	EXPANSION VALVE - COMPRESSOR PIPE	M6	0.7 ÷ 1.1

Tighten the bolt securing the coolant pipe mounting brackets to the air conditioner compressor.Connect the lower coolant outlet hose from the radiator, radiator side, and tighten the band.Connect the upper coolant inlet hose to the radiator, thermostat side, and tighten the band. Place the hose from the air filter to the intake manifold back in its housing, connect it to the intake manifold and tighten the band.Connect the engine oil vapour inlet pipe to the intake manifold.Connect the engine oil vapour intake pipe to the tappet cover and tighten the band. Proceed with refitting  - 1048A10  air cleaner filtering element - replace . Proceed with refitting  - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. . Proceed with refitting  - 5530B10  battery - 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 cooling system with coolant  - 0010T20  coolant change . Fill the air conditioner coolant circuit  - 0010T84  coolant for air conditioning system dehydrate and recharge . Remove the car from the ramps.