2400050 - 1004B10 power unit with manual gearbox - r + r

Removing ( Refitting ) Position the vehicle on the ramp Proceed with removal  - 4450B12  front or rear wheels (two) - r+r Proceed with removal Proceed with removal  - 7055B66  Engine compartment DUST SHIELD protection in right front wheel arch - R.R. Proceed with removal  - 7055B90  Left front WHEEL ARCH LINER - 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.1. Disconnect the electrical connection from the air flow meter.

	Name	Connector
1	Air flow meter	K41

2. Loosen the band and disconnect the the turbocharger air inlet sleeve from the rigid pipe, air flow meter side. 1. Remove the air filter (1a) complete with air flow meter (1b) by releasing from the underlying pins and then from the rear fastenings. 1. Undo the bolts (1a) and move the clutch operating cylinder (1b) aside without disconnecting the pipe. 1. Disconnect the gear engagement/selector cables.2. Remove the stops and release the gear engagement/selector cables from the mounting bracket. Drain the air conditioner coolant circuit  - 0010T84  coolant for air conditioning system dehydrate and recharge . 1. Loosen the band and disconnect the lower radiator coolant outlet hose from the radiator, radiator side.

Collect the engine coolant in a suitable container.

1. Loosen the band and disconnect the upper coolant inlet hose to the radiator, thermostat side.2. Loosen the band and disconnect the heater supply and return pipe, water pump rigid inlet pipe side. 1. Loosen the band and disconnect the single heater water supply and return pipe, E.G.R. exhaust gas/water heat exchanger side. 1. Disconnect the brake servo single-acting valve from the brake servo.2. Undo the nut (2a) and disconnect the pipe from expansion valve to the compressor (2b), expansion valve side.

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

1. Undo the bolt (1a) and disconnect the pipe from the compressor to the condenser for the air conditioner (1b), compressor side.

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

1. Loosen the band and disconnect the coolant return pipe from the engine coolant reservoir.2. Loosen the band and disconnect the supply pipe, reservoir side, from the engine coolant reservoir.3. Undo nut (3a), bolt (3b) and remove engine coolant reservoir (3c). 1. Disconnect the electrical connections from the diesel electronic injection control unit.

	Name	Connector
1	Engine management control unit	M10

Undo the fuel filler cap and remove it to discharge the pressure in the system.1. Disconnect the rapid connector (1a) for the fuel supply pipe from the fuel filter to the pressure pump, pressure pump side and release it from the fastening (1b). 2. Disconnect the rapid attachment (2a) for the fuel return pipe to the tank, single fuel manifold pipe side and release it from the fastening (2b). 1. Disconnect the electrical connection from the reversing lights switch.

	Name	Connector
1	Reversing lights switch	I20

2. Undo the bolt (2a) and disconnect the battery earth lead (2b) from the gearbox.

	Name	Connector
2b	Battery earth	C1

1. Undo the bolts fixing the left driveshaft to the differential internal driveshaft.2. Undo the top bolt (2a) and loosen the bottom bolt (2b) securing the front left damper to the steering knuckle.Move the left drive shaft away from the differential internal drive shaft and secure it as appropriate. 1. Unscrew the bolts securing the right drive shaft to the intermediate drive shaft.Recover the safety plates.2. Undo the top bolt (2a) and loosen the bottom boltt (2b) securing the front right damper to the steering knuckle.Move the right drive shaft away from the intermediate drive shaft and secure it as appropriate. 1. Tighten the nuts fastening the rigid section of the exhaust pipe between the catalytic converter and the silencer, silencer side.Release the rigid pipe for the exhaust pipe between the catalytic converter and silencer from the silencer.2. Loosen the collar (2a) and remove the rigid pipe for the exhaust pipe between the catalytic converter and the silencer (2b). 1. Undo the bolt fixing the power unit lower reaction rod to the front suspension crossmember. 1. Loosen the band and disconnect the air supply hose between the turbocharger and the heat exchanger, heat exchanger side. 2. Loosen the band and disconnect the air supply hose from the heat exchanger to the rigid pipe, heat exchanger side. Proceed with removal  - 7055A43  central front grille - r r1. Disconnect the electrical connection from the engine fan motor.

	Name	Connector
1	Engine electric fan motor	N11

2. Disconnect the electrical connections from the engine cooling fan resistor.

	Name	Connector
2	Engine fan adjustment resistor	O10

Release the electrical wiring from the fastenings on the fan and move it aside. 1. Undo the nut securing the upper cooling fan bracket to the upper beam.2. Undo the side bolts fixing the radiator cooling fan to the radiator.3. Remove radiator cooling fan (3a) after releasing lower pins (3b) from the lower radiator beam and tabs (3c) press-fitted to the radiator. 1. Support the power unit using a hydraulic hoist fitted with suitable chains connected to the special brackets on the engine. Position a suitable support under the power unit.1. Undo the nut fixing the air conditioning system pipes mounting bracket.2. Undo the nuts (2a) and (2b), then remove the timing side power unit support flexible mounting (2c). 1. Undo the nut fixing the gearbox side power unit 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. Tighten the nut securing the gearbox side rigid power unit support to the flexible mounting to the recommended torque.

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

1. Place the timing side power unit support flexible mounting (1a) in position and secure it tightening the nuts (1b) and (1c) to the recommended torque.

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

	Fastening	Component	Ø	Value(daNm)
1c	Nut	FRONT RUBBER MOUNTS	M10	(Bodyshell side) 4.1 ÷ 5.0

2. Tighten the nut securing the air conditioning system pipe bracket to the power unt flexible mounting block, timing side. Remove the support positioned under the power unit.Remove the hydraulic hoist fitted with suitable chains used for supporting the power unit.Refit radiator cooling fan, securing the lower pins to the lower radiator beam and press-fitting the tabs to the radiator.Tighten the side bolts securing the radiator cooling fan to to the radiator.Tighten the nut securing the upper radiator cooling fan to the upper beam.Refit the electrical wiring in its seating and attach it to the fan.Connect the electrical connections to the resistor for the engine cooling fan.Connect the electrical connection to the engine fan motor. Proceed with removal  - 7055A43  central front grille - r r . Connect the air supply hose from the heat exchanger to the rigid pipe, heat exchanger side and tighten the band.Connect the air supply hose between the turbocharger and the intercooler, heat exchanger side and tighten the band. 1. Tighten the bolt fixing the power unit lower reaction rod to the front suspension crossmember to the recommended torque.

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

Refit the rigid exhaust pipe section between the catalytic converter and the silencer and secure it using the collar.Tighten the nuts fastening the rigid section of the exhaust pipe between the catalytic converter and the silencer, silencer side.Connect the right drive shaft to the intermediate drive shaft.1. Tighten the bolts securing the front right damper to the steering knuckle to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	FRONT DAMPER	M10	(Front steering knuckle side) 6.2 ÷ 6.8

2. Tighten the bolts securing the right drive shaft to the intermediate drive shaft to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M8	(Intermediate driveshaft side) 3.6 ÷ 4.4

Connect the left drive shaft to the differential inner drive shaft.1. Tighten the bolts securing the front left shock absorber to the steering knuckle to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	FRONT DAMPER	M10	(Front steering knuckle side) 6.2 ÷ 6.8

2. Tighten the bolts fixing the left driveshaft to the left differential internal driveshaft to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M8	(Differential internal driveshaft side) 3.6 ÷ 4.4

Connect the battery earth lead to the gearbox and fix it using the bolt.Connect the electrical connection to the reversing lights switch. Connect the rapid connector for the intermediate coupling for the tank fuel return pipe.Connect the rapid attachment for the fuel return pipe to the tank, fuel single fuel manifold pipe side and fasten it.Connect the rapid connector for the fuel supply pipe from the filter to the pressure pump, pressure pump side and fasten it. Connect the electrical connections to the diesel electronic injection control unit.Refit the coolant reservoir in its seating and secure with the nut and bolt.Connect the engine coolant reservoir supply pipe and tighten the band.Connect the coolant return pipe to the engine coolant reservoir and tighten the band.1. Connect the pipes from the air conditioning compressor to the condenser (1a), compressor side and secure them tightening the bolt (1b) to the recommended torque.

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.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	PIPES FROM COMPRESSOR TO CONDENSOR	M6	(Compressor side) 0.7 ÷ 1.1

1. Connect the pipe from the expansion valve to the compressor (1a), expansion valve side and fix it tightening the nut (1b) to the recommended torque.

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.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	EXPANSION VALVE - COMPRESSOR PIPE	M6	(Expansion valve side) 0.7 ÷ 1.1

2. Connect the brake servo one-way valve to the brake servo. Connect the heater single coolant supply and return pipe, E.G.R. exhaust gas/water heat exchanger side and tighten the band.Connect the heater single coolant supply and return pipe, water pump rigid inlet pipe side and tighten the band.Connect the upper coolant inlet hose to the radiator, thermostat side, and tighten the band. Connect the lower coolant outlet hose from the radiator, radiator side, and tighten the band.Secure the gear engagement/selector cables to the mounting bracket with the stops.Connect the gear engagement/selector cables.Replace the clutch operating cylinder, then fix it using the bolts.Replace the air filter, complete with air flow meter, in its housing.Connect the air intake sleeve to the turbocharger, air flow meter side, and tighten the band.Connect the electrical connection to the air flow meter. Proceed with refitting  - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. . Proceed with refitting  - 5530B10  battery - 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 . Proceed with refitting  - 7055B91  Right front WHEEL ARCH LINER - R.R. . Proceed with refitting  - 7055B90  Left 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 . Proceed with refitting  - 4450B12  front or rear wheels (two) - r+r . Remove the car from the ramps.