3314031 - 1004D11 power unit (manual gearbox) with support frame, front suspension detached separate and rebuild

1. Undo the nuts (1a) and disconnect the right and left joints (1b) from the front anti-roll bar.2. Undo the bolts (2a) and disconnect the right and left half shafts (2b) from the intermediate shaft/differential.

The above bolts have been treated with an eslok type material therefore they should be replaced each time they are removed.

1. Undo the nuts (1a) and remove the exhaust manifold heat shield (1b). 1. Secure the engine (1a) on a hydraulic hoist (1b) fitted with suitable chains.2. Undo the nut fixing the timing side rigid engine support to the flexible mounting.3. Undo the nut securing the power unit rigid rear support to the flexible mounting.4. Undo the bolts fixing the gearbox side flexible mounting to the front suspension frame. Raise the power unit and separate it from the front suspension frame.Place the power unit on a suitable support.1. Undo the bolts (1a) and remove the front intermediate half shaft (1b). 1. Undo the nuts (1a) and remove the right exhaust manifold (1b) complete with gasket (1c).2. Undo the bolts (2a) and remove the starter motor (2b).3. Undo the bolt securing the engine block to the manual gearbox and differential. 1. Undo the bolts (1a) and remove the lower engine flywheel protection (1b). 1. Undo the bolts (1a) and remove the manual gearbox and differential (1b) from the engine.

Two operators are needed for this operation.

2. Undo the bolts (2a) and remove the clutch cover (2b) complete with thrust bearing (2c).3. Remove the clutch driven disc. 1. Remove the clutch release bearing (1a) from the clutch cover using the tool (1b).

	Name	Country
1b	Extractor	1.821.215.000

1. Lift up the tapered seal (1a) for the clutch release bearing until the spring (1b) is covered.2. Fit the clutch release bearing (2a) on the main shaft and match it with the clutch release fork (2b). 1. Fit the clutch driven disc (1a) and clutch cover (1b) on the flywheel, centering them using the tool (1c).

	Name	Country
1c	Centering	1.820.124.000

2. Tighten the clutch cover bolts to the specified torques.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	CLUTCH ASSEMBLY	M8	Engine flywheel side 2.4 - 2.9

3. Place the gearbox with differential (3a) back in its housing and fix it tightening the bolts (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	MANUAL GEARBOX	M10	Engine side 3.7 - 4.5

Act on the gear control lever to engage the clutch release bearing in the clutch.Fit the lower engine flywheel protection and fix it using the bolts.1. Fit the starter motor (1a) and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	STARTER MOTOR	M8	Gearbox side 1.8 - 2.2

2. Fit the right exhaust manifold (2a) complete with gasket and tighten the nuts (2b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2b	Nut	EXHAUST MANIFOLD/S	M8	Cylinder head side 2.2 - 2.7

1. Refit the front intermediate half shaft (1a) in its seating and tighten its bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	INTERMEDIATE DRIVE SHAFT	M6	(Support side) 0.5 - 0.8

Secure the power unit for hoisting using a hydraulic hoist fitted with suitable chains.Place the power unit back in its seating on the front suspension frame.1. Tighten the bolts securing the gearbox side flexible mounting to the front suspension frame to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	GEARBOX SIDE RUBBER MOUNT	M8	(Front suspension frame side) 2.4 - 2.9

2. Tighten the nut fixing the power unit rear support to the power unit intermediate flexible mounting, to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2	Nut	POWER UNIT RIGID REAR MOUNT	M10	(Flexible mounting side) 3.8 - 4.7

3. Tighten the nut fixing the timing gear side rigid engine support to the power unit front flexible mounting.

	Fastening	Component	Ø	Value(daNm)
3	Nut	ENGINE MOUNT TIMING SIDE	M10	(Flexible mounting side) 3.8 - 4.7

Remove the hydraulic hoist supporting the power unit. Fit the left exhaust manifold heat shield and fix it using the nuts.1. Connect the right and left front half shafts (1a) to the intermediate shaft/differential and tighten the bolts (1b) to the specified torque.

The above bolts have been treated with an eslok type material therefore they should be replaced each time they are removed.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M10	Intermediate driveshaft/differential side 5.2 - 5.8

2. Connect the joints (2a) to the front anti-roll bar and tighten the nuts (2b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2b	Nut	FRONT ANTI-ROLL BAR JOINTS	M10	Front anti-roll bar side. 3.8 - 4.7