3314290 - 1004B17 power unit with automic transmission, complete with front suspension subframe - r r for version with air conditioner (Automatic transmission)

Removing ( Refitting ) Place the car on a ramp with the wheels perfectly straight. Make sure that the ignition is OFF (STOP position), then disconnect the negative battery terminal (refer to op.   5530B10  battery - r+r ).

NameConnector
-Battery  A1B 
1. Remove the rubber protector (1a) and the accelerator pedal travel stop (1b).
 - 7040A65  passenger compartment box lock , one , r r . 1. Move aside the floor carpet, unscrew the nuts (1a) and remove the steering column universal joint guard (1b).2. Undo the bolt securing the steering column to the power steering box.
The bolt is pretreated and cannot be refitted.
 - 4450B12  front or rear wheels (two) - r+r .  - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R. (right and left)  - 7040D12  engine front side cover (one) lh or rh - r r (left and right).  - 7040D30  engine bay front beam cover - r r .  - 7040D14  engine bay rear side cover (one) lh or rh - r r (left and right).  - 7055A43  central front grille - r r .  - 7055A41  RIGHT FRONT GRILLE - R.R. . Discharge the fuel supply pressure. - 1048A34  sleeve(s) from flow meter to air supply capacity case - r + r . 1. Disconnect the electrical connection from the air flow meter.

NameConnector
1Air flow meter  K41 
 - 7055B54  under-engine guard - r r .  - 1088D10  lower sleeve for coolant outlet from radiator - r + r .  - 1088D14  upper sleeve for coolant inlet to radiator - r + r . 1. Disconnect the engine/i.e. connection.

NameConnector
1Engine-i.e coupling.  D24 
1. Disconnect the electrical connection from the throttle casing integrated with the D.V.L.

NameConnector
1Integrated throttle body actuator  N75 
2. Disconnect the electrical connection for the engine rpm and timing sensor.

NameConnector
2Rpm sensor  K46 
3. Disconnect the electrical connection for the detonation sensor.

NameConnector
3Detonation sensor  K50 
4. Disconnect the electrical connection for the cam angle sensor.

NameConnector
4Cam angle sensor  K47 
5. Remove the protection (5a) and disconnect the electrical connection (5b).

NameConnector
5bData not available yet-
1. Disconnect the electrical connection of the gear engagement selector and release the wiring from the band.

NameConnector
1CAE sensors connection  D79 
2. Disconnect the electrical connection from the gear selection solenoids assembly.

NameConnector
2CAE solenoids assembly  L50 
Release the electrical wiring from the securing band and move it.
1. Disconnect the electrical connection from the engine coolant temperature sensor.

NameConnector
1Engine coolant temperature sensor-sender unit  K36 
2. Release the electrical wiring from the securing band and move it.
1. Remove the cover from the junction unit.2. Disconnect the starter motor supply cable from the junction unit.

NameConnector
2Data not available yet-
Release the starter motor supply cable from the band located on the brake pump, and move it aside.
1. Remove the retainer (1a) and disconnect the gear selector cable (1b).2. Remove the retainer and release the gear selector cable from the bracket on the gearbox, then move it aside.
1. Disconnect the return pipe to the coolant reservoir from the connector on the right cylinder head.2. Disconnect the coolant delivery pipe to the climate control system heater from the connector on the right cylinder head.3. Disconnect the coolant return pipe from the climate control system heater from the engine thermostat.
1. Disconnect the fuel vapour recovery pipe from the air chamber.2. Disconnect the vacuum socket pipe from the air chamber.
1. Disconnect the electrical connection for the Lambda sensor.

NameConnector
1Lambda sensor  K40 
2. Disconnect the electrical connection for the detonation sensor.

NameConnector
2Knock sensor 2  K51 
3. Disconnect the fuel supply pipe from the injector fuel manifold.
Undo the bolt securing the cold air intake to the bodyshell.1. Undo the bolt securing the air cleaner casing to the A.B.S. mounting bracket.2. Remove the air cleaner complete with air flow meter, after releasing it from the air intake duct between the intake and cleaner.
Remove the cold air intake complete with air intake duct between intake and cleaner.- 7090G06 HEADLAMP HOUSING CONNECTING CROSSMEMBER - Replace. . Remove the engine cooling radiator upper mounting bracket.1. Disconnect the electrical connection for the air conditioning compressor electro-magnet.

NameConnector
1Air conditioning compressor engagement electro-magnet  L20 
2. Disconnect the electrical connection for the engine oil level sensor.

NameConnector
2Engine oil level sensor  K32 
1. Disconnect the electrical connection from the climate control system multi-level sensor.

NameConnector
14 stage pressure switch  K10 
2. Undo the bolts (2a) and move aside the dehumidifier filter/accumulator (2b) complete with mounting bracket and pipes.
1. Disconnect the electrical connection from the engine cooling fan.

NameConnector
1Engine electric fan motor  N11 
2. Disconnect the electrical connections from the engine radiator fan resistor.

NameConnector
2Engine fan adjustment resistor  O10 
3. Undo the bolt (3a) and release the electrical wiring (3b).
1. Undo the bolts securing the air conditioner condenser to the engine cooling radiator.
1. Undo the bolts (1a) and remove the air duct to the automatic transmission hydraulic circuit cooling radiator (1b).2. Undo the bolts securing the automatic transmission hydraulic circuit cooling radiator to the engine cooling radiator.
Withdraw and remove the engine cooling radiator.1. Undo the bolts securing the engine oil cooling radiator to the lower crossmember.2. Undo the bolt (2a) and remove the bracket (2b) connecting the engine oil supply and return pipes to the cooling radiator.
Move the engine oil radiator and air conditioning condenser and fix them, together with the dehumidifying filter/accumulator, to the bodyshell. - 1092G10  single engine belt r r . 1. Undo the nuts (1a) and remove the heat shield (1b) from the exhaust manifold.2. Undo the bolts (2a) and move the air conditioning compressor (2b) complete with pipes and fix it to the bodyshell.
 - 1008C10  power unit upper reaction link r r . 1. Undo the bolt (1a) and disconnect the earth lead (1b) from the gearbox side rigid power unit support.

NameConnector
1bBattery earth  C1 
 - 1076B52  exhaust pipe (one) leaving l/h or r/h exhaust manifold - r + r (right and left) 1. Release the front brake caliper flexible pipes from the mounting brackets.2. Remove the clips securing the brake calipers to the brackets.3. Undo the bolts (3a) and move aside the front brake calipers (3b) complete with pads and secure them as appropriate to the bodyshell.
1. Undo the bolts (1a) and remove the front wheel rpm sensors (1b) from the steering knuckles.2. Undo the bolts (2a) and remove the brackets (2b) supporting the wiring for the front wheel rpm sensors.3. Undo the nuts (3a) and disconnect the front anti-roll bar joints (3b) from their brackets.4. Undo the bolts fixing the front shock absorber forks to the track control arms, track control arm side.
Position a hydraulic jack under the hub steering knuckle.1. Undo the nut (1a) and disconnect the upper track control arm (1b) from the front hub steering knuckle using tool (1c).

NameCountry
1cExtractor1.821.169.000
Remove the hydraulic jack from under the hub steering knuckles.
1. Position the tools (1a) and (1b) for removing the power unit under the vehicle.

NameCountry
1aPulley1.860.823.000

NameCountry
1bAdaptors1.860.823.001
Lower the vehicle until the front suspension frame is positioned on the tool.
1. Undo the bolts fixing the front suspension frame to the bodyshell.
1. Undo the bolts (1a) and remove the brackets (1b) complete with spacers (1c) fixing the front suspension frame to the bodyshell.
1. Raise the vehicle until the power unit with automatic transmission complete with front suspension frame is fully separated from the bodyshell.
Refitting ( Removing ) Position the power unit with the manual gearbox, complete with front suspension frame, under the vehicle.Lower the vehicle until the power unit is correctly positioned in its housing.1. Fit the brackets (1a), complete with spacers (1b) and tighten the bolts (1c) to the recommended torque.

FasteningComponentØValue(daNm)
1cRear boltsFRONT SUSPENSION SUBFRAMEM12(Bodyshell side) 12.4 - 13.7
1. Tighten the bolts securing the front suspension frame to the bodyshell to the recommended torque.

FasteningComponentØValue(daNm)
1Front boltsFRONT SUSPENSION SUBFRAMEM12(Bodyshell side) 10.5 -11.6
Raise the vehicle and remove the tools used for refitting the power unit.

NameCountry
-Pulley1.860.823.000

NameCountry
-Adaptors1.860.823.001
Position a hydraulic jack under the hub steering knuckles.Connect the upper track control arms to the front steering knuckles and fix them tightening the nuts to the recommended torque.

FasteningComponentØValue(daNm)
-NutFRONT SUSPENSION TOP LEVERM10Front hub steering knuckle side 4.3 - 4.7
Remove the hydraulic jack from under the hub steering knuckle.1. Tighten the bolts fixing the front shock absorber forks to the track control arms to the recommended torque.

FasteningComponentØValue(daNm)
1BoltFRONT DAMPER FORK ON WISHBONEM12Lower track control arm side 8.6 - 9.5
2. Connect the front anti-roll bar joints (2a) to the brackets and tighten the nuts (2b) to the specified torque.

FasteningComponentØValue(daNm)
2bNutFRONT ANTI-ROLL BAR JOINTSM10(Shock absorber fork side) 3.8 ÷ 4.7
3. Refit in their seatings the brackets (3a) for the front wheel rpm sensor wiring and fix them using the bolts.4. Refit in their seatings the front wheel rpm sensors (4a) and fix them using the bolts (4b) to the steering knuckles.
1. Place the front brake calipers (1a) complete with brake pads back in their housings and tighten the bolts (1b) to the specified torque.

FasteningComponentØValue(daNm)
1bBoltFRONT BRAKE CALIPER ASSEMBLYM14Bracket side 15.2 - 16.8
2. Fit the clips securing the brake calipers to the brackets.3. Fit the front brake caliper flexible pipes to their mounting brackets.
 - 1076B52  exhaust pipe (one) leaving l/h or r/h exhaust manifold - r + r (right and left) Connect the earth lead to the gearbox side rigid power unit support and fix it using the bolt. - 1008C10  power unit upper reaction link r r . 1. Refit the air conditioner compressor (1a) complete with pipes in its seating and tighten the bolts (1b) to the specified torque.

FasteningComponentØValue(daNm)
1bBoltAIR CONDITIONER ASSEMBLY COMPRESSORM10Support side 3.4 - 4.2
2. Fit the exhaust manifold heat shield (2a) and fix it using the nuts (2b).
 - 1092G10  single engine belt r r . Place the air conditioning condenser, engine oil radiator and dehumidifying filter/accumulator back in their housings.Fit the bracket securing the engine oil supply and return pipes to the cooling radiator and fix it using the bolt.Tighten the bolts securing the engine oil cooling radiator to the lower crossmember.Place the engine cooling radiator back in its housing.Tighten the bolts securing the automatic transmission hydraulic circuit cooling radiator to the engine cooling radiator.Fit the air duct to the automatic transmission hydraulic circuit cooling radiator and fix it using the bolts.Tighten the bolts securing the air conditioner condenser to the engine cooling radiator.Fix the electrical wiring with its band on the engine cooling fan.Connect the electrical connection to the engine radiator fan resistor.Connect the electrical connection to the engine cooling fan.Place the dehumidifying filter/accumulator, complete with mounting bracket and pipes, back in its housing, and fix it using the bolts.Connect the electrical connection to the climate control system multi-level sensor.Connect the electrical connection to the engine oil level sensor.Connect the electrical connection for the air conditioning compressor electro-magnet.Fit the engine cooling radiator upper mounting bracket.- 7090G06 HEADLAMP HOUSING CONNECTING CROSSMEMBER - Replace. . Fit the cold air intake complete with air inlet duct between intake and cleaner.Fit the air cleaner complete with air flow meter and connect it to the air inlet duct between intake and cleaner.Tighten the bolt securing the air cleaner casing to the A.B.S. mounting bracket.Tighten the bolt securing the cold air intake to the bodyshell.Connect the fuel supply pipe to the fuel injector manifold.Connect the electrical connection for the detonation sensor.Connect the electrical connection for the Lambda sensor.Connect the vacuum intake pipe to the air chamber.Connect the fuel vapour recovery pipe to the air chamber.Connect to the thermostat the coolant return pipe from the climate control system heater.Connect, to the connector on the right cylinder head, the coolant supply pipe to the climate control system heater.Connect, to the connector on the right cylinder head, the return pipe to the engine coolant reservoir.Place the gear selector cable back in its seating and fix it to the bracket on the gearbox with the relevant retainer.Connect the gear selector cable and secure it with its retainer.Refit the starter motor supply cable in its seating and secure it with the band on the brake pump.Connect the starter motor supply cable to the junction unit.Fit the junction unit cover.Connect the electrical connection to the water temperature sensor and secure the electrical wiring to the band.Connect the electrical connection to the gear selection solenoids assembly and fix the wiring to the relevant band.Connect the electrical connection of the gear engagement selector and secure the wiring to the band.Connect the electrical connection for the cam angle sensor.Connect the electrical connection for the detonation sensor.Connect the electrical connection for the engine rpm and timing sensor.Connect the electrical connection to the throttle body integrated with the D.V.L.Connect the engine/i.e. connection. - 1088D14  upper sleeve for coolant inlet to radiator - r + r .  - 1088D10  lower sleeve for coolant outlet from radiator - r + r .  - 7055B54  under-engine guard - r r . Connect the electrical connection to the air flow meter. - 1048A34  sleeve(s) from flow meter to air supply capacity case - r + r .  - 7055A41  RIGHT FRONT GRILLE - R.R. .  - 7055A43  central front grille - r r .  - 7040D14  engine bay rear side cover (one) lh or rh - r r (right and left)  - 7040D30  engine bay front beam cover - r r .  - 7040D12  engine front side cover (one) lh or rh - r r (right and left)  - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R. (right and left)  - 4450B12  front or rear wheels (two) - r+r . 1. Tighten the bolt securing the steering column to the power steering box to the specified torque.

FasteningComponentØValue(daNm)
1BoltSTEERING SHAFTSM8(Power steering box pinion side) 2.8 - 3.2
2. Fit the steering column universal joint guard (2a) and secure it with its nuts (2b).Put the floor carpet back in place.
 - 7040A65  passenger compartment box lock , one , r r . Fit the accelerator pedal travel stop complete with rubber protector. Adjust the potentiometer (Refer to op.   1068A50  accelerator potentiometer - r+rConnect the battery terminal (-).Remove the car from the ramp.