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

1. Loosen the bands (1a) and disconnect the front driveshafts (1b). 1. Loosen the band and disconnect the flexible pipe from the power assisted steering pump rigid inlet pipe.2. Unscrew the connector and disconnect the delivery pipe from pump to power steering box, pump side. 1. Loosen the band and disconnect the coolant supply pipe to the independent heater unit. 1. Release the power assisted steering fluid radiator (1a) from the bands (1b) and move it sideways. 1. Loosen the bands (1a) and remove the air supply pipe between the turbocharger and the heat exchanger (1b). 1. Remove the turbocharging air/air heat exchanger. 1. Disconnect the electrical connection from the air flow meter.

	Name	Connector
1	Air flow meter	K41

2. Disconnect the electrical connection from the turbocharger vane actuator solenoid.

	Name	Connector
2	Variable geometry turbine fan	L36

3. Disconnect the vacuum pipes from the solenoid valve for the turbocharger vanes actuator. 1. Loosen the band and disconnect the air intake hose from the turbocharger.2. Remove the air filter (2a) complete with air flow meter (2b), hose (2c) and resonator (2d). 1. Loosen the bands (1a) and remove the lower radiator coolant outlet hose (1b). 1. Loosen band and disconnect the upper coolant inlet hose to the radiator, thermostat side. 2. Remove the engine cooling radiator assembly (2a), radiator cooling fans (2b) and air conditioning condenser (2c). 1. Undo the bolt (1a) and remove the bracket (1b) fixing the engine oil supply and return pipes to the cooling radiator.2. Undo the bolts (2a) and move the engine oil cooling radiator (2b) sideways. Secure and support the power unit using a hydraulic hoist fitted with suitable chains. 1. Undo the nut fixing the power unit timing side rigid support to the flexible mounting.2. Undo the nut fixing the rear power unit rigid support to the flexible mounting. 1. Undo the bolts fixing the power unit gearbox side support flexible mounting to the front suspension frame. Using the hydraulic lift, position the power unit on a suitable workbench and secure it.1. Undo the bolts (1a) and remove the intermediate drive shaft (1b). 1. Open the cover (1a), undo the nut (1b) and disconnect the electrical connections from the starter motor (1c).

	Name	Connector
1c	Starter motor	A20

2. Undo the bolts (2a) and remove the starter motor (2b). Support the manual gearbox and differential using a hydraulic lift fitted with suitable chains.1. Undo the top bolts securing the manual gearbox with differential to the crankcase. 2. Loosen the nuts fixing the manual gearbox and differential to the crankcase.3. Undo the bolts fixing the crankcase sump to the manual gearbox with differential.4. Remove the manual gearbox and differential from the engine using the hydraulic lift. IF TOOL 1.871.003.100 IS AVAILABLE, REMOVE THE CLUTCH UNIT AS DESCRIBED BELOW.1. Fit the flywheel lock.

	Name	Country
1	Counter-torque	1.860.846.001

2. Undo the three bolts at 120 degrees securing the clutch cover.3. Fit the centring device (3a) and the rest of the tool (3b), tightening the bolts (3c) in the seats of the bolts removed previously.

	Name	Country
3	Tool for Extracting/Fitting	1.871.003.100

4. Turn the handwheel of the tool until the pins (4a) come into contact with the disc (4b).5. Undo the remaining bolts securing the clutch cover.6. Unscrew the handwheel of the tool to discharge the clutch mechanism's diaphragm spring.Remove the tool.

	Name	Country
-	Tool for Extracting/Fitting	1.871.003.100

7. Remove the clutch cover.Remove the clutch disc. IF TOOL 1.871.003.100 IS NOT AVAILABLE, REMOVE THE CLUTCH UNIT AS DESCRIBED BELOW.1. Fit the flywheel lock.

	Name	Country
1	Counter-torque	1.860.846.001

2. Undo the clutch cover bolts by slackening them off a little at a time, in diagonal order, to discharge the diaphragm spring.3. Remove the clutch cover.Remove the clutch disc. IF TOOL 1.871.003.100 IS AVAILABLE, REFIT THE CLUTCH UNIT AS DESCRIBED BELOW.1. Fit the tool's centring device in the crankshaft.Refit the clutch disc in its seating.

When fitting the clutch disc, make sure the clutch is orientated as indicated by the words 'engine side' or 'gearbox side'.

Handle the clutch plate carefully. Do not touch the friction surfaces with your hands.

2. Refit the clutch cover in its seating.

Clean the protective anti-corrosion products or detergents from the friction surface of the clutch cover.

3. Fit the remaining part of the tool (3a) for fitting the clutch unit, by tightening the bolts (3b).4. Turn the handwheel of the tool until the pins (4a) come into contact with the disc (4b).5. Manually tighten the thre free bolts for securing the clutch unit.6. Unscrew the handwheel of the tool to discharge the clutch mechanism's diaphragm spring.Remove the tool.

	Name	Country
-	Tool for Extracting/Fitting	1.871.003.100

Tighten by hand the remaining bolts securing the clutch unit.Gradually tighten, in diagonal order, the bolts securing the clutch unit until the recommended torque is reached.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CLUTCH ASSEMBLY	M8	(Engine flywheel side) 2.8

7. Remove the flywheel lock.

	Name	Country
7	Counter-torque	1.860.846.001

IF TOOL 1.871.003.100 IS NOT AVAILABLE, REMOVE THE CLUTCH UNIT AS DESCRIBED BELOW.1. Place the clutch disc and the clutch cover (1a) back in its housing using the centring tool (1b).

When fitting the clutch disc, make sure the clutch is orientated as indicated by the words 'engine side' or 'gearbox side'.

Handle the clutch plate carefully. Do not touch the friction surfaces with your hands.

Clean the protective anti-corrosion products or detergents from the friction surface of the clutch cover.

	Name	Country
1b	Clutch centering	1.875.086.000

Manually tighten the clutch unit bolts.2. Gradually tighten, in diagonal order, the bolts securing the clutch unit until the recommended torque is reached.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	CLUTCH ASSEMBLY	M8	(Engine flywheel side) 2.8

3. Remove the flywheel lock.

	Name	Country
3	Counter-torque	1.860.846.001

1. Place the manual gearbox with differential in its seating on the engine using the hydraulic lift.2. Tighten the bolts fixing the crankcase sump to the manual gearbox with differential to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	MANUAL GEARBOX	M12	(Crankcase sump side) 7.2 ÷ 8.8

3. Tighten the nuts fixing the manual gearbox and differential to the crankcase to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3	Nut	MANUAL GEARBOX	M12	(Crankcase side) 7.2 ÷ 8.8

4. Tighten the top bolts securing the manual gearbox with differential to the crankcase to the specified torque.

	Fastening	Component	Ø	Value(daNm)
4	Bolt	MANUAL GEARBOX	M10	(Crankcase side) 5.0 ÷ 6.1

Remove the hydraulic lift fitted with suitable chains used to support the manual gearbox with differential. 1. Place the starter motor (1a) back in its housing and fix it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	-	-	-	-

2. Connect the electrical connections (2a) to the starter motor, tighten the nut (2b) and close the protective cover (2c). 1. Refit the intermediate half shaft (1a) in its seating and tighten its bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	-	-	-	-

Using a hydraulic lift fitted with suitable chains, position the power unit on the front suspension frame.1. Tighten the bolts fixing the power unit gearbox side rigid support flexible mounting to the front suspension frame to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	-	-	-	-

1. Tighten the nut securing the rear power unit rigid support to the flexible mounting to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	-	-	-	-

2. Tighten the nut fixing the timing side rigid power unit support to the flexbile mounting to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	-	-	-	-

Remove the hydraulic lift fitted with suitable chains used for supporting the power unit.Place the engine cooling radiator back in its housing and fix it using the bolts.Place the bracket securing the cooling radiator engine oil supply and return pipes back in its housing and secure it using the bolt.Place the engine cooling radiator, complete with radiator cooling fans and air conditioning condenser, back in its housing.Connect the upper coolant inlet hose to the radiator, thermostat side, and tighten the band. Place the lower radiator coolant outlet hose back in its housing and connect it and tighten the bands.Place the air filter assembly, complete with air flow meter, hose and resonator, in its housing. Connect the air intake hose to the turbocharger and secure with the band.Connect the vacuum pipes to the solenoid valve for the turbocharger vanes actuator. Connect the electrical connection to the turbocharger vane actuator solenoid. Connect the electrical connection to the air flow meter.Place the turbocharging air-air heat exchanger back in its housing.Place the air supply pipe between the turbocharger and the heat exchanger back in its housing and tighten the bands.Place the power assisted steering coolant radiator in its housing and secure it using the bands.Connect the coolant supply pipe to the independent heater unit and tighten the relevant band.1. Connect the supply pipe from pump to power steering box (1a), power steering pump side, and tighten the connector (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	-	-	-	-

2. Connect the flexible pipe to the power assisted steering pump rigid intake pipe and tighten the band. Connect the front driveshafts and tighten the bands.