3024748 - 1004D10 power unit (manual gearbox), removed, remove and re-build

Work with the power unit positioned on a platform and supported for safety purposes by a hydraulic hoist.1. Undo the drain plug and drain the manual gearbox-differential oil.

Collect the gearbox and differential oil in a suitable container.

1. Undo the bolt (1a) and nut (1b) and remove the reinforcement link (1c).2. Undo the bolts (2a) and nut (2b) and remove the power unit rear rigid mounting (2c). 1. Undo the bolts (1a) and remove the intermediate drive shaft (1b).2. Remove the dust cover. 1. Open the cover (1a), undo the nuts (1b) and (1c) and disconnect the electrical connections (1d) from the starter motor.

	Name	Connector
1d	Starter' motor	A20

1. Undo the bolts (1a) and remove the starter motor (1b). 1. Undo the bolts fixing the manual gearbox and differential to the oil sump.2. Undo the bottom bolt securing the manual gearbox with differential to the crankcase. 1. Undo the top bolts securing the manual gearbox with differential to the crankcase. 1. Separate the manual gearbox with differential from the engine. 1. Fit the flywheel lock.

	Name	Country
1	Counter-torque	1.860.161.001

2. Undo the bolts (2a) and remove the clutch cover (2b) and clutch disc (2c). 1. Place the clutch disc (1a) and clutch cover (1b) back in its seating using the tool (1c) to centre them.

	Name	Country
1c	Centering	1.870.447.001

2. Tighten the bolts securing the clutch cover to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	CLUTCH ASSEMBLY	M8	(Engine flywheel side) 2.5 ÷ 3.1

3. Remove the flywheel lock.

	Name	Country
3	Counter-torque	1.860.161.001

Place the manual gearbox with differential back in its housing.1. Tighten the top bolts securing the manual gearbox with differential to the crankcase to the specified torque.

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

1. Tighten the bottom bolt securing the manual gearbox with differential to the crankcase to the specified torque.

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

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

	Fastening	Component	Ø	Value(daNm)
2	Bolt	MANUAL GEARBOX	M10	(Crankcase sump side) 5.0 ÷ 6.0

1. Place the starter motor (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	STARTER MOTOR	M8	(Gearbox side) 2.4 ÷ 3.0

Connect the electrical connections to the starter motor and fix them using the nuts, then close the cover.1. Place back in its housing the intermediate drive shaft (1a) complete with dust cover (1b) and secure it with its bolts (1c) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	INTERMEDIATE DRIVE SHAFT	M8	(Support side) 2.5 ÷ 2.8

1. Refit the power unit rear rigid support (1a) in its seating and tighten the bolts (1b) and (1c) and nut (1d) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT RIGID REAR MOUNT	M12	(Gearbox side) 6.8 ÷ 8.3

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	POWER UNIT RIGID REAR MOUNT	M8	(Crankcase sump side) 6.8 ÷ 8.3

	Fastening	Component	Ø	Value(daNm)
1d	Nut	POWER UNIT RIGID REAR MOUNT	M12	(Gearbox side) 7.2 ÷ 8.8

2. Refit the reinforcement strut (2a) and tighten the bolt (2b) and nut (2c) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	POWER UNIT RIGID REAR SUPPORT REINFORCEMENT ROD....	M12	(Power unit rear rigid mounting side) 6.8 ÷ 8.3

	Fastening	Component	Ø	Value(daNm)
2c	Nut	POWER UNIT RIGID REAR SUPPORT REINFORCEMENT ROD....	M12	(Engine crankcase side) 2.7 ÷ 3.4

1. Tighten the manual gearbox and differential fluid drain plug to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Plug	GEAR CASING PADS	M22	2.9 ÷ 4.3

After fitting the power unit, refill the manual gearbox with differential with oil  - 2110A04  Manual gearbox and differential OIL - Check level and top up, if necessary .