3024746 - 1004B10 power unit with manual gearbox - r + r

Removing ( Refitting ) Position the vehicle on the ramp.Drain the air conditioner coolant circuit  - 5040A10  Air conditioning refrigerant CIRCUIT - Draining and Refilling .Proceed with removal  - 1048A48  throttle heater sleeve - r r .Proceed with removal  - 5530B10  battery - r+r .Proceed with removal  - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. .Proceed with removal  - 1048A10  air cleaner filtering element - replace .Proceed with removal  - 4450B12  front or rear wheels (two) - r+r .Proceed with removal  - 7055B54  under-engine guard - r r .Proceed with removal  - 7055B64  Engine compartment DUST shield in front wheel arch (one), left or right - R.R. .Proceed with removal  - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R. .Proceed with removal  - 7210E10  R.R. FRONT BUMPER .Proceed with the removal  - 5540B76  Front LIGHT CLUSTER with fog light (one), left or right - R.R. with interfering components removed (Right and left sides).Proceed with removal  - 7025A34  bonnet lid lock (one) - r+r or repair .Proceed with removal  - 7210A15  R.R. HEADLAMP HOUSING/FRONT WING CROSSMEMBER .Proceed with removal  - 1088B20  engine cooling radiator - r + r .1. Loosen the band and disconnect the upper coolant inlet hose to the radiator thermostat side and remove it.2. Loosen the band and disconnect the lower radiator coolant outlet hose from the radiator, thermostat side.3. Loosen the band and disconnect the intermediate coupling for the engine cooling system supply pipe. 1. Undo the bolts (1a) and remove the lower radiator crossmember (1b) complete with engine cooling system pipes (1c). 1. Undo the nut (1a) and disconnect the earth lead (1b) from the gearbox side rigid power unit support.

	Name	Connector
1b	Battery earth	C1

2. Loosen the bands and disconnect the radiator power assisted steering fluid supply and return pipes, rigid pipes side.

Collect the power assisted steering fluid in a suitable container.

1. Undo the nuts (1a) and remove the power assisted steering fluid system cooling radiator mounting bracket (1b) complete with radiator (1c), duct (1d) and pipes (1e). 1. Undo the bolt (1a) and remove the cold air intake for the air filter (1b) 1. Undo the connector (1a) and disconnect the delivery pipe from pump to power steering box (1b), steering box side. 1. Loosen the band and disconnect the intermediate coupling for the return pipe from the power assisted steering box to the radiator. Proceed with removal  - 1076B82  left exhasust pipe between catalytic preconverter and converter r r .1. Undo the bolts (1a) and disconnect the engine oil inlet and outlet pipes (1b), engine oil cooling radiator side.

Collect the engine oil in a suitable container.

2. Undo the nuts (2a) and remove the engine oil cooling radiator (2b). 1. Undo the nut (1a) and disconnect the starter motor electrical connection (1b) from the maxi-fuse box. 1. Disconnect the electrical connection from the reversing lights switch.

	Name	Connector
1	Reversing lights switch	I20

2. Disconnect the gear selector and engagement cables. 1. Loosen the band and disconnect the coolant return pipe to the climate control heater, connector side.2. Loosen the band and disconnect the coolant return pipe from the climate control heater, thermostat side. Remove the protective cap on the master cylinder bleed valve.Connect the collection system (pipe and reservoir) to the bleed valve on the master cylinder.Operate the clutch pedal until the brake-clutch fluid reservoir is empty.1. Remove the split pin (1a) and disconnect the pipe between the vibration damper and the clutch operating cylinder (1b), vibration damper side. 1. Disconnect the rapid connector for the fuel vapour recirculation pipe from the air chamber.2. Loosen the band and disconnect the servo brake vacuum intake pipe from the air chamber.3. Disconnect the electrical connection from the fuel injection/ignition control unit.

	Name	Connector
3	Engine management ECU	M10

4. Open the electrical connections box cover.5. Disconnect the engine coupling.6. Disconnect the electrical connections (6a) and (6b) for the rear Lambda sensors and the catalytic converter.

	Name	Connector
6a	Lambda sensor downstream of post-catalyzer	K17

	Name	Connector
6b	Lambda sensor on catalyzer -2	K18

1. Undo the bolts (1a) and remove the electrical connections box (1b). 1. Loosen the band and disconnect the coolant return pipe from the engine coolant reservoir.2. Undo the bolts (2a) and remove the power unit reaction rod (2b). Discharge the fuel supply pressure.1. Disconnect the rapid attachment for the fuel supply pipe. 1. Undo the bolts (1a) and disconnect the right driveshaft (1b) from the intermediate shaft. 1. Undo the bolts (1a) and disconnect the left driveshaft (1b) from the differential inner shaft. Proceed with removal  - 1008A44  rear rigid mount - r r .Position a suitable support under the power unit.1. Fit a suitable bracket for supporting the power unit on the left cylinder head. 1. Fit a suitable bracket for supporting the power unit on the right cylinder head. 1. Support the power unit using a hydraulic hoist (1a), fitted with suitable chains (1b) connected to the brackets fitted previously and to the bracket (1c) already on the gearbox. 1. Undo the bolts fixing the power unit gearbox side rigid support to the flexible mounting. 1. Undo the nut fixing the timing side rigid engine support to the flexible mounting. Move the power unit forwards to prevent interference with the front suspension crossmember, then 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 fixing the timing side rigid engine support to the flexible mounting.

	Fastening	Component	Ø	Value(daNm)
1	Nut	ENGINE MOUNT TIMING SIDE	M10	(Flexible mounting side) 4.5 ÷ 5.5

1. Tighten the bolt fixing the power unit gearbox side rigid support to the flexible mounting.

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

Remove the hydraulic hoist fitted with suitable chains for supporting the power unit.Remove the brackets fitted for supporting the power unit.Remove the support positioned previously under the power unit.Proceed with refitting  - 1008A44  rear rigid mount - r r .1. Connect the left driveshaft (1a) to the differential inner shaft and fix it tightening the bolts (1b) to the recommended torque.

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

1. Connect the right driveshaft (1a) to the intermediate driveshaft and tighten the bolts (1b) to the specified torque.

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

Connect the rapid attachment for the fuel supply pipe.1. Place the power unit reaction rod (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	REACTION ROD	M10	4.5 ÷ 5.5

2. Connect the coolant return pipe to the engine coolant reservoir and tighten the band. Place the electrical connections box back in its housing and secure it using the bolts.Connect the electrical connections for the rear Lambda sensors to the catalytic converter.Connect the engine junction.Close the electrical connections box cover.Connect the electrical connection to the fuel injection/ignition control unit.Connect the brake servo vacuum intake pipe to the air chamber and tighten the band.Connect the rapid connector for the fuel vapour recirculation pipe to the air chamber.Connect the pipe from the vibration damper to the clutch operating cylinder, vibration damper side and secure it using the split pin.Connect the engine coolant return pipe from the climate control system heater, thermostat side, and tighten the band.Connect the engine coolant return pipe from the climate control system heater, connector side, and tighten the band.Connect the gear selector and engagement cables.Connect the electrical connection to the reversing lights switch.Connect the starter motor supply connector to the maxi-fuse box and tighten the nut.Place the engine oil cooling radiator back in its housing and fix it using the nuts.Connect the engine oil inlet and outlet pipes, engine cooling radiator side and tighten the bolts.Proceed with refitting  - 1076B82  left exhasust pipe between catalytic preconverter and converter r r .Connect the intermediate coupling for the return pipe from the power assisted steering box to the radiator and tighten the band.1. Connect the supply pipe from pump to power steering box (1a), power steering box side, and tighten the connector (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Connector	PIPE BTWN PUMP + POWER STEERING BOX	M14	(Power assisted steering box side) 3.6 ÷ 4.4

Place the cold air intake back in its housing and secure it using the appropriate bolts.Place the power assisted steering system fluid cooling radiator mounting bracket back in its housing complete with radiator, duct and pipes and fasten it using the nuts.Connect the power assisted steering fluid supply and return pipes to the radiator, rigid pipes side and tighten the bands.Connect the earth lead to the gearbox side rigid power unit support and secure it using the nut.Place the lower radiator crossmember back in its housing complete with engine cooling system pipes and fasten it using the bolts.Connect the intermediate coupling for the engine cooling system supply pipe and tighten the band.Connect the lower coolant outlet hose from the radiator, thermostat side, and tighten the band.Place the radiator coolant upper hose in its housing, connect it to the thermostat and tighten the band.Proceed with refitting  - 1088B20  engine cooling radiator - r + r .Proceed with refitting  - 7210A15  R.R. HEADLAMP HOUSING/FRONT WING CROSSMEMBER .Proceed with refitting  - 7025A34  bonnet lid lock (one) - r+r or repair .Proceed with the refitting  - 5540B76  Front LIGHT CLUSTER with fog light (one), left or right - R.R. with interfering components removed (Right and left sides).Proceed with refitting  - 7210E10  R.R. FRONT BUMPER .Proceed with refitting  - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R. .Proceed with refitting  - 7055B64  Engine compartment DUST shield in front wheel arch (one), left or right - R.R. .Proceed with refitting  - 4450B12  front or rear wheels (two) - r+r .Proceed with refitting  - 1048A10  air cleaner filtering element - replace .Proceed with refitting  - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. .Proceed with refitting  - 5530B10  battery - r+r .Proceed with refitting  - 1048A48  throttle heater sleeve - r r .Refill the engine oil lubrication system  - 0010T11  engine oil check level and top up .Refill the engine cooling system with coolant  - 0010T20  coolant change .Bleed the air and top up the level in the hydraulic clutch system  - 0010T67  hydraulic clutch system bleed air .Fill the air conditioner coolant circuit  - 5040A10  Air conditioning refrigerant CIRCUIT - Draining and Refilling .Fill the power steering circuit with the recommended fluid.

	Type	Component	Name	Qty.
-	Fluid [l]	HYDRAULIC POWER ASSISTED STEERING SYSTEM	TUTELA GI/A	1.2

The table shows the total quantity of fluid present in the power assisted steering circuit.

Bleed the power steering system as described belowWith the front wheels raised off the ground, with the engine switched off turn the steering wheel to full lock, left and right, 4-5 times.Check and, if necessary, top up the fluid level in the reservoir.Remove the car from the ramps.Start the engine and carry out 4 - 5 full steering wheel turn cycles (right and left).Top up the fluid level in the reservoir.Proceed with refitting  - 7055B54  under-engine guard - r r .