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

Removing ( Refitting ) Place the car on a ramp. - 5040A10  Air conditioning refrigerant CIRCUIT - Draining and Refilling - 4450B12  front or rear wheels (two) - r+r - 7055B54  under-engine guard - r r - 7055B64  Engine compartment DUST shield in front wheel arch (one), left or right - R.R. - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R. - 7210E10  R.R. FRONT BUMPER - 1016A10  sound-proofing cover - r + r - 5530B10  battery - r+r - 5530B52  Battery DRIP TRAY/SUPPORT - R.R.1. Open the band and disconnect the air pipe from the throttle casing. Position a suitable container under the engine to collect the coolant.1. Disconnect the lower pipe (1a) for the radiator from the rigid pipe (1b) and from the radiator (1c), the remove it.

To disconnect the pipe from the radiator, press the spring manually and release the rapid attachment for the pipe from the connector on the radiator.

1. Disconnect the upper pipe (1a) for the radiator from the thermostat (1b) and from the radiator (1c), then remove it.

To disconnect the pipe from the radiator, press the spring manually and release the rapid attachment for the pipe from the connector on the radiator.

1. Disconnect the recirculation pipe (1a) and the water supply pipe (1b) to the water pump rigid supply pipe from the coolant reservoir. 1. Disconnect the two heater supply and return pipes from the thermostat. 1. Disconnect the electrical connection from the air flow meter.

	Name	Connector
1	Air flow meter	K41

2. Disconnect the band (2a), release it from the lower fixing pins (2b), release the filter casing from the cold air intake pipe, then remove the complete air filter casing (2c). 1. Disconnect the single-acting valve for the vacuum pipe from the brake servo. 1. Lift up the retaining spring (1a) and release the oil pipe (1b) for the hydraulic clutch release cylinder.2. Undo the nut (2a) and disconnect the earth lead (2b) from the gearbox.

	Name	Connector
2b	Battery earth	C1

3. Undo the nuts fixing the damper to the bracket.4. Disconnect the electrical connection on the gearbox for the reversing sensor.

	Name	Connector
4	Reversing lights switch	I20

1. Remove the two gear selection and engagement flexible transmission cable ends from the gear lever.2. Undo the fixing nuts (2a) and move the gear selector and engagement cables (2b), complete with mounting bracket, away from the working area. 1. Undo the fixing nut (1a), lift up the pre-heating control unit and disconnect the electrical connection (1b).

	Name	Connector
1b	Plug preheating control unit	M15

2. Disconnect the supply pipe to the pressure pump from the fuel filter.3. Disconnec the supply pipe to the fuel filter (3a) and the return pipe to the reservoir (3b) from the return manifold. 1. Undo the fixing bolts.2. Remove the reaction link. 1. Disconnect the electrical connections for the engine management control unit.

	Name	Connector
1	Engine management ECU	M10

2. Undo the retaining nuts.3. Remove the engine management control unit from its housing. 1. Disconnect the supply pipe from the power steering fluid reservoir to the pump.2. Disconnect the supply pipe from the power assisted steering fluid pump to the box. 1. Withdraw the retaining bolt.2. Disconnect the two high and low pressure pipes from the compressor.3. Undo the fixing nut (3a) and separate the two sections (3b) of the low pressure pipe. 1. Undo the bolt (1a) and disconnect the pipe (1b) connected to the condenser from the drier filter. 2. Undo the fixing bolt and remove the high and low pressure pipe assembly. 1. Undo the upper bolt fixing the radiator to the upper crossmember.Raise the lift.Position a hydraulic lift under the lower crossmember.2. Undo the fixing bolts (2a) for the lower crossmember, slowly lower the hydraulic lift and remove the radiator-fan-condenser (2b) assembly. - 1. Disconnect the air supply pipe to the air/air heat exchanger. 1. Undo the bolts fixing the left and right driveshafts.2. Release the brake caliper flexible pipes, the electrical wiring for the brake pad wear sensors and the electrical wiring for the ABS sensors from the fastenings. 1. Undo the nuts (1a) and disconnect the front upper wishbones (1b) from the vertical links with the tool (1c).

	Name	Country
1c	Extractor	1.821.169.000

Release the left and right driveshafts from the attachments.  - 1076B50  exhaust pipe attachment to engine - r + r - 1008A44  rear rigid mount - r rPosition a suitable support under the power unit.1. Position a bracket (1a), complete with hook (1b), on the engine support for the reaction rod.2. Fit the bracket (2a) on the bell housing and secure the chain and hook assembly (2b) to it.3. Use the hook (3a), complete with chain (3b) and secure it to the exhaust manifold.4. Secure the chains to the hydraulic lifting device and tension the engine. 1. Undo the bolt fixing the timing side engine support. Lift the power unit, tilting the gearbox assembly downwards, rotate the assembly placing the timing side towards the front of the vehicle then, using the hydraulic lift, position the power unit on a suitable support.

Take great care when rotating and removing the engine not to damage the components fitted on the vehicle. Whilst rotating the power unit, check that the gearbox-differential unit does not come into contact with the ABS unit.

Refitting ( Removing ) Support the power unit using a hydraulic hoist fitted with suitable chains and position the power unit in the special housing in the vehicle.Tighten the bolt fixing the timing side engine support to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ENGINE MOUNT TIMING SIDE	M12	4.2 - 5.2

Remove the chains, the hooks and the brackets fitted for supporting the power unit.Remove the stand positioned previously under the power unit. - 1008A44  rear rigid mount - r r - 1076B50  exhaust pipe attachment to engine - r + rFit the left and right driveshafts on the differential and the intermediate driveshaft.Connect the front upper track control arms to the steering knuckles.Tighten the nuts fixing the track control arms to the steering knuckle to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	FRONT SUSPENSION TOP LEVER	M10	(Steering knuckle side) 4.3 ÷ 4.7

Tighten the bolts securing the drive shafts to the differential internal drive shaft/intermediate drive shaft to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	DRIVESHAFT	M8	(Differential. internal. driveshaft./side..) 3.5 ÷ 4.3

Secure the front brake hoses, brake pad wear wiring and BAS inductive sensor wiring.Connect the air supply pipe to the air/air heat exchanger.Place back in its housing the engine cooling radiator, complete with fan, air conditioning condenser with pipes and bottom crossmember.

Check that the fan's top pin is fitted correctly in its mounting bracket.

Tighten the bolts securing the radiator bottom crossmember to the bodywork.Fit the high and low pressure pipes assembly.

Replace the O-Ring seals for the connectors. Only use green coloured seals, resistant to R134A refrigerant. Lubricate the threads of the connectors using anti-freeze.

Tighten the bolt fixing the pipe to the drier filter to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	COOLANT SYSTEM FITTINGS	M6	0.9

Connect the low pressure pipes and tighten the securing nut to torque.

Replace the O-Ring seals for the connectors. Only use green coloured seals, resistant to R134A refrigerant. Lubricate the threads of the connectors using anti-freeze.

	Fastening	Component	Ø	Value(daNm)
-	Nut	COOLANT SYSTEM FITTINGS	M6	0.9

Connect the pipes to the air conditioning compressor.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	COMPRESSOR PIPE CONNECTORS	M10	(Air conditioning compressor side) 2.8 ÷ 4.2

Connect the supply pipe from the pump to the power assisted steering box.Connect the supply pipe from the power steering fluid reservoir to the pump.Fit the engine management control unit in the housing.Tighten the nuts fixing the control unit to the support.Connect the electrical connections for the engine management control unit.

	Name	Connector
-	Engine management ECU	M10

Place the power unit reaction rod back in its housing and fix it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	REACTION ROD	M10	(Support side) 4.5 ÷ 5.1

	Fastening	Component	Ø	Value(daNm)
-	Bolt	REACTION ROD	M10	(Support side) 4.5 ÷ 5.1

Connect the supply pipe to the fuel filter and the return pipe to the reservoir to the return manifold.Connect the fuel supply pipe to the pressure pump to the fuel filter.Position the pre-heating control unit, tighten the nut and connect the electrical connection.

	Name	Connector
-	Plug preheating control unit	M15

Position the gear selection and engagement flexible transmission cables, complete with mounting bracket, on the gearbox.Tighten the nuts fixing the bracket to the gearbox.Fit the two gear selection and engagement flexible transmission cables on the mounting bracket.Connect the electrical connection for the reversing sensor to the gearbox.

	Name	Connector
-	Reversing lights switch	I20

Tighten the nuts fixing the damper to the mounting bracket on the gearbox.Connect the earth lead to the gearbox.

	Name	Connector
-	Battery earth	C1

Connect the oil pipe for the hydraulic clutch release cylinder.

Check that the spring is fully engaged and that the pipe is correctly positioned.

Connect the vacuum pipe single-acting valve to the brake servo.Fit the complete air filter casing complete with filter element.Fasten the lower pins, secure the cold air intake pipe and connect the turbocharger air supply pipe.Connect the electrical connection for the air flow meter.

	Name	Connector
-	Air flow meter	K41

Connect the two heater supply and return pipes to the thermostat.Connect the recirculation pipe and the water supply pipe to the pump water supply rigid pipe to the reservoir.Connect the upper radiator pipe to the thermostat and the radiator.Fit the lower radiator pipe, connecting it to the rigid pipe and the radiator.Connect the air pipe to the throttle casing. - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. - 5530B10  battery - r+r - 1016A10  sound-proofing cover - r + r - 7210E10  R.R. FRONT BUMPER - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R. - 7055B64  Engine compartment DUST shield in front wheel arch (one), left or right - R.R. - 7055B54  under-engine guard - r r - 4450B12  front or rear wheels (two) - r+r - 5040A10  Air conditioning refrigerant CIRCUIT - Draining and Refilling - 0010T20  coolant change - 0010T21  coolant check density and top up if necessary - 0010T62  BRAKE and/or CLUTCH FLUID - Replace. fluid - Includes. washing pipes and bleeding air