3362383 - 1004B10 power unit with manual gearbox - r + r

Removing ( Refitting ) Place the car on the ramp. - 1016A10  sound-proofing cover - r + r - 5530B56  BATTERY DRIP TRAY COVER - R.R.Remove the protective cover on the battery.1. Undo the nut (1a) and disconnect the starter motor electrical connection (1b).

	Name	Connector
1b	Battery	A1

- 5530B10 battery - r+r  - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. - 1048A32  sleeve from air cleaner to intake manifold - r + r - 4450B12  front or rear wheels (two) - r+r - 7055B54  under-engine guard - r r - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R.1. Disconnect the bottom coolant outlet hose from the radiator.

To disconnect the hose, press the clips manually and remove the rapid attachment.

Recover the coolant using a suitable container.

1. Acting on the retaining springs, disconnect the upper coolant inlet hose from the radiator. 1. Disconnect the engine cooling fan (1b) electrical connection (1a).

	Name	Connector
1a	ELECTRIC FRONT WINDOWS MECHANISM	N11

 - 7025A34  bonnet lid lock (one) - r+r or repair - 7210E10  R.R. FRONT BUMPER1. Disconnect the electrical connections for the light clusters.

	Name	Connector
1	Left headlamp	F10

	Name	Connector
1	Right headlamp	F11

2. Loosen the nuts and bolts (2a) fixing the light clusters (2b) and move them inwards. 1. Disconnect the electrical connection for the horn.

	Name	Connector
1	Horn	P5

1. Disconnect the electrical connection for the Air Bag sensor.

	Name	Connector
1	Air-Bag front sensor	K39

1. Undo the wing fixing bolts.2. Undo the strut fixing bolts.3. Remove the crossmember/light cluster/radiator and fan assembly. 1. Undo the bolt (1a) and disconnect the earth lead (1b) from the gearbox.

	Name	Connector
1b	Battery earth	C1

1. Undo the fixing bolts (1a) and move the clutch release cylinder (1b) to the side. 1. Disconnect the gear engagement/selector cables.2. Undo the fixing bolts (2a) then move the mounting bracket (2b) complete with gear engagement/selector cables. 1. Disconnect the brake servo pipe (1a) from the single-acting valve and release it from the retaining band (1b).2. Act on the retaining bands and disconnect the heater pipes. 1. Disconnect the rapid attachment for the fuel supply pipe.Disconnect the electrical connection from the fuel vapour recovery solenoid.

	Name	Connector
-	Fuel vapour recovery solenoid	L10

2. Disconnect the fuel vapour recover pipe (2a) from the air chamber and release it from the retaining band (2b).3. Undo the fixing bolts (3a) and move the coolant expansion tank (3b). 1. Undo the fixing nuts (1a) and disconnect the exhaust pipe (1b) from the manifold (1c). Cut the bands securing the driveshaft boots to the differential.1. Undo the nuts (1a) and disconnect the steering box track rods (1b) from the front hub vertical links using tool (1c).

	Name	Country
1c	Extractor	1.847.038.000

2. Undo the upper bolt fixing the hub to the shock absorber.3. Loosen the lower bolt fixing the hub to the shock absorber.Tilt the brake disc/hub assembly outwards and disconnect the driveshafts from the differential releasing them from their housings.

Secure the driveshafts to a fixed point on the vehicle so that they do not interfere with the operations.

 - 1008C32  GEARBOX LOWER REACTION ROD ' -R.R.Lower the car.1. Fit the bracket (1a), complete with hook (1b), on the alternator mounting bracket.2. Fit the bracket (2a), complete with hook (2b), on the gearbox.3. Position the hook (3a) on the intake manifold.Secure the chains to the hydraulic lifting device and tension the engine. 1. Undo the bolts (1a) fixing the timing side engine support (1b) to the strut and turret. 1. Undo the bolts fixing the gearbox side engine support (1b) to the strut. Using a hydraulic lift, raise the power unit and place it on a suitable support.

Take great care when removing the engine not to damage the components fitted on the vehicle.

Refitting ( Removing ) Use the hydraulic lift to position the engine in its housing.

Take great care when positioning the engine not to damage the components fitted on the vehicle.

Tighten the bolts fixing the gearbox side engine support to the strut to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX SIDE RUBBER MOUNT	M10 x 1.25	(Strut vertical partition) 4,5

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX SIDE RUBBER MOUNT	M12 x 1.25	(Strut horizontal partition) 8,5

Tighten the bolts fixing the timing side engine support to the strut and the turret to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ENGINE MOUNT TIMING SIDE	M10 x 1.25	(Bodyshell/turret) side 5

 - 1008C32  GEARBOX LOWER REACTION ROD ' -R.R.Remove the hooks and brackets used for securing the engine.Position the driveshafts in the special housings in the differential.Position the wheel hubs and tighten the upper and lower bolts fixing the hub to the shock absorber to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT DAMPER	M10 x 1.25	(Shock absorber side) 7

Position the steering box rods in the front steering knuckles and tighten the fixing bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	ADJUSTABLE LINK BALL JOINTS	M10 x 1.25	7

Lock the driveshaft boots with new bands.Position the exhaust pipe on the manifold and tighten the fixing nuts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	EXHAUST PIPE TO ENGINE	M8	2.5

Position the coolant expansion tank and tighten the fixing bolts.Connect the rapid connector for the fuel vapour recovery pipe and secure it using the band.Connect the electrical connection from the fuel vapour recovery solenoid.

	Name	Connector
-	Fuel vapour recovery solenoid	L10

Connect the quick-release attachment for the fuel supply pipe.Connect the heater pipes securing them using the special retaining bands.Connect the brake servo pipe, brake servo side, and secure it using the retaining band.Position the mounting bracket, complete with gear engagement/selector cables, and tighten the fixing bolts.Connect the gear engagement/selector cables.Position the clutch release cylinder and tighten the fixing bolts.Position the battery earth lead on the gearbox and tighten the fixing bolt.

	Name	Connector
-	Battery earth	C1

Position the crossmember/light cluster/radiator assembly and fan on the vehicle.Tighten the wing fixing bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ENGINE ASSEMBLY	M10 x 1.25	(Strut side) 3

Tighten the strut fixing bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ENGINE ASSEMBLY	M10 x 1.25	(Strut side) 3

Renew the electrical connection for the Air Bag sensor.

	Name	Connector
-	Air-Bag front sensor	K39

Renew the electrical connection for the horn.

	Name	Connector
-	Horn	P5

Renew the electrical connection for the engine cooling fan.

	Name	Connector
-	ELECTRIC FRONT WINDOWS MECHANISM	N11

Restore the correct position for the light clusters then tighten the fixing nuts and bolts.Renew the electrical connections for the light clusters.

	Name	Connector
-	Left headlamp	F10

	Name	Connector
-	Right headlamp	F11

 - 7210E10  R.R. FRONT BUMPER - 7025A34  bonnet lid lock (one) - r+r or repairActing on the retaining springs, connect the radiator upper coolant inlet hose, radiator side.Acting on the retaining springs, connect the radiator lower coolant outlet hose, radiator side. - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R. - 7055B54  under-engine guard - r r - 4450B12  front or rear wheels (two) - r+r - 1048A32  sleeve from air cleaner to intake manifold - r + r - 5530B52  Battery DRIP TRAY/SUPPORT - R.R.- 5530B10 battery - r+r Renew the starter motor electrical connection.

	Name	Connector
-	Starter' motor	A20

Secure the wiring using retaining bands.Position the protective cover on the battery. - 5530B56  BATTERY DRIP TRAY COVER - R.R. - 1016A10  sound-proofing cover - r + r - 0010T20  coolant changeRemove the car from the ramps.