194000226 - 1004B10 POWER UNIT WITH MANUAL GEARBOX - R.R

Removing ( Refitting ) - Position the vehicle on a lift.- Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).
DescriptionConnector
-Battery    See A001 BATTERY
    Op. 4450B12 FRONT WHEELS (TWO) - R+R    Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.    Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.    Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.    Op. 1080B95 REAR LAMBDA SENSOR TO CATALYTIC CONVERTER - R.R    Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R    Op. 7055A43 CENTRE FRONT GRILLE - R.R.    Op. 4410D10 FRONT SUSPENSION FRAME - R+R    Op. 5530B10 BATTERY - R+R    Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R    Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE1. Undo the bolts (1a) and remove the upper radiator crossmember guard (1b).
    Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.1. Undo the radiator coolant drain plug.
Collect the coolant in a suitable container.
1. Undo the water pump coolant drain plug.
Collect the coolant that comes out in a suitable container.
1. Disconnect the left driveshaft from the differential and move it to the side.
1. Disconnect the right driveshaft from the intermediate driveshaft and move it to the side.
1. Remove the electrical connection holder cover.
1. Rotate the electrical connections holder casing and disconnect the electrical connections.
DescriptionConnector
1Engine compartment junction unit    See B001 ENGINE COMPARTMENT JUNCTION UNIT
1. Undo the nut (1a) and disconnect the earth lead (1b) from the bodyshell.
DescriptionConnector
1bEarth on engine    See C040 EARTH ON ENGINE
1. Undo the nut (1a) and disconnect the earth lead (1b) from the bodyshell.
DescriptionConnector
1bEarth on engine    See C040 EARTH ON ENGINE
1. Disconnect the electrical connection (1a) from the fans, then release the electrical wiring from the fastenings (1b) and move it aside.
DescriptionConnector
1aEngine fan motor    See N011 ELECTRIC FAN MOTOR
1. Undo the nut (1a), loosen the bands and remove the engine coolant return pipe to the supply reservoir (1b).
1. Loosen the band and disconnect the engine oil vapour recovery pipe from the cylinder head cover.2. Loosen the bands and remove the air supply hose from the air flow meter to the throttle casing.
1. Disconnect the electrical connection from the air flow meter.
DescriptionConnector
1Air flow meter    See K041 AIR FLOW METER
2. Undo the bolts (2a) and remove the air filter cover (2b), complete with air flow meter (2c).3. Remove the air cleaner filter element.
1. Release the fuel vapour pipe (1a) from the band (1b) on the air filter casing.
1. Disconnect the cold air intake from the air filter casing.2. Remove the air filter casing fastened to the bodyshell by three pins.
1. Connect the tool to the bleed valve on the fuel supply pipe and discharge the fuel pressure.
Follow the safety instructions and specific recommendations.
ToolDescriptionFunctionValidity
2000002900Breather connectorFuel system pressure drainage1.82.2
1. Undo the connector (1a), disconnect the fuel supply pipe (1b), fuel manifold pipe side and move it to the side.
1. Disconnect the electrical connection from the air conditioning system multi-stage pressure switch.
DescriptionConnector
14 stage pressure switch    See K120 LINEAR SENSOR FOR FANS
2. Undo the nut fixing the air conditioning system pipe flange.
Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.
1. Disconnect the rapid connector for the air intake chamber fuel vapour inlet pipe, intermediate fuel vapour pipe side.
1. Loosen the bands and disconnect the engine coolant supply reservoir pipes.
1. Working underneath the vehicle, loosen the band and disconnect the radiator upper coolant inlet hose, radiator side.
1. Loosen the band and disconnect the radiator upper coolant inlet hose, thermostat side and remove it.
1. Disconnect the rapid connectors for the air conditioning system heater coolant inlet and outlet pipes.
1. Disconnect the quick-release fitting for the brake servo vacuum intake pipe, air chamber side.
1. Undo the bolt fixing the gear selector-engagement rods mounting bracket.2. Disconnect the gear selection-engagement rods, then move them aside together with the mounting bracket.
- Replace the brake-clutch fluid reservoir plug using the tool.
ToolDescriptionFunctionValidity
2000001400PlugBrake/clutch fluid reservoir cap
1. Release the retaining clip (1a) and disconnect the pipe (1b) between the damper and the clutch operating cylinder (1b), operating cylinder side.
- Postion a suitable footboard beneath the power unit.1. Support the power unit using a hydraulic hoist (1a) and the tool (1b) connected to the mounting brackets (1c).
ToolDescriptionFunctionValidity
1871001700BalanceRemoving-refitting power unit
1. Undo the bolts fixing the timing side power unit support flexible mounting, rigid support side.
1. Undo the power unit gearbox side rigid support fixing bolts, manual gearbox side.
1. Lower the power unit with the hydraulic hoist until it rests on the board positioned previously.
- Release the power unit from the support tools. Refitting ( Removing ) - Secure the power unit using the support tools.- Place the power unit in its housing using the hydraulic hoist.1. Tighten the power unit gearbox side rigid support fixing bolts, manual gearbox side to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Gearbox side power unit rigid supportBoltM10/12(gearbox side) 5.0 - 6.0
1. Tighten the bolts fixing the timing side power unit support flexible mounting, rigid support side to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Timing side power unit rigid support flexible mountingBoltM10(rigid support side) 5.0 - 6.01.82.21.9 JTD 16v1.9 JTD 8v
- Remove the hydraulic hoist and tool used for supporting the power unit safely.- Remove the support used for supporting the power unit.- Connect the pipe between the damper and clutch operating cylinder, operating cylinder side and secure it using the retaining clip.- Support the brake-clutch fluid reservoir plug using the tool.
ToolDescriptionFunctionValidity
2000001400PlugBrake/clutch fluid reservoir cap
- Connect the gear selection-engagement rods.- Tighten the bolt fixing the gear selection-engagement rods mounting bracket.- Connect the quick-release fitting for the brake servo vacuum intake pipe, air chamber side.- Connect the rapid connectors for the air conditioning system heater coolant inlet and outlet pipes.- Place the radiator upper coolant inlet hose in position, connect it to the thermostat and tighten the band.- Connect the radiator upper coolant inlet hose and tighten the band.- Connect the pipes to the engine coolant supply reservoir and tighten the bands.- Connect the rapid connector for the air intake chamber fuel vapour inlet pipe, intermediate fuel vapour pipe side.- Connect the air conditioning system pipe flange and tighten the nut to the recommended torque.
Replace any O-Rings for the connectors using green coloured seals only which are resistant to the R134a refrigerant fluid.Lubricate the connector threads using anti-freeze.
ComponentFasteningdia  Value (daNm)Validity
AIR CONDITIONING PIPE TO CONDENSERNut1.6 ÷ 2.41.8 16v
- Connect the electrical connection to the air conditioning system multi-stage pressure switch.1. Place the fuel supply pipe (1a) in its housing, connect it and tighten the connector (1b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Front fuel supply pipeConnector-(fuel manifold side) 1.02.2
- Place the air filter casing in its housing and secure it to the bodyshell using the three pins.- Connect the cold air intake to the air filter casing.- Fasten the fuel vapour pipe to the air filter casing using the band.- Fit the air filter filter element in place.- Fit the cover for the air filter, complete with air flow meter, and secure it using the bolts.- Connect the electrical connection to the air flow meter.- Place the air supply hose from the air flow meter to the throttle casing back in its housing and secure it using the bands.- Connect the engine oil vapour recovery pipe to the cylinder head cover and secure it using the band.- Place the coolant return pipe to the engine coolant reservoir in position and tighten the bands and the nut.- Place the electrical wiring back in its housing, then secure it and connect the electrical connection to the fans.- Connect the earth leads to the bodyshell and secure them using the nuts.- Connect the electrical connections, then place the electrical connections casing in its housing.- Place the cover for the electrical connections casing in position.- Connect the right driveshaft to the intermediate driveshaft.- Connect the left driveshaft to the differential.- Tighten the coolant drain plug to the water pump to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Drain plug on water pump-M20 x 1.5(water pump side) 2.02.2
- Tighten the radiator coolant drain plug.    Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.- Place the upper radiator crossmember guard back in its housing and secure it using the bolts.    Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE    Op. 0010T64 BRAKE AND/OR CLUTCH FLUID CHECK LEVEL AND TOP UP AS NECESSARY    Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR    Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R    Op. 5530B10 BATTERY - R+R    Op. 4410D10 FRONT SUSPENSION FRAME - R+R    Op. 7055A43 CENTRE FRONT GRILLE - R.R.    Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R    Op. 1080B95 REAR LAMBDA SENSOR TO CATALYTIC CONVERTER - R.R    Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.    Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.    Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.    Op. 4450B12 FRONT WHEELS (TWO) - R+R    Op. 0010T20 ENGINE COOLANT - CHANGE- Connect the negative battery terminal.- Remove the vehicle from the lift.