194002121 - 1004B14 POWER UNIT WITH AUTOMATIC TRANSMISSION R + R (AUTOMATIC TRANSMISSION)
Removing
(
Refitting
)
- Position the vehicle on a lift. Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. Op. 0010T20 ENGINE COOLANT - CHANGE 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. 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- Loosen the band and disconnect the air outlet hose from the supercharging air/air heat exchanger.1. Undo the bolts (1a) and remove the air supply pipe from the supercharging air/air heat exchanger to the throttle casing (1b) assembly.
1. Loosen the band and disconnect the upper coolant inlet hose to the radiator, thermostat side.2. Loosen the band and disconnect the coolant delivery pipe to the climate control system heater, thermostat side.3. Loosen the band and disconnect the coolant return pipe from the climate control system heater, water pump rigid inlet pipe side.
1. Loosen the coolar and disconnect the coolant return pipe from the engine coolant reservoir.
1. Disconnect the quick-release fitting for the brake servo vacuum intake pipe from the vacuum pump.
1. Disconnect the electrical connection from the automatic transmission control unit.2. Undo the nut (2a) and disconnect the earth lead (2b) from the automatic gearbox.
1. Disconnect the gear selection cable from the gear selector and reaction bracket.
1. Disconnect the electrical connections from the diesel electronic injection system control unit.2. Undo the bolts (2a) and remove the diesel electronic injection system control unit (2b).
1. Disconnect the electrical connection from the air flow meter.2. Loosen the band and disconnect the hose from the air filter to the turbocharger, air filter side.3. Remove the air filter (3a) assembly after having released it from the cold air intake. | The air filter is fastened to the bodyshell by two pins and a side fitting. |
1. Disconnect the electrical connection from the air conditioning system multistage pressure switch. | Description | Connector |
|---|
| 1 | 4 stage pressure switch | See K010 4 STAGE PRESSURE SWITCH |
2. Undo the nut (2a) and disconnect the earth lead (2b).
1. Loosen the band and disconnect the engine oil vapour recovery pipe from the corrugated hose.2. Loosen the band and remove the corrugated hose from the air filter to the turbocharger.
1. Loosen the band and disconnect the lower coolant inlet hose from the radiator, water pump rigid coolant inlet pipe side.2. Undo the bolt (2a) and disconnect the coolant inlet and outlet pipes flange (2b), air conditioning compressor side. | Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system. |
1. Disconnect the fuel supply pipe rapid connector, pressure pump side.2. Disconnect the rapid connector for the fuel return pipe, fuel return manifold side.
- Disconnect the electrical connection from the heater plugs control unit.1. Disconnect the electrical connections from the alternator.
1. Disconnect the engine wiring coupling.
1. Open the protective cover, loosen the nuts (1a) and disconnect the electrical connections (1b) from the starter motor.
1. Loosen the band and disconnect the air supply hose from the turbocharger to the supercharging air/air heat exchanger.
1. Undo the nut (1a) and disconnect the flange for the automatic transmission fluid supply and return pipes to the radiator (1b), automatic gearbox side. | Collect the transnmission fluid that comes out in a suitable container. |
1. Undo the bolts (1a) and disconnect the engine oil supply and return pipe to the heat exchanger (1b), engine oil filter mounting side. | Collect the engine oil that comes out in a suitable container. |
1. Disconnect the turbocharger actuator control pipe, vane position actuator control solenoid valve side on the turbocharger.
- Postion a footboard beneath the power unit.1. Support the power unit using a hydraulic hoist (1a) and the tool (1b) fitted with suitable chains.| Tool | Description | Function | Validity |
|---|
| 1871001700 | Balance | Removing-refitting power unit | |
1. Undo the bolts fixing the automatic gearbox side power unit flexible mounting to the rigid support.
1. Undo the bolts fixing the timing side power unit support flexible mounting, rigid support side.
- Slowly 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 bolts fixing the timing side power unit support flexible mounting, rigid support side to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Timing side power unit rigid support flexible mounting | Bolt | M12 | (rigid support side) 7.5 - 8.5 | 2.4 JTD 20V |
1. Tighten the bolts fixing the automatic gearbox side power unit flexible mounting to the rigid support to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Gearbox side support flexible mounting | Bolt | M10 | (support side) 5.0 - 6.0 | |
- Remove the hydraulic hoist and tool used for supporting the power unit safely.| Tool | Description | Function | Validity |
|---|
| 1871001700 | Balance | Removing-refitting power unit | |
- Remove the support used for supporting the power unit.- Connect the turbocharger actuator control pipe, vane position actuator control solenoid valve side on the turbocharger.1. Connect the engine oil supply and return pipes to the radiator (1a), engine oil filter mounting side and tighten the bolts (1b) to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Engine oil radiator supply and return pipes | Connector | M22 | (oil filter mounting side) 4.0 - 4.5 | 2.4 JTD 20v |
1. Connect the flange for the automatic transmission fluid supply and return pipes to the radiator (1b), automatic gearbox side and tighten the nut (1b) to the recommended torque.| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| Automatic transmission fluid radiator supply and return pipes | Nut | - | (automatic gearbox side) 0.7 | 2.4 JTD 20v CAE |
- Connect the air supply hose from the turbocharger to the supercharging air/air heat exchanger and tighten the band.- Connect the starter motor electrical connections and secure them using the nuts, then close the protective cover.- Connect the engine wiring coupling.- Connect the electrical connections to the alternator.- Connect the electrical connection to the heater plugs control unit.- Connect the rapid connector for the fuel return pipe, fuel return manifold side.- Connect the fuel supply pipe rapid connector, pressure pump side.1. Connect the flange for the coolant inlet and outlet pipes (1a), air conditioning compressor side and tighten the bolt (1b) 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. |
| Component | Fastening | dia | Value (daNm) | Validity |
|---|
| EVAPORATOR/COMPRESSOR PIPE ON COMPRESSOR | Bolt | M8 | 1,8 ÷ 2,2 | |
2. Connect the lower coolant inlet hose from the radiator, water pump rigid coolant inlet pipe side and tighten the band.
- Place the corrugated hose from the air filter to the turbocharger in its housing and tighten the band.- Connect the engine oil vapour recovery pipe to the corrugated hose and tighten the band.- Connect the electrical connection to the air conditioning system multistage pressure switch.- Connect the earth lead and tighten the nut.- Place the air filter assembly back in its housing and connect it to the cold air intake.- Connect the hose from the air filter to the turbocharger, air filter side and tighten the band.- Connect the electrical connection to the air flow meter.- Refit the diesel electronic injection system control unit in its housing and secure it using the bolts.- Connect the electrical connections to the diesel electronic injection system control unit.- Connect the gear selector cable to the gear selector and to the bracket.- Connect the earth lead to the automatic gearbox and tighten the nut.- Connect the electrical connection to the automatic transmission control unit.- Connect the vacuum intake pipe for the brake servo to the vacuum pump.- Connect the coolant return pipe to the engine coolant reservoir to the coolant reservoir and tighten the band.- Connect the coolant return pipe from the climate control system heater, water pump rigid coolant inlet pipe side and tighten the band.- Connect the coolant delivery pipe to the climate control system heater, thermostat side, and tighten the band.- Connect the radiator upper coolant inlet hose, thermostat side, and tighten the band.- Refit the air supply pipe from the supercharging air/air heat exchanger to the throttle casing anse cure it using the bolts.- Connect the air outlet hose from the supercharging air/air heat exchanger and tighten the band. 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. 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 Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 5530B10 BATTERY - R+R Op. 0010T12 ENGINE OIL AND FILTER - REPLACE Op. 0010T45 AUTOMATIC TRANSMISSION FLUID CHECK LEVEL AND TOP UP IF NECESSARY Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. Op. 4450A10 FRONT WHEEL GEOMETRY - CHECK USING OPTICAL EQUIPMENT - INCLUDES ADJUSTMENT IF NECESSARY- Remove the vehicle from the lift.
