198000068 - 1004B10 POWER UNIT WITH MANUAL GEARBOX - R.R

Removing ( Refitting )     Op. 5530B10 BATTERY - R+R     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R + R    Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R     Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.    Op. 1072C16 EXHAUST MANIFOLD WITH CATALYTIC CONVERTER - R.R.     Op. 0010T20 ENGINE COOLANT - CHANGE     Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.     Op. 1088D10 RADIATOR COOLANT OUTLET HOSE - R.R.     Op. 1088D14 UPPER RADIATOR COOLANT INLET HOSE - R.R.     Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE     Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 7055B65 ENGINE COMPARTMENT DUST COVER IN LEFT FRONT WHEEL ARCH - R.R.     Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. 1. Disconnect the rapid connectors for the heater water supply and return pipes. 1. Disconnect the electrical connection for the reversing switch.

	Description	Connector
1	Reversing lights switch	See I020 REVERSING LIGHTS SWITCH

2. Undo the bolts and move the clutch control actuator aside.3. Undo the nut and disconnect the earth lead.

	Description	Connector
3	Battery earth on engine	See C002 BATTERY EARTH ON ENGINE

1. Disconnect the gear selector and engagement cables.2. Undo the bolts and remove the bracket complete with gear selection and engagement cables. 1. Disconnect the single-acting valve from the brake servo and move it to one side. 1. Disconnect the fuel pipe rapid connector from the rail. 1. Disconnect the intermediate rapid connector for the fuel vapour pipe. 1. Remove the brake caliper fluid flexible pipe from the retaining bracket.2. Remove the ABS wheel rpm sensor wiring from the retaining bracket.3. Remove the wiring for the left front brake pad wear sensor from the retaining bracket.4. Unscrew the nut (4a), fit the tool (4b) and disconnect the steering link (4c) from the wheel strut.

Tool	Description	Function	Validity
1871000700	Extractor	Extracting steering rod from strut

5. Undo the bolts securing the shock absorber to the wheel strut. - Proceed in the same way for the right side.1. Loosen the band (1a) and disconnect the left driveshaft (1b) from the differential internal driveshaft (1c). 1. Loosen the band (1a) and disconnect the right driveshaft (1b) from the differential internal driveshaft (1c). 1. Disconnect the rapid connector for the air conditioning coolant supply pipe. 1. Disconnect the rapid connector for the air conditioning coolant return pipe. - Lower the lift and place a suitable support underneath the power unit.1. Fit the element on the hydraulic hoist.

Tool	Description	Function	Validity
1871001700	Balance	Removing/ refitting power unit

2. Attach the power unit at the points shown in the diagram (2a), (2b) and (2c). - Gently raise the power unit and make sure that the chains have the same tension.1. Undo the nuts fixing the flexible mounting to the timing side front support.2. Undo the bolts (2a) and remove the timing front support flexible mounting (2b). 1. Undo the nut securing the flexible mounting to the gearbox side rigid power unit support. - Lower the power unit until it rests on the board positioned previously.- Release the power unit from the support tools. Refitting ( Removing ) - Fit the support tools to the power unit.- Place the power unit in its housing using the hydraulic hoist.- Tighten the nut fixing the flexible mounting to the gearbox side rigid power unit support to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side support flexible mounting to rigid support	Nut (to replace)	M12	9.0 ÷ 11.0

- Place the timing front support flexible mounting in position and tighten the bolts fixing it to the bodyshell to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing side flexible mounting - bodyshell side	Bolt (to be replaced)	M10	4.5 ÷ 5.5

- Tighten the nuts fixing the flexible mounting to the timing side front support to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing side flexible mounting - rigid support side	Nut (to replace)	M10	4.5 ÷ 5.5	1.4 16v

- Remove the hydraulic hoist and tool used for supporting the power unit safely.- Connect the rapid connector for the air conditioning coolant pipes.- Connect the right driveshaft to the differential internal driveshaft and fasten the boot using the band.- Connect the left driveshaft to the differential internal driveshaft and fasten the boot using the band.- Connect the left steering links to the knuckle and tighten the new nut to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Steering rod to pillar	Nut	M10	3.6 ÷ 4.4

- Tighten the new bolts fixing the shock absorber to the steering knuckle to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Front shock absorber to wheel strut	Bolt (to be replaced)	M10	6.7 ÷ 7.3	1.4 16v1.9 JTD 8v

- Place the wiring for theleft front brake pad wear sensor in its housing and secure it to the retaining bracket.- Position the wiring for the ABS rpm sensor in its housing and secure it to the retaining bracket.- Place the brake caliper fluid flexible pipe in position and fasten it to the retaining bracket.- Proceed in the same way for the right side.- Connect the intermediate rapid connector for the fuel vapour pipe.- Connect the fuel pipe rapid connector to the rail.- Connect the single-acting valve to the brake servo.- Refit the bracket complete with gear selection and engagement cables in its seat and tighten the bolts.- Connect the cables to the gear selector and engagement unit.- Connect the battery earth lead and tighten the nut.- Place the clutch control actuator in its housing and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Hydraulic clutch actuator	Bolt	M8	1.8 ÷ 2.2	1.4 16v

- Connect the electrical connection for the reversing switch.- Connect the rapid connectors for the heater water supply and return pipes.    Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.     Op. 7055B65 ENGINE COMPARTMENT DUST COVER IN LEFT FRONT WHEEL ARCH - R.R.     Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 1088D14 UPPER RADIATOR COOLANT INLET HOSE - R.R.     Op. 1088D10 RADIATOR COOLANT OUTLET HOSE - R.R.     Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.     Op. 1072C16 EXHAUST MANIFOLD WITH CATALYTIC CONVERTER - R.R.     Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.    Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R     Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R + R    Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE     Op. 0010T20 ENGINE COOLANT - CHANGE     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 5530B10 BATTERY - R+R