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

Removing ( Refitting )     Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.    Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - 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.     Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE     Op. 0010T20 ENGINE COOLANT - CHANGE     Op. 0010T40 CHANGE MANUAL GEARBOX OIL     Op. 5530B10 BATTERY - R+R     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 1016A10 SOUND-PROOFING COVER - R.R     Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 1048B27 RIGID PIPE FOR AIR INLET TO THROTTLE BODY - R R    Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.     Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE     Op. 1076B20 REAR EXHAUST SILENCER - R + R - For versions with DPF only:    Op. 1080B81 PARTICULATE FILTER (D.P.F.) - R.R.- For versions without DPF only:    Op. 1080B62 CATALYTIC CONVERTER - R + R     Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R     Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R     Op. 1048A41 HOSE FROM FLOW METER TO TURBOCHARGER - R.R.    Op. 1080C83 EXHAUST GAS INLET PIPING FROM EXHAUST MANIFOLD TO HEAT EXCHANGER EGR - R R    Op. 1048B19 TURBOCHARGER AIR OUTLET HOSE -R.R.    Op. 7210E10 R.R. FRONT BUMPER     Op. 1048B10 RIGID SUPPLY PIPE (ONE) BETWEEN TURBOCHARGER AND HEAT EXCHANGER -R.R.    Op. 1064A27 PIPE BETWEEN VACUUM RESERVOIR AND ACTUATOR CONTROL SOLENOID VALVE - R.R.    Op. 3310A60 FRONT BRAKE PADS - REPLACE     Op. 1008C30 POWER UNIT LOWER REACTION LINK - R.R.    Op. 1008C33 BRACKET ON ENGINE FOR LOWER REACTION ROD - R.R.    Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R 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. 1. Loosen the band (1a) and disconnect the left driveshaft (1b) from the differential internal driveshaft (1c).     Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.1. Disconnect the electrical connection from the turbocharger vane position actuator solenoid valve.

	Description	Connector
1	Turbine variable geometry control solenoid	See L036 TURBINE VARIABLE GEOMETRY CONTROL SOLENOID VALVE

2. Disconnect the vacuum inlet pipe for the turbocharger vane position actuator control solenoid valve. 1. Undo the bolts and disconnect the supply and return pipes from the air conditioning compressor.2. Loosen the band and disconnect the coolant outlet hose from the radiator, water pump side. 1. Disconnect the quick connector for the fuel return pipe to the tank. 1. Undo the nut (1a) securing the heater plugs control unit (1b) to the bracket and disconnect the electrical connection (1c).

	Description	Connector
1c	Heater plugs control unit	See M015 PLUG PREHEATING CONTROL UNIT

1. Open the retaining clip (1a), disconnect the single-acting valve for the brake servo assembly (1b) and move it aside.2. Disconnect the rapid connectors and disconnect the heater supply and return pipes. 1. Disconnect the gear selector and engagement cables.2. Undo the nuts and remove the bracket complete with gear selection and engagement cables. 1. Lift up the clip and disconnect the flexible pipe from the clutch control actuator.2. Undo the nut and disconnect the battery earth lead.

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

3. Loosen the band and disconnect the radiator water supply pipe, thermostat side. - Postion a suitable footboard beneath the power unit.- Remove the power unit support flexible mounting, timing side referring to    Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE 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 illustrated.- Gently raise the power unit and make sure that the chains have the same tension. 1. Undo the nut securing the rigid support flexible mounting, gearbox side.2. Open the clutch hydraulic system rigid pipe retaining clip. - Raise the vehicle until the power unit is released from the engine compartment.- Disconnect the arm for the hydraulic hoist from the balance and complete the raising of the vehicle.- Reconnect the hydraulic hoist arm to the balance, raise the power unit and position it on a suitable support.- Release the power unit from the support tools. Refitting ( Removing ) - Fit the support tools to the power unit.- Raise the vehicle and place the power unit on a suitable support by the engine compartment.- Remove the power unit support tools.- Lower the vehicle until the power unit is back in place.- Tighten the nut fixing the rigid support flexible mounting, gearbox side 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

- Close the clutch hydraulic system rigid pipe retaining clip.- Place the power unit support flexible mounting, timing side back in position referring to    Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE - Raise the vehicle as necessary and remove the support from underneath the power unit.- Connect the battery earth lead and tighten the nut.- Connect the flexible pipe to the clutch control actutator and secure it using the clip.- Connect the raidator coolant supply pipe, thermostat side and tighten the band.- Refit the bracket with gear selection and engagement cables in its seat and tighten the nuts.- Connect the gear selector and engagement cables to the levers.- Connect the rapid connectors for the heater supply and return pipes.- Connect the brake servo assembly single-acting valve and close the retaining clip.- Connect the electrical connection for the heater plugs control unit and tighten the nut to the bracket.- Connect the rapid connector for the fuel return pipe to the tank, return manifold side.- Connect the radiator coolant outlet hose, water pump side, and tighten the band.- Connect the supply and return pipes from the air conditioning compressor and tighten the bolts.- Connect the vacuum inlet pipe for the turbocharger vane position actuator control solenoid valve.- Connect the electrical connection from the turbocharger vane position actuator solenoid valve.    Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.    Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R. - 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)	M12	9.5 ÷ 10.5	1.9 JTD 16v

- 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.     Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R     Op. 1008C33 BRACKET ON ENGINE FOR LOWER REACTION ROD - R.R.    Op. 1008C30 POWER UNIT LOWER REACTION LINK - R.R.    Op. 3310A60 FRONT BRAKE PADS - REPLACE     Op. 1064A27 PIPE BETWEEN VACUUM RESERVOIR AND ACTUATOR CONTROL SOLENOID VALVE - R.R.    Op. 1048B10 RIGID SUPPLY PIPE (ONE) BETWEEN TURBOCHARGER AND HEAT EXCHANGER -R.R.    Op. 7210E10 R.R. FRONT BUMPER     Op. 1048B19 TURBOCHARGER AIR OUTLET HOSE -R.R.    Op. 1080C83 EXHAUST GAS INLET PIPING FROM EXHAUST MANIFOLD TO HEAT EXCHANGER EGR - R R    Op. 1048A41 HOSE FROM FLOW METER TO TURBOCHARGER - R.R.    Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R     Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R - For versions with DPF only:    Op. 1080B81 PARTICULATE FILTER (D.P.F.) - R.R.- For versions without DPF only:    Op. 1080B62 CATALYTIC CONVERTER - R + R     Op. 1076B20 REAR EXHAUST SILENCER - R + R     Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE     Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.     Op. 1048B27 RIGID PIPE FOR AIR INLET TO THROTTLE BODY - R R    Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 1016A10 SOUND-PROOFING COVER - R.R     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 5530B10 BATTERY - R+R     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. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.     Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.    Op. 0010T40 CHANGE MANUAL GEARBOX OIL     Op. 0010T20 ENGINE COOLANT - CHANGE     Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE