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

Removing ( Refitting ) - Position the vehicle on a lift.    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. 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     Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R     Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.    Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R 1. Undo the two bolts securing the shock absorber to the steering knuckle.
1. Unscrew the nut (1a), fit the tool (1b) and disconnect the steering link (1c) from the strut.
ToolDescriptionFunctionValidity
1871000700ExtractorExtracting steering rod from strut
- Prise up the left driveshaft from the differential and secure it appropriately.     Op. 1016A10 SOUND-PROOFING COVER - R.R     Op. 5530B10 BATTERY - R+R     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R - Unscrew the brake-clutch fluid reservoir plug and fit the tool.
ToolDescriptionFunctionValidity
2000001400PlugBrake/ clutch system vacuum
1. Undo the bolt and remove the earth lead.2. Adjust the retaining clips and disconnect the oil input pipe to the clutch control actuator.
1. With the gear lever in neutral, insert the locking pin in the gear selection-engagement unit.2. Disconnect the gear selector and engagement cables.3. Adjust the clips and disconnect the gear selection-engagement cables from the reaction bracket.
    Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.     Op. 1064B38 WASTE GATE SUPERCHARGING PRESSURE ADJUSTMENT SOLENOID VALVE - R.R.    Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R. 1. Loosen the band and disconnect the lower coolant outlet hose from the radiator, water pump side.
    Op. 1048B19 TURBOCHARGER AIR OUTLET HOSE -R.R.- Remove the air pressure pipes, refer to    Op. 1048B25 INTERMEDIATE RIGID PIPE BETWEEN HEAT EXCHANGER AND THROTTLE BODY - R R    Op. 1048B20 AIR SUPPLY HOSE FROM HEAT EXCHANGER TO RIGID PIPE - REPLACE 1. Loosen the band and disconnect the upper coolant inlet hose to the radiator, thermostat side.
1. Disconnect the reversing light switch cable electrical connection..
DescriptionConnector
1Front junction/reversing switch braid    See D187 FRONT/REVERSING SWITCH BRIDGE COUPLING
1. Disconnect the rapid connectors for the engine coolant supply and return pipes, heater side.2. Undo the nut and disconnect the low pressure coolant pipe, expansion valve side.
1. Undo the bolt and disconnect the pressurised coolant pipe, compressor side.- Open the retaining clip of the pipe disconnected earlier, compressor side.
1. Undo the bolt of the intermediate retainer bracket for the pressurised coolant pipe.
1. Loosen the band and disconnect the brake servo vacuum pipe, intake chamber side.2. Disconnect the engine front coupling.
DescriptionConnector
2Engine cables/engine services cable coupling    See D004 FRONT/ENGINE COUPLING
3. Disconnect the electrical connection for the injection/ignition control unit.
DescriptionConnector
3Engine management control unit    See M010 ENGINE MANAGEMENT ECU
1. Disconnect the fuel supply pipe rapid connector, pressure regulator side.
1. Disconnect the rapid connector for the fuel return pipe, fuel manifold pipe side.2. Disconnect the rapid connector for the fuel vapour recovery pipe, air chamber side.
1. Fit the power unit mounting bracket on the air conditioning compressor support as shown in the figure.
1. Fit the power unit mounting bracket, exhaust manifold side. as shown in the figure.
1. Support the power unit using a hydraulic hoist (1a) and the tool (1b) connected to the mounting brackets fitted earlier and to the gearbox at point (1c).
ToolDescriptionFunctionValidity
1871001700BalanceRemoving/ refitting power unit
- Undo the nut securing the flexible mounting to the rigid power unit support, gearbox side, refer to    Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE - Undo the nut securing the flexible mounting to the rigid power unit support, timing side, refer to    Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE - Remove the power unit from the engine compartment and position it to a platform.- 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 nuts fixing the flexible mounting to the timing side rigid power unit support to the recommended torque, refer to    Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE - Tighten the nut fixing the flexible mounting to the gearbox side of the rigid power unit support to the recommended torque, refer to    Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE - Remove the hydraulic hoist and tool used for supporting the power unit.- Connect the rapid connector for the fuel vapour recovery pipe, air chamber side.- Connect the rapid connector for the fuel return pipe, fuel manifold pipe side.- Connect the fuel supply pipe rapid connector, pressure regulator side.- Connect the electrical connection for the injection/ignition control unit.- Connect the engine front coupling.- Connect the vacuum pump pipe for the brake servo, intake chamber side and tighten the band.- Tighten the bolt of the intermediate retainer bracket for the pressurised coolant pipe.- Connect the pressurised engine coolant pipe, compressor side, tighten the bolt and close the retaining clips.- Connect the low pressure coolant pipe, expansion valve side and tighten the nut.- Connect the rapid connectors for the engine coolant supply and return pipes, heater side.- Disconnect the reversing light switch cable electrical connection..- Connect the radiator upper coolant inlet hose, thermostat side, and tighten the band.- Replace the air pressure pipes in their seats, refer to    Op. 1048B25 INTERMEDIATE RIGID PIPE BETWEEN HEAT EXCHANGER AND THROTTLE BODY - R R    Op. 1048B20 AIR SUPPLY HOSE FROM HEAT EXCHANGER TO RIGID PIPE - REPLACE     Op. 1048B19 TURBOCHARGER AIR OUTLET HOSE -R.R.- Connect the radiator lower coolant outlet hose, water pump side, and tighten the band.     Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R.     Op. 1064B38 WASTE GATE SUPERCHARGING PRESSURE ADJUSTMENT SOLENOID VALVE - R.R.    Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R. - Place the gear selection and engagements cables in their seats and secure to the reaction bracket using the clips.- Connect the cables to the gear selection and engagement unit and remove the locking pin.- Use a three-way connector to connect the oil input pipe to the clutch control actuator and close the retaining clip.- Connect the earth lead to the gearbox and tighten the bolt.     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 5530B10 BATTERY - R+R     Op. 1016A10 SOUND-PROOFING COVER - R.R - Connect the left driveshaft to the gearbox differential.- Connect the steering link to the steering knuckle and tighten the nut to the specified torque.
ComponentFasteningdia  Value (daNm)Validity
Steering rod to pillarNutM103.6 ÷ 4.4
- Tighten the new bolts fixing the shock absorber to the steering knuckle to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Front shock absorber to wheel strutBolt (to be replaced)M106.7 ÷ 7.31.4 16v1.9 JTD 8v
    Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R     Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.    Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R     Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.    Op. 0010T40 CHANGE MANUAL GEARBOX OIL - Check the clutch-brake fluid level and bleed if necessary, refer to    Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR     Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE     Op. 0010T20 ENGINE COOLANT - CHANGE     Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - 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 - Remove the vehicle from the lift.