199000402 - 1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, DISMANTLE AND REASSEMBLE

1. Open the cover (1a), loosen the nuts and disconnect the electrical connections (1b) from the starter motor.

	Description	Connector
1b	Starter motor	See A020 STARTER MOTOR

2. Undo the bolts (2a) and remove the starter motor (2b). - Undo the bolts and remove the plate between the gearbox and engine.1. Undo the fastenings (1a) and remove the manual gearbox and differential (1b). 1. Fit the flywheel lock.

Tool	Description	Function	Validity
1860846000	Counter-torque	Flywheel lock

2. Unscrew the three bolts spaced at 120 degrees securing the clutch mechanism.3. Fit the locating pin (3a) and the remaining part of tool (3b), tightening the bolts (3c) into the seats of the bolts removed previously.

Tool	Description	Function	Validity
1871003100	Extractor/ Fitting tool	Removing-refitting clutch mechanism	1.4 16v TJet1.9 Multijet

4. Turn the tool handwheel until the pins (4a) are in contact with the disc (4b).5. Undo the remaining bolts securing the clutch mechanism.6. Undo the tool handwheel to discharge the clutch mechanism diaphragm spring.- Remove the tool.

Tool	Description	Function	Validity
1871003100	Extractor/ Fitting tool	Removing-refitting clutch mechanism	1.4 16v TJet1.9 Multijet

7. Remove the clutch mechanism.- Remove the clutch plate. 1. Fit the tool locating pin into the crankshaft.- Refit the clutch plate in position.

When fitting the clutch plate the correct position is shown by the words "engine side" and "gearbox side".Handle the clutch plate carefully. Do not touch the surfaces of the friction linings with your hands.

2. Refit the clutch mechanism in position.

Clean any anti-corrosion protection or detergents from the friction surface of the clutch mechanism.

3. Fit the remaining part of tool (3a) for fitting the clutch device and tighten the bolts (3b).4. Turn the tool handwheel until the pins (4a) are in contact with the disc (4b).5. Tighten the three clutch device fixing bolts by hand.6. Undo the tool handwheel to discharge the clutch mechanism diaphragm spring.- Remove the tool.

Tool	Description	Function	Validity
1871003100	Extractor/ Fitting tool	Removing-refitting clutch mechanism	1.4 16v TJet1.9 Multijet

- Tighten the remaining clutch fixing bolts by hand.- Gradually tighten the bolts fixing the clutch diagonally until the recommended torque is reached.

Component	Fastening	dia	Value (daNm)	Validity
Clutch mechanism	Bolt (to be replaced)	M8	2.5	1.9 Multijet

7. Remove the flywheel lock.

Tool	Description	Function	Validity
1860846000	Counter-torque	Flywheel lock

- Place the manual gearbox-differential unit in its housing and secure it tightening the bolts and the nuts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox to engine - crankcase side	Bolt	M12	4.8 ÷ 7.2

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox to engine - crankcase side	Nut	M12	4.8 ÷ 7.2

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox to oil sump	Bolt	M10	3.6 ÷ 4.4	1.4 16v1.9 Multijet

- Place the plate in position between the gearbox and engine and secure it using the bolts.- Place the starter motor in its housing and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Starter motor	Bolt	M8	2.25 ÷ 2.75

- Connect the electrical connections to the starter motor and secure them using the nut.- Close the cover.