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

Removing ( Refitting ) 1. Open the protective cover (1a), loosen the nut (1b) and disconnect the wiring (1c) from the starter motor.

	Description	Connector
1c	Starter motor	See A020 STARTER MOTOR

2. Undo the bolts (2a) and remove the starter motor (2b). 1. Undo the bolt fixing the flywheel guard to the gearbox.2. Undo the nut fixing the gearbox to the engine block. 1. Undo the bolt fixing the flywheel guard to the gearbox. 1. Undo the lower bolts fixing the gearbox to the engine oil sump. 1. Undo the remaining upper bolts fixing the gearbox to the engine block. - Remove the gearbox from the engine.1. Fit the flywheel lock.

Tool	Description	Function	Validity
1860846000	Counter-torque	Flywheel lock

2. Undo the bolts (2a) diagonally and remove the clutch mechanism assembly (2b). Refitting ( Removing ) - Place the clutch mechanism assembly in position with a suitable centering tool and tighten the bolts diagonally to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Clutch mechanism	Bolt (to be replaced)	M6	1.2 ÷ 1.5	1.4 16v

- Remove the flywheel lock fitted previously.- Fit the gearbox in its seat and tighten the fastenings 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

- Tighten the bolts securing the lower flywheel guard.- 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 starter motor electrical wiring, tighten the nut and close the protective cover.