199000400 - 1004B10 POWER UNIT WITH MANUAL GEARBOX - R.R

Removing ( Refitting ) - Position the vehicle on a lift.    Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - 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. 0010T20 ENGINE COOLANT - CHANGE     Op. 0010T40 CHANGE MANUAL GEARBOX OIL     Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE     Op. 7210E10 R.R. FRONT BUMPER     Op. 7210A18 R.R FRONT CROSSMEMBER     Op. 5540B07 LEFT FRONT HEADLAMP - R.R     Op. 5540B08 RIGHT FRONT HEADLAMP - R.R     Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.     Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R     Op. 1048B17 HEAT EXCHANGER AIR INLET HOSE - R.R.    Op. 1048B32 AIR SUPPLY PIPE ON HEAT EXCHANGER - R.R.    Op. 7210A02 FRONT END ASSEMBLY - R.R.     Op. 1048B45 RIGID AIR SUPPLY PIPE BETWEEN HEAT EXCHANGER AND INTERMEDIATE HOSE - R.R.    Op. 1048B20 AIR SUPPLY HOSE FROM HEAT EXCHANGER TO RIGID PIPE - REPLACE     Op. 1048B25 INTERMEDIATE RIGID PIPE BETWEEN HEAT EXCHANGER AND THROTTLE BODY - R R    Op. 1048B30 AIR SUPPLY HOSE FROM RIGID PIPE TO THROTTLE BODY - REPLACE    Op. 1016A10 SOUND-PROOFING COVER - R.R     Op. 5530B10 BATTERY - R+R     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R.     Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.    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.- Remove the fastenings for the brake calipers, with reference to    Op. 3310A60 FRONT BRAKE PADS - REPLACE     Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R 1. Unscrew the nut, fit the tool and disconnect the left steering link from the strut.

Tool	Description	Function	Validity
1871000700	Extractor	Extracting steering rod from strut

2. Undo the bolts securing the left front shock absorber to the strut.3. Undo the bolt and remove the ABS sensor. 1. Loosen the band and disconnect the left driveshaft from the differential internal driveshaft. 1. Unscrew the brake fluid reservoir cap and fit the tool.

Tool	Description	Function	Validity
2000001400	Plug	Brake/ clutch system vacuum

1. Loosen the band and disconnect the brake servo vacuum pipe from the air intake chamber.2. Disconnect the fuel supply pipe rapid connector, pressure regulator side.- Open the retaining clips and move the pipes disconnected previously aside. 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.- Open the retaining clips and move the pipes disconnected previously aside. 1. Undo the bolts and disconnect the refrigerant fluid pipes from the air conditioning compressor. 1. Undo the bolt fixing the refrigerant fluid pipe. 1. Disconnect the engine intermediate coupling.

	Description	Connector
1	Engine cables/engine services cable coupling	See D029 ENGINE CABLES/ENGINE SERVICES CABLE COUPLING

2. Disconnect the electrical connection for the injection/ignition control unit.

	Description	Connector
2	Engine management control unit	See M010 ENGINE MANAGEMENT ECU

1. Disconnect the electrical connection for the reversing light switch.

	Description	Connector
1	Reversing light switch	See I020 REVERSING LIGHTS SWITCH (GEARBOX BRIDGE)

2. Undo the bolt and disconnect the battery earth lead.

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

3. Push the clip and disconnect the flexible pipe from the coaxial clutch release actuator. 1. Disconnect the gear selector and engagement cables.2. Move the locking cursors (2a) backwards and remove the gear selector and engagement cables (2b). 1. Disconnect the rapid connectors for the coolant supply and return pipes, heater side. 1. Fit the power unit mounting brackets on the gearbox as illustrated. 1. Fit the power unit mounting bracket on the compressor support as illustrated. 1. Fit the power unit mounting bracket, exhaust manifold side as illustrated. 1. Support the power unit using a hydraulic hoist and the tool connected to the mounting brackets.

Tool	Description	Function	Validity
1871001700	Balance	Removing/ refitting power unit

- Undo the bolts fixing the flexible mounting to the gearbox side rigid power unit support, with reference to    Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE - Undo the bolts fixing the flexible mounting to the timing side rigid power unit support, with reference to    Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE - Remove the power unit from the engine compartment and place it on a suitable 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 bolts fixing the flexible mounting to the timing side rigid power unit support to the recommended torque with reference to    Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE - Tighten the bolts fixing the flexible mounting to the gearbox side rigid power unit support to the recommended torque with reference 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 connectors for the coolant supply and return pipes, heater side.- Working in the engine compartment, introduce the two quick-fits for the gear selector and engagement cables in the openings in the bracket keeping the cursors retracted and inserting them fully into the seats using manual pressure until they are attached.Release the cursors.- Using manual pressure, connect the ends of the gear selection and engagement cables to the ball joints for the levers on the gearbox.- Adjust the clip and connect the flexible pipe to the coaxial clutch release actuator.- Connect the battery earth lead to the gearbox and tighten the bolt.- Connect the electrical connection for the reversing light switch.- Connect the electrical connection for the injection/ignition control unit.- Connect the engine intermediate coupling.- Tighten the bolt securing the refrigerant fluid pipe to the alternator mounting.- Connect the refrigerant fluid pipes to the air conditioning compressor and tighten the bolts.- Refit the fuel vapour return pipe, connect the rapid connector, air chamber side and close the retaining clips.- Refit the fuel vapour return pipe, connect the rapid connector, fuel manifold pipe side and close the retaining clips.- Refit the fuel vapour supply pipe, connect the rapid connector, pressure regulator side and close the retaining clips.- Place the brake servo vacuum pipe in position, connect it to the air chamber using the band and close the retaining clips.- Connect the left driveshaft to the differential internal driveshaft and tighten the band.- Tighten the new bolts fixing the left front shock absorber to the steering knuckle to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Front shock absorber - strut side	Bolt (to be replaced)	M12	10.3 ÷ 12.6 + 45°

- Connect the left steering links to the knuckle and tighten the nut to the specified torque.

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

- Connect the ABS sensor to the knuckle and secure it using the bolt.     Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R - Tighten the fastenings for the brake calipers, with reference to    Op. 3310A60 FRONT BRAKE PADS - REPLACE     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. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R.     Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 5530B10 BATTERY - R+R     Op. 1016A10 SOUND-PROOFING COVER - R.R     Op. 1048B30 AIR SUPPLY HOSE FROM RIGID PIPE TO THROTTLE BODY - REPLACE    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. 1048B45 RIGID AIR SUPPLY PIPE BETWEEN HEAT EXCHANGER AND INTERMEDIATE HOSE - R.R.    Op. 7210A02 FRONT END ASSEMBLY - R.R.     Op. 1048B32 AIR SUPPLY PIPE ON HEAT EXCHANGER - R.R.    Op. 1048B17 HEAT EXCHANGER AIR INLET HOSE - R.R.    Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R     Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.     Op. 5540B08 RIGHT FRONT HEADLAMP - R.R     Op. 5540B07 LEFT FRONT HEADLAMP - R.R     Op. 7210A18 R.R FRONT CROSSMEMBER     Op. 7210E10 R.R. FRONT BUMPER     Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. Op. 7055B65     Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE     Op. 0010T40 CHANGE MANUAL GEARBOX OIL     Op. 0010T20 ENGINE COOLANT - CHANGE     Op. 0010T64 BRAKE AND/OR CLUTCH FLUID CHECK LEVEL AND TOP UP AS NECESSARY     Op. 0010T65 HYDRAULIC BRAKE SYSTEM - BLEED AIR     Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. - Remove the vehicle from the lift.