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

Removing ( Refitting ) 1. Open the protective cover, loosen the nut (1a) and remove the starter motor wiring (1b).
1. Undo the bolts (1a) and remove the starter motor (1b).
1. Undo the bolts fixing the gearbox to the engine oil sump.2. Undo the bolt fixing the flywheel guard to the gearbox.
1. Undo the bolts securing the gearbox to the engine block.
1. Undo the bolts fixing the flywheel guard to the gearbox.2. Undo the nut (2a) and remove the gearbox (2b).
1. Fit the flywheel lock.
ToolDescriptionFunctionValidity
1860846000Counter-torqueFlywheel lock
2. Unscrew the three bolts spaced at 120 degrees securing the clutch mechanism.3. Fit tool (3a) and tool (3b) tightening the bolts (3c) in the seats of the bolts removed previously.
ToolDescriptionFunctionValidity
2000024900Clutch centering kitRemoving-refitting clutch mechanism1.4 16v TJet
ToolDescriptionFunctionValidity
1871003100Extractor/ Fitting toolRemoving-refitting clutch mechanism1.4 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 tools fitted previously.7. Remove the clutch mechanism.- Remove the clutch plate.
Refitting ( Removing ) 1. Fit the tool on the crankshaft.
ToolDescriptionFunctionValidity
2000024900Clutch centering kitRemoving-refitting clutch mechanism1.4 16v TJet
- 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 surface 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 tool (3a) using the bolts (3b).
ToolDescriptionFunctionValidity
1871003100Extractor/ Fitting toolRemoving-refitting clutch mechanism1.4 16v TJet1.9 Multijet
4. Turn the tool handwheel until the pins (4a) are in contact with the disc (4b).5. Tighten the remaining free clutch fixing bolts by hand.6. Undo the tool handwheel to discharge the clutch mechanism diaphragm spring.- Remove the tools fitted previously.- Tighten the remaining clutch fixing bolts by hand.- Gradually tighten the bolts fixing the clutch diagonally until the recommended torque is reached.
ComponentFasteningdia  Value (daNm)Validity
Clutch mechanismBolt (to be replaced)M61.2 ÷ 1.51.4 16v
7. Remove the flywheel lock.
- Fit the gearbox in its seat and tighten the fastenings to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Manual gearbox to engine - crankcase sideNutM124.8 ÷ 7.2
ComponentFasteningdia  Value (daNm)Validity
Manual gearbox to oil sumpBoltM103.6 ÷ 4.41.4 16v1.9 Multijet
ComponentFasteningdia  Value (daNm)Validity
Manual gearbox to engine - crankcase sideBoltM124.8 ÷ 7.2
- Tighten the bolts fixing the flywheel guard to the gearbox.- Place the starter motor in its housing and secure it tightening the bolts to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Starter motorBoltM82.25 ÷ 2.75
- Connect the starter motor electrical wiring, tighten the nut and close the protective cover.