223000116 - 1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, REMOVE AND REASSEMBLE

Removing ( Refitting ) 1. Open the protective cover (1a), loosen the nut (1b) and disconnect the wiring (1c) from the starter motor.
DescriptionConnector
1cStarter motor    See A020 STARTER MOTOR
2. Undo the bolts (2a) and remove the starter motor (2b).
1. Unscrew bolt (1a), screws (1b) and (1c) and remove the reinforcement bracket (1d).
1. Undo the screws (1a), bolt (1b) and remove the flywheel side oil seal cover (1c).- Recover the exhaust manifold mounting bracket.2. Undo the nut fixing the gearbox to the cylinder block/crankcase.
1. Undo the remaining bolts fixing the gearbox to the engine block.- Remove the gearbox from the engine.
1. Fit the flywheel lock.
DescriptionCodeFunction
1Counter-torque1.860.846.000Flywheel lock
2. Undo the bolts (2a) and remove the clutch mechanism assembly (2b).
Refitting ( Removing ) - Refit the clutch mechanism assembly using the centring tool.
DescriptionCodeFunction
-Centering1.875.086.000Removing-refitting clutch plate/mechanism
- Tighten the bolts securing the clutch mechanism to the recommended torque.
Value daNmFasteningComponentdia  
-1.2 ÷ 1.5Clutch mechanismBolt (to be replaced)M6
- Remove the centring tool.
DescriptionCodeFunction
-Centering1.875.086.000Removing-refitting clutch plate/mechanism
- Remove the flywheel lock.
DescriptionCodeFunction
-Counter-torque1.860.846.000Flywheel lock
- Place the manual gearbox in position and secure it tightening the bolts and nut to the recommended torque.
Value daNmFasteningComponentdia  
-4.8 ÷ 7.2Manual gearbox to engine - crankcase sideBoltM12
Value daNmFasteningComponentdia  
-4.8 ÷ 7.2Manual gearbox to engine - crankcase sideNutM12
- Place the engine flywheel protective cover back in its housing and secure it using the bolts.- Refit the exhaust pipe bracket and secure by tightening the bolt to the specified torque.
Value daNmFasteningComponentdia  
-4.5 ÷ 5.5Exhaust pipe mounting bracketBoltM10
- Place the reinforcement pillar in its housing and secure it tightening the screws and bolt to the recommended torque.
Value daNmFasteningComponentdia  
-2.2 ÷ 2.7Bracket joining manual gearbox/differential to engine - differential sideBoltM8
Value daNmFasteningComponentdia  
-5.0 ÷ 6.0Bracket joining manual gearbox/differential to engine - gearbox sideBoltM12
Value daNmFasteningComponentdia  
-3.6 ÷ 4.4Bracket joining manual gearbox/differential to engine - gearbox sideBoltM10
- Place the starter motor in its housing and secure it tightening the bolts to the recommended torque.
Value daNmFasteningComponentdia  
-2.25 ÷ 2.75Starter motorBoltM8
- Connect the starter motor electrical wiring, tighten the nut and close the protective cover.    Op. 0010T40 CHANGE MANUAL GEARBOX OIL