1004B12 POWER UNIT WITH MANUAL GEARBOX - R+R FOR VERSIONS WITH A/C - Fiat - DUCATO - eLearn

244000618 - 1004B12 POWER UNIT WITH MANUAL GEARBOX - R+R FOR VERSIONS WITH A/C

) - Position the vehicle on a lift. Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R- Disconnect the negative battery terminal.1. Disconnect the windscreen washer jet pipe.2. Undo the bolts fixing the bonnet lid hinges to the bodyshell.3. Remove the bonnet lid, with the help of a second mechanic, and place it on a surface taking care over the paintwork.

Op. 1048A31 RIGID PIPE CONNECTING AIR CLEANER TO INLET MANIFOLD RIGID PIPE R R See in Op. 1048A141. Undo the bolts fixing the cold air intake to the upper crossmember.2. Disconnect the intake hose from the air filter casing.3. Remove the cold intake and intake hose assembly from the engine compartment.

1. Work on the band (1a) and undo the fixing nuts (1b).2. Remove the air filter casing and hoses.

1. Undo the bolts securing the power steering fluid reservoir bracket.2. Move the power assisted steering fluid reservoir complete with bracket aside.

1. Undo the fixing bolts.2. Remove the front grille.

1. Undo the fixing nuts.2. Move the bonnet lid lock aside.

Op. 7055B54 UNDER-ENGINE GUARD - R R Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R Op. 7055B64 LH OR RH REFLECTOR(ONE) ON REAR BUMPERS - R R- < R1 > - [On both sides] Op. 7210E10 R.R. FRONT BUMPER- Position a suitable container for collecting the coolant.1. Act on the band (1a) and release the lower coolant outlet hose (1b) from the two-way metal connector.

- Lower the vehicle.1. Disconnect the retaining band and release the coolant pipe on the reservoir.2. Work on the band and disconnect the water pump fluid supply pipe.3. Undo the fixing nuts (3a) and remove the expansion tank (3b).

1. Undo the fixing bolts (1a) and remove the crossmember (1b).

- Raise the vehicle.1. Disconnect the electrical connection.2. Undo the bolt fixing the pipes to the compressor.3. Undo the nut fixing the bracket (3a) and move the pipes (3b) aside.

1. Undo the bolt fixing the connector to the expansion valve.2. Undo the bolt fixing the connector to the drier filter.- Release the pipes from the fastenings.

1. Undo the fixing bolts (1a) and the nut (1b) and remove the side plastic shield (1c).2. Undo the fixing bolts and disconnect the connectors from the condenser.3. Release the pipes from the retaining springs and remove it.

1. Undo the fixing bolts (1a) and remove the protective cover (1b) for the relays.

1. Release the relays from the bracket and move them aside.2. Undo the fixing nuts (2a) and remove the bracket (2b).

1. Remove the retaining band (1a) and release the hose from the thermostat (1b).2. Disconnect the electrical connections for the fans.3. Disconnect the electrical connections from the resistor.4. Remove the plastic fastening bands and move the electrical lead aside.

- Disconnect the left and right front light cluster electrical connection.

	Description	Connector
.	Left headlamp	F010

	Description	Connector
.	Right headlamp	F011

1. Unscrew the upper light cluster retaining bolt.2. Use a suitable tool (2a) to prise light cluster from its seat, while releasing the pin from the opening in the wing.

	Description	Code	Function
2a	Knife	1.078.077.000	Prise light cluster out of beam

3. Undo the nuts fixing the hinges for the left light cluster (3a) and remove the left front light cluster (3b).- Repeat the same operation on the right front light cluster.

	Description	Code	Function
2a	Knife	1.078.077.000	Prise light cluster out of beam

1. Unscrew the nuts and bolts securing the upper beam located inside the light cluster seats.2. Remove the upper crossmember from the engine compartment.

1. Remove the radiator and condenser assembly.

1. Undo the fixing nuts (1a) for the cable mounting bracket (1b) and move it aside.2. Release the leads from the fastenings on the radiator supporting crossmember and move them aside.

1. Undo the bolt (1a) fixing the ABS control unit (1b) mounting bracket to the mass supporting crossmember (1c).

- Partly raise the lift.1. Undo the fixing bolts.2. Remove the radiator supporting crossmember.

1. Remove the bands (1a) and release the pipes (1b).2. Disconnect the brake servo vacuum pipe.

- Disconnect the electrical connection for the multi-stage valve.1. Disconnect the electrical connection for the cam angle sensor.2. Disconnect the electrical connection for the air temperature sensor.

1. Undo the fixing nut (1a) and disconnect the positive lead (1b) from battery control unit.

- Undo the bolt fixing the negative lead to the side member.- Disconnect the connection for the ABS sensor.1. Remove the plastic protective caps.2. Undo the fixing nuts.3. Disconnect the cables and move them aside.

	Description	Connector
3	Alternator	A010A

	Description	Connector
3	Alternator	A010B

1. Remove the protective boot, undo the fixing nuts (1a) and disconnect the electrical wiring for the starter mtor (1b).

	Description	Connector
1b	Starter motor	A020A

	Description	Connector
1b	Starter motor	A020B

1. Remove the retaining band (1a) and disconnect the petrol vapour recovery pipe (1b) from the throttle casing.2. Disconnect the pipe on the throttle casing coming from the oil vapour heater.

1. Disconnect the electrical connection for the reversing lights switch (1a) and move the electrical wiring (1b) aside.2. Undo the bolt (2a) and move the earth lead (2b) fastened to the gearbox aside.3. Undo the fixing nuts (3a) and move the clutch actuator cylinder (3b) aside.

1. Disconnect the small pipe from the absolute pressure sensor.2. Disconnect the electrical connection frrom the pressure sensor.3. Disconnect the electrical connection from the fuel vapour enablement solenoid valve.4. Disconnect the rapid connector for the pipe coming from the petrol vapour separator from the active charcoal filter.5. Undo the bolt fixing the active charcoal filter mounting bracket (5a) and remove the active charcoal filter complete with bracket.

1. Disconnect the electrical connections for the injectors.2. Working on the nut, disconnect the coupling for the fuel supply pipe and the single manifold.3. Disconnect the electrical connection from the detonation sensor.

1. Disconnect the electrical connection for the air temperature sensor.2. Disconnect the electrical connection for the throttle position sensor.3. Disconnect the electrical connection for the idle air heater.4. Disconnect the electrical connection for the stepping actuator on the throttle casing.

- Raise the vehicle.1. Disconnect the electrical connections for the Lambda sensors.

1. Disconnect the electrical connection for the speedometer sensor.

- Lower the vehicle.1. Remove the band (1a) and disconnect the fuel return pipe (1b) from the single fuel manifold.

- Raise the vehicle.- Have a suitable container for collecting the transmission fluid ready.1. Undo the plug, using a suitable spanner, and drain the transmission fluid.

	Description	Code	Function
.	Spanner	1.850.182.000	Wrench for slackening/tightening differential fluid plug

1. Disconnect the electrical connection for the left front brake pad wear sensor cable.2. Undo the bolts fixing the brake caliper to the bracket and move it aside without disconnecting the oil pipe.

1. Undo the nut fixing the track rod end to the steering knuckle.2. Extract the track rod end (2b) from the housing in the steering knuckle using the tool (2a).3. Undo the centering pins (3a) and remove the brake disc (3b).

	Description	Code	Function
2a	Head extractor	1.847.038.000	Ball joint removal

1. Undo the bolts fixing the steering knuckle to the shock absorber.2. Undo the fixing bolt.3. Remove the left ABS sensor from the housing and place it outside the work area.

1. Undo the bolts fixing the stub axle to the steering knuckle.

1. Undo the fixing bolt (1a) and remove the casing (1b).

1. Release the inner driveshaft (1a) from the housing on the differential, then remove the driveshaft - steering knuckle assembly (1b).

1. Undo the nut fixing the track rod end to the steering knuckle.2. Extract the track rod end (2b) from the housing in the steering knuckle using the tool (2a).

	Description	Code	Function
2a	Head extractor	1.847.038.000	Ball joint removal

1. Undo the bolts fixing the brake caliper to the bracket and move it aside without disconnecting the oil pipe.

1. Undo the bolts fixing the steering knuckle to the shock absorber.2. Undo the fixing bolt.3. Remove the right ABS sensor from the housing and place it outside the work area.

1. Undo the bolts fixing the stub axle to the steering knuckle.

1. Undo the fastening pins (1a) and remove the brake disc (1b).2. Undo the fixing bolt (2a) and remove the casing (2b).

1. Undo the nuts fixing the intermediate driveshaft to the support.2. Remove the intermediate driveshaft - right driveshaft assembly complete with steering knuckle.

- Position a suitable container for collecting the power assisted steering fluid.1. Undo the connector (1a) fastening the rigid pipe to the pump and move the pipe (1b) aside.

1. Undo the bolt fixing the lower engine support (1a) and undo the bolts fixing the lower engine mounting bracket (1b).2. Move the engine mounting bracket aside.

1. Release the two ends (1a), move the two gear selector and engagement flexible cables (1b) out of the slot in the bracket (1c) and place them outside of the work area.

1. Secure the power unit to a hydraulic lift for its removal.

- Place a support under the power unit to rest the power unit on later on.1. Undo the bolts fixing the flexible mounting to the timing side rigid power unit support.

1. Undo the nuts fixing the gearbox side flexible mounting to the rigid support.

1. Manoeuvre the power unit acting on the hydraulic lift and lower it slowly until it is resting on the support.- Raise the vehicle and extract the support placing it away from the actual vehicle.

Take the greatest care not to damage parts fitted to the vehicle during the removal of the engine.

Refitting ( Removing

) - Support the power unit by means of a hydraulic lift with chains and position the power unit in its compartment on the vehicle.

Take the greatest care not to damage parts fitted to the vehicle during engine installation.

- Tighten the nuts fixing the gearbox side flexible mounting to the rigid support.

	Value - daNm	Fastening	Component	Ø
.	(Rigid mount) 5	Nuts	GEARBOX SIDE RUBBER MOUNT	M10

- Tighten the nut and the two bolts fixing the flexible mounting to the timing side rigid power unit support to torque.

	Value - daNm	Fastening	Component	Ø
.	(Rigid mount on engine) 5	Bolt	FRONT FLEXIBLE MOUNTING BLOCKS, POWER UNIT	M10

	Value - daNm	Fastening	Component	Ø
.	(Rigid mount on engine) 8	Nut	FRONT FLEXIBLE MOUNTING BLOCKS, POWER UNIT	M12

- Remove the hydraulic lift for removing the power unit.- Remove the hydraulic lift for removing the power unit.- Connect both ends of the gear selection and engagement cables and secure them to the mounting bracket.- Position the engine mounting bracket.- Tighten the bolts fixing the lower engine mounting bracket to torque.

	Value - daNm	Fastening	Component	Ø
.	0,4 - 0,8	Bolt	ENGINE ASSEMBLY	M6

- Fit the lower reaction rod in the housing and tighten the bolt fixing it to the engine support to torque.- Fit the intermediate driveshaft - right driveshaft assembly complete with steering knuckle and brake disc.- Tighten the nuts fixing the intermediate driveshaft to the support to torque.- Tighten the bolts fixing the stub axle to the steering knuckle to torque.- Fit the right ABS sensor in its housing and tighten the retaining bolt.- Tighten the bolts fixing the steering knuckle to the shock absorber to torque.

	Value - daNm	Fastening	Component	Ø
.	damper to shock absorber) 19	Bolts	FRONT HUB STRUT	M16

- Fit the brake caliper - bracket assembly and tighten the bolts fixing the bracket to the left disc to torque.

	Value - daNm	Fastening	Component	Ø
.	21	Bolt	FRONT BRAKE CALIPER BRACKET	M16

- Tighten the nut fixing the ball joint to the steering rod to torque.

	Value - daNm	Fastening	Component	Ø
.	6.9	Nut	ADJUSTABLE LINK BALL JOINTS	M16

- Fit the left driveshaft assembly and press fit the inner driveshaft in the housing on the left differential.- Tighten the bolts fixing the stub axle to the left hub to torque.- Fit the right ABS sensor in its housing and tighten the retaining bolt.- Tighten the bolts fixing the steering knuckle to the shock absorber to torque.

	Value - daNm	Fastening	Component	Ø
.	damper to shock absorber) 19	Bolts	FRONT HUB STRUT	M16

- Tighten the nut fixing the ball joint to the steering rod to torque.

	Value - daNm	Fastening	Component	Ø
.	6.9	Nut	ADJUSTABLE LINK BALL JOINTS	M16

- Fit the brake caliper - bracket assembly and tighten the bolts fixing the bracket to the left disc to torque.

	Value - daNm	Fastening	Component	Ø
.	21	Bolt	FRONT BRAKE CALIPER BRACKET	M16

- Connect the engine coolant return pipe to the heater.- Connect the fluid supply pipe to the power assisted steering box and tighten the connector.- Connect the fuel pipes to the return manifold, securing them to the retaining bands.- Connect the gearbox earth lead to the bodyshell.- Connect the electrical connections and reposition the junction unit in the casing.- Fit the engine compartment junction unit protective cover and tighten the fixing bolt.- Connect the electrical connection for the speedometer sensor.- Connect the electrical connection for the reversing light switch.- Connect the electrical connections for the engine management control unit.- Place the clutch release cylinder in the housing and tighten the fixing bolts.- Fit the lower radiator pipe, tighten the bolts fixing it to the bellhousing and connect the hose to the thermostat.- Fit the air filter casing.- Tighten the nuts fixing the filter casing to the mounting bracket.- Connect the electrical connection for the air flow meter.- Fit the filter element in the filter casing and fit the protective cover securing it using the fastenings.- Connect the single-acting valve to the brake servo.- Fit the junctiton unit and solenoid valve mounting bracket and tighten the fixing nuts.- Fit the engine coolant reservoir and connect the coolant hoses.- Fit the radiator supporting crossmember and tighten the fixing bolts to torque.

	Value - daNm	Fastening	Component	Ø
.	8.5	Bolt	COOLANT RADIATOR SUPPORT BEAM	M12

- Connect the electrical wiring for the starter motor.- Connect the alternator electrical wiring.- Connect the electrical connection for the right front wheel A.B.S. sensor.- Tighten the fixing bolt and connect the earth lead to the bodyshell.- Fit the radiator assembly complete with fans.- Fit the engine coolant reservoir and connect the coolant hoses.- Connect the electrical connections for the fans.- Tighten the bolt fixing the side plastic shield.- Fit the upper radiator pipe and connect it to the thermostat and to the radiator.- Connect the lower radiator hose to the rigid section of the pipe.- Fit the upper crossmember in the engine bay complete with front light clusters.- Tighten the retaining bolts and nuts to torque.

	Value - daNm	Fastening	Component	Ø
.	2.9	Nuts	FRONT WING - HEADLAMP SEAT BEAM	M8

- Tighten the nuts fixing the light clusters to the headlamp carrier crossmember.- Connect the left and right front light cluster electrical connection.- Connect the bonnet lid opening cable.- Fit the bonnet catch by screwing in the nuts without tightening.- Fit the cold air intake hose and connect it to the air filter casing and to the cold air intake.- Fit the power assisted steering fluid reservoir.- Connect the oil hoses to the reservoir and tighten the power steering fluid reservoir bracket bolts to the beam.- Fit the crossmember and tighten the fixing bolts to torque. Op. 7210E10 R.R. FRONT BUMPER Op. 7055B64 LH OR RH REFLECTOR(ONE) ON REAR BUMPERS - R R- < R1 > - [On both sides] Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE

Removing ( Refitting

) - Disconnect the negative battery terminal. Op. 7055B54 UNDER-ENGINE GUARD - R R Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R Op. 7055B64 LH OR RH REFLECTOR(ONE) ON REAR BUMPERS - R R Op. 7210E20 R.R. BONNET LID Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE Op. 7210E10 R.R. FRONT BUMPER Op. 7072E32 HEADLAMP HOLDER CROSSMEMBER - R.R.1. Open the bands (1a) securing the heat exchanger hoses (1b) and release them.

1. Open the securing band (1a) and disconnect the recirculation pipe (1b).

1. Release the power assisted steering fluid reservoir pipes (1a) from the fastening spring (1b).

1. Disconnect the fan wiring electrical connections.

	Description	Connector
1	Fan motor	N011

	Description	Connector
1	Engine fan motor 2	N012

1. Undo the fixing bolt (1a) and remove the earth lead on the bodyshell (1b).

	Description	Connector
1b	Battery earth	C001

1. Undo the bolt (1a) fixing the ABS control unit (1b) mounting bracket to the mass supporting crossmember (1c).

1. Undo the nut (1a) fixing the air conditioning pipes mounting bracket (1b).2. Undo the air conditioning pipe connector (2a) from the compressor (2b).

1. Release the wiring (1a) for the retaining springs (1b).

1. Undo the fixing nuts (1a) and disconnect the leads (1b) from the starter motor (1c).

	Description	Connector
1b	Starter motor	A020A

	Description	Connector
1b	Starter motor	A020B

1. Undo the fixing nut.2. Disconnect the earth lead.

	Description	Connector
2	Battery earth	C001

1. Undo the fixing nut (1a) and disconnect the positive lead (1b) from battery control unit.

	Description	Connector
1b	Battery	A001A

1. Undo the fixing bolt (1a) for the earth lead on the bodyshell (1b).

	Description	Connector
1b	Battery earth	C001

1. Undo the nut (1a) fixing the air conditioning pipes mounting bracket (1b).2. Undo the fixing bolt (2a) and remove the return pipe (2b) from the evaporator to the drier filter.

1. Open the retaining bands.2. Disconnect the hoses from the thermostat and drain the coolant collecting it in a suitable container.

1. Undo the bolts (1a) fixing the crossmember (1b) supporting the engine cooling radiator (1c) and heat exchanger (intercooler) (1d).

1. Disconnect the breather pipe (1a) from the expansion tank and open the bands (1b) and disconnect the pipes (1c).2. Undo the fixing nuts (2a) and remove the expansion tank (2b).

1. Open the retaining springs (1a) and disconnect the single-acting valve (1b) on the brake servo, then undo the nuts (1c).2. Remove the protective cover.

1. Undo the nuts (1a) and disconnect the electrical connections (1b) from the heat flange relay (1c).

	Description	Connector
1b	Heat-flange relay	J130A

	Description	Connector
1b	Heat-flange relay	J130B

	Description	Connector
1b	Heat-flange relay	J130C

1. Disconnect the electrical connection (1a) and the pipes (1b) from the EGR solenoid valve.

	Description	Connector
1a	EGR solenoid valve	L030

1. Undo the fixing nuts (1a) and remove the mounting bracket (1b).

1. Undo the fixing bolt (1a) and disconnect the air conditioning rigid pipe (1b).

1. Open the retaining bands.2. Disconnect the pipes connected to the heater.

1. Open the retaining springs (1a) and remove the filter casing cover (1b).2. Remove the filter element.3. Disconnect the electrical connection (3a) and open the securing band (3b).

	Description	Connector
3a	Air flow meter	K041

4. Undo the fixing nuts (4a) and remove the air filter casing (4b).

1. Undo the fixing nuts (1a) and remove the hydraulic clutch actuator cylinder (1b) fom the housing on the gearbox.

1. Undo the retaining bolt.2. Remove the engine bay junction unit protective cover.

1. Disconnect the connectors (1a) and (1b).

	Description	Connector
1a	Engine compartment junction unit	B001C

	Description	Connector
1b	Front/facia coupling	D001A

1. Disconnect the connectors for the engine management control unit.

	Description	Connector
1	Engine management control unit	M010A

	Description	Connector
1	Engine management control unit	M010B

1. Undo the fixing bolt (1a) and disconnect the earth lead on the bodyshell (1b).

	Description	Connector
1b	Battery earth	C001

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

	Description	Connector
1	Reversing lights switch	I020

1. Disconnect the electrical connection (1a) for the multi-stage pressure switch (1b).

	Description	Connector
1a	4 stage pressure switch	K010

1. Disconnect the electrical connector for the right side ABS sensor.

	Description	Connector
1	Right front wheel sensor for ABS	K071

1. Release the two ends (1a), move the two gear selector and engagement flexible cables (1b) out of the slot in the bracket (1c) and place them outside of the work area.

1. Disconnect the electrical connection (1a) for the speedometer sensor (1b) on the gearbox.

	Description	Connector
1a	Speedometer sensor	K084

Op. 1080B62 CATALYTIC CONVERTER - R + R1. Disconnect the oil pressure sensor electrical connection.

	Description	Connector
1	Engine oil pressure sensor	K028

2. Undo the fixing nuts (2a) and disconnect the leads (2b).

	Description	Connector
2b	Alternator	A010A

	Description	Connector
2b	Alternator	A010B

1. Undo the fixing bolt (1a) and release the rigid pipe (1b).2. Undo the fixing bolt (2a) and release the pipe (2b) from the bracket (2c).

1. Open the retaining bands (1a) and disconnect the pipes (1b).2. Remove the power assisted steering fluid reservoir.

1. Undo the bolt fixing the reaction rod to the differential.

- Have a suitable container for collecting the transmission fluid ready.1. Undo the plug, using a suitable spanner, and drain the transmission fluid.

	Description	Code	Function
.	Spanner	1.850.182.000	Wrench for slackening/tightening differential fluid plug

1. Undo the fixing bolts.- Carry out the same operation for both brake calipers and move them outside of the work area.2. Undo the bolts fixing the shock absorber hub.- Carry out the same operation on both shock absorber hubs.

1. Undo the bolt (1a) fixing the ABS sensor (1b) and move it aside.- Carry out the same operation on both front ABS sensors.2. Undo the nut (2a) fixing the track rod end (2b) and extract it using the special tool (2c).- Carry out the same operation on both track rod ends.

1. Undo the fixing nuts (1a) for the intermediate driveshaft (1b).

1. Undo the track control arm stub axle fixing bolts.- Carry out the same operation on both track control arms.2. Remove the steering knuckle hub complete with driveshaft.- Carry out the same operation on both hubs complete with driveshaft and right side intermediate driveshaft.

1. Disconnect the rapid connector pipes (1a) from the fuel filter (1b).

1. Open the retaining band.2. Disconnect the additional heater pipe.

1. Fit the two brackets secured to the engine.2. Position the tool and secure to the brackets positioned previously.3. Secure the tool to a hydraulic lift for supporting and removing the power unit.

	Description	Code	Function
2	Crossmember	1.860.851.003	Power unit anchorage beam

1. Undo the nuts (1a) fixing the gearbox side flexible mounting (1b).

1. Undo the nuts (1a) fixing the timing side flexible mounting (1b).

- Manoeuvre the power unit by tilting and turning. Then adjust the hydraulic lift to move the power unit onto the platform.

Take the greatest care not to damage parts fitted to the vehicle during engine rotation and removal.

Refitting ( Removing

) - Support the power unit by means of a hydraulic lift with chains and position the power unit in its compartment on the vehicle.

Take the greatest care not to damage parts fitted to the vehicle during engine installation.

- Fit the power unit inside the engine compartment.- Tighten the fastenings securing the flexible mounting to the gearbox side rigid support to torque.

	Value - daNm	Fastening	Component	Ø
.	(Flexible block on rigid mount) 5	Nut	GEARBOX SIDE RUBBER MOUNT	M10 X 1.25

- Tighten the fastenings securing the flexible mounting to the timing side rigid support to torque.

	Value - daNm	Fastening	Component	Ø
.	(Flexible block on rigid mount) 8	Bolt	FRONT FLEXIBLE MOUNTING BLOCKS, POWER UNIT	M12 X 1.25

- Remove the tool and hydraulic lift for supporting and removing the power unit.

	Description	Code	Function
.	Crossmember	1.860.851.000	Power unit anchorage beam

- Remove the two brackets secured to the engine.- Connect the additional heater pipe and tighten the retaining band.- Connect the rapid connector pipes to the fuel filter.- Fit the steering knuckle hub complete with driveshaft for both hubs in position.- Tighten the bolts fixing the track control arm stub axle for both track control arms.- Tighten the nuts fixing the intermediate driveshaft to the support to torque.- Fit the steering track rod ends in position and tighten the nut for both to torque.

	Value - daNm	Fastening	Component	Ø
.	6.9	Nut	ADJUSTABLE LINK BALL JOINTS	M16

- Fit the ABS sensor in place and tighten the fixing bolt, carry out the same operation on both sides.- Tighten the bolt fixing the steering knuckle to the shock absorber to torque and carry out the same operation on both hubs.

	Value - daNm	Fastening	Component	Ø
.	(damper strut) 19	Bolt	FRONT HUB STRUT	M16

- Fit the brake caliper-bracket assembly and tighten the bolts fixing the bracket to the disc to torque and carry out the same operation for both brake calipers.

	Value - daNm	Fastening	Component	Ø
.	21	Bolt	FRONT BRAKE CALIPER BRACKET	M16

- Tighten the bolt fixing the reaction rod to the differential to torque.- Tighten the bolt fixing the power assisted steering rigid pipe connector to the power assisted steering pump to torque.- Tighten the bolt fixing the retaining bracket for the power assisted steering fluid rigid pipe.- Connect the electrical connection for the oil pressure sensor.

	Description	Connector
.	Engine oil pressure sensor	K028

- Tighten the fixing nuts and connect the leads to the alternator. Op. 1080B62 CATALYTIC CONVERTER - R + R- Connect the electrical connection for the speedometer sensor on the gearbox.

	Description	Connector
.	Speedometer sensor	K084

- Fit both heads of the gear selection and engagement cables and secure them to the bracket.- Connect the electrical connector for the right side ABS sensor.

	Description	Connector
.	Right front wheel sensor for ABS	K071

- Connect the electrical connection for the multi-stage pressure switch.

	Description	Connector
.	4 stage pressure switch	K010

- Connect the electrical connection for the reversing light switch.

	Description	Connector
.	Reversing lights switch	I020

- Tighten the fixing bolt and connect the earth on the bodyshell.

	Description	Connector
.	Battery earth	C001

- Connect the electrical connections for the engine management control unit.

	Description	Connector
.	Engine management control unit	M010A

	Description	Connector
.	Engine management control unit	M010B

- Connect the electrical connections to the junction unit.

	Description	Connector
.	Engine compartment junction unit	B001C

	Description	Connector
.	Front/facia coupling	D001A

- Position the junction unit in its seat on the mount and fit the protective cover tightening the fixing bolt.- Fit the clutch release cylinder and tighten the retaining bolts to the bracket.- Place the filter casing in position and tighten the fixing nuts.- Fit the filter mass inside the filter casing.- Fit the filter casing cover and close it using the retaining springs.- Connect the electrical connection for the air flow meter.

	Description	Connector
.	Air flow meter	K041

- Fit the heater pipes in place and secure them using the retaining bands.- Fit the air conditioning rigid pipe in place and tighten the bolt.- Fit the EGR solenoid valve and heat-flange relay mounting bracket.- Fit the pipes on the EGR solenoid valve and connect the electrical connection.

	Description	Connector
.	EGR solenoid valve	L030

- Connect the electrical connections to the heat flange relay.

	Description	Connector
	Heat-flange relay	J130A

	Description	Connector
	Heat-flange relay	J130B

	Description	Connector
	Heat-flange relay	J130C

- Fit the EGR solenoid valve and heater plugs control unit cover and tighten the fixing nuts.- Fit the single-acting valve in place on the brake servo and secure it to the retaining springs.- Place the expansion tank in position and tighten the fixing nuts.- Fit the pipes to the tank and secure them using the retaining bands.- Fit the radiator and heat exchanger (intercooler) supporting crossmember and secure it tightening the fixing bolts to torque.

	Value - daNm	Fastening	Component	Ø
.	8.5	Bolt	COOLANT RADIATOR SUPPORT BEAM	M12

- Fit the hoses to the thermostat and secure them with the retaining bands.- Connect the return pipe from the evaporator to the drier filter and secure it using the fixing bolt.- Tighten the fixing bolt and connect the earth on the bodyshell.

	Description	Connector
.	Battery earth	C001

- Connect the positive lead ot the battery control unit and secure it using the fixing nut.- Connect the earth lead to the bodyshell and secure it using the fixing bolt.- Connect the starter motor wiring using the nuts.

	Description	Connector
.	Starter motor	A020A

	Description	Connector
.	Starter motor	A020B

- Fit the wiring on the crossmember and secure it using the retaining springs.- Tighten the connectors for the air conditioning rigid pipes on the compressor.- Secure the compressor rigid pipes to the mounting bracket and tighten the fixing nut.- Tighten the bolt fixing the ABS control unit support to the engine cooling radiator supporting crossmember.- Fasten the earth lead to the bodyshell using the bolt.

	Description	Connector
.	Battery earth	C001

- Connect the electrical connections for the fan.

	Description	Connector
.	Fan motor	N011

	Description	Connector
.	Engine fan motor 2	N012

- Fit the power assisted steering fluid reservoir pipes retaining springs.- Fit the hoses for the heat exchanger (intercooler) in place and secure them with the retaining bands. Op. 7072E32 HEADLAMP HOLDER CROSSMEMBER - R.R. Op. 7210E10 R.R. FRONT BUMPER Op. 7210E20 R.R. BONNET LID Op. 7055B64 LH OR RH REFLECTOR(ONE) ON REAR BUMPERS - R R Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE Op. 0010T10 ENGINE OIL CHECK LEVEL AND TOP UP Op. 0010T20 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY Op. 0010T21 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY

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