244000619 - 1004B10 POWER UNIT WITH MANUAL GEARBOX - R + R

Removing ( Refitting ) - Position the vehicle on a lift.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.
1. 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. Remove the air delivery sleeve to the air-air heat exchanger (intercooler).
- Raise the vehicle.1. Disconnect the oil pipe from the power steering pump and drain the power steering system into a suitable container.- Reconnect the power steering fluid pipe.
1. Undo the bolts securing the power steering fluid reservoir bracket.2. Disconnect the fluid pipes from the reservoir.3. Remove the power assisted steering fluid reservoir complete with bracket.
1. Remove the second section of the air delivery sleeve to the air-air heat exchanger (intercooler).
1. Disconnect the right front light cluster electrical connection.
DescriptionConnector
1Right headlampF011
2. Disconnect the collars at both ends and remove the air hose from intercooler to intake manifold.
- Arrange a container beneath the engine to recover the engine coolant.1. Disconnect lower pipe (1a) and upper pipe (1b) from the radiator.2. Disconnect the pipes from the rigid pipes.3. Remove the lower and upper radiator pipes.
1. Undo the fixing bolts.2. Remove the front grille.
1. Undo the retaining nuts.2. Disconnect the bonnet lid opening cable.3. Remove the bonnet lid catch.- Release the cable from the retaining collars in the engine bay.
    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- [From both sides]    Op. 7210E10 R.R. FRONT BUMPER1. Disconnect the recirculation pipe from the engine coolant reservoir.
1. Disconnect the fan electrical connections and release the wiring from the retaining collars.
DescriptionConnector
1Fan motorN011
DescriptionConnector
1Engine fan motor 2N012
2. Unscrew the upper radiator/fan unit and intercooler retaining bolts.- Raise the vehicle and release the lower radiator support beam from the attached wiring.- Arrange an appropriate hydraulic safety lift beneath the beam.3. Unscrew the bolts securing the lower beam to the struts.4. With the aid of a second operator, remove the assembly from the lower part of the engine bay.
- Disconnect the left front light cluster electrical connection.
DescriptionConnector
.Left headlampF010
1. Unscrew the upper light cluster retaining bolt.2. Use a suitable tool (2a) to prise light cluster (2b) from its seat, while releasing the pin from the wing.- Repeat the same operation on the right front light cluster.
DescriptionCodeFunction
2aKnife1.078.077.000Prise 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 beam from the engine bay complete with front light clusters.
1. Undo the fixing bolts.2. Remove the crossmember.
1. Disconnect the band retaining the coolant pipe on the reservoir to the cylinder head.2. Remove the electrical connection from its seat on the reservoir.3. Undo the nuts fixing the expansion tank.4. Disconnect the water pump coolant supply pipe (4a) and remove the expansion tank (4b).
1. Undo the fixing bolts (1a) and remove the protective cover (1b) for the heater plugs control unit.2. Disconnect the electrical connections for the heater plugs control unit (2a) and (2b) and the control unit positive electrical connection (2c).
DescriptionConnector
2aHeater plugs control unitM015A
DescriptionConnector
2bHeater plugs control unitM015B
DescriptionConnector
2cHeater plugs control unitM015C
3. Undo the fixing nuts (3a) and remove the mounting bracket (3b) complete with heater plugs control unit.
1. Disconnect coolant delivery line (1a) and return line (1b) from the heater.
1. Disconnect the band fastening the air supply hose to the turbocharger.2. Disconnect the vapour recovery pipe from the air supply hose to the turbocharger.3. Disconnect the band from the air filter casing (3a) and remove the air supply hose to the turbocharger (3b).
1. Undo bolts (1a) and remove the clutch release cylinder (1b) from its housing.
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 engine management unit electrical connections.
DescriptionConnector
1Engine management control unitM010A
DescriptionConnector
1Engine management control unitM010B
1. Disconnect the wiring from the starter motor.
DescriptionConnector
1Starter motorA020A
DescriptionConnector
1Starter motorA020B
1. Disconnect the electrical connection for the reversing light switch.
DescriptionConnector
1Reversing lights switchI020
1. Disconnect the electrical connection for the voltage regulator on the alternator.
DescriptionConnector
1AlternatorA010A
- Disconnect the remaining electrical wiring from the alternator.
DescriptionConnector
.AlternatorA010B
1. Undo the bolts fixing the air filter casing mounting bracket.2. Undo the bolt fixing the air filter casing to the bracket joined to the windscreen washer fluid reservoir.3. Remove the air filter casing from the engine compartment.
1. Disconnect the electrical connection for the speedometer sensor.
DescriptionConnector
1Speedometer sensorK084
1. Undo the retaining bolt.2. Remove the engine bay junction unit protective cover.
1. Release the junction unit from its seat in the mount and disconnect electrical connections (1a) and (1b).
DescriptionConnector
1aEngine compartment junction unitB001C
DescriptionConnector
1bFront/facia couplingD001A
1. Disconnect the brake servo vacuum pipe from the vacuum unit
1. Disconnect the two rapid connectors for the fuel supply and return pipes.
- Have a suitable container for collecting the transmission fluid ready.1. Undo the plug, using a suitable spanner, and drain the transmission fluid.
DescriptionCodeFunction
.Spanner1.850.182.000Wrench for slackening/tightening differential fluid plug
- Position a hydraulic column lift under the track control arm to work safely.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).
DescriptionCodeFunction
2aHead extractor1.847.038.000Ball joint removal
1. Undo the fixing bolts (1a) and remove the brake caliper-bracket assembly (1b) from the brake disc without disconnect the fluid pipes.
1. Remove the staking and undo the right hub nut.2. Undo the bolts fixing the steering knuckle to the shock absorber.3. Undo the nuts (3a) and remove the right driveshaft (3b) complete with intermediate shaft (3c).
1. Undo the fixing bolts (1a) and remove the left brake caliper-bracket assembly (1b) from the brake disc without disconnect the fluid pipes.
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).
DescriptionCodeFunction
2aHead extractor1.847.038.000Ball joint removal
3. Undo the bolts fixing the steering knuckle to the shock absorber.
1. Release the inner driveshaft (1a) from the differential and move the right driveshaft (1b) away from the work area.
1. Undo the fixing nuts (1a) and separate the ridid middle section of the exhaust pipe from the turbocharger hose flange (1b).2. Undo the bolts fixing the rear flange (2a) and remove the rigid middle section (2b) of the exhaust pipe.
1. Undo the bolt securing the lower reaction rod to the suspension crossmember.2. Undo the bolt securing the lower reaction rod to the mounting bracket on the gearbox.3. Remove the lower reaction link.
1. Disconnect the return pipe from the power steering pump.2. Open collar (2a) and disconnect power steering pump delivery pipe (2b) to the steering box.
- Lower the vehicle.1. Undo retaining bolts (1a) and remove the wiring channel (1b).
1. Loosen the bolt fixing the collar joining the rigid section of the intake pipe to the turbocharger.2. Undo the nut (2a) fixing the pipe to the bracket on the cylinder head and the bolt (2b) fixing the connector for the engine oil vapour pipe.3. Remove the rigid section of the air pipe from the turbocharger.
1. Undo the fixing bolts.2. Remove the engine oil vapour separator.
1. Fit the two brackets secured to the cylinder head.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.
DescriptionCodeFunction
2Crossmember1.860.851.003Power unit anchorage beam
1. Undo the nut and both bolts securing the flexible mount to the timing side rigid power unit mount.
1. Undo the bolts fixing the gearbox side flexible mounting to the rigid support.
1. 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.
- Tighten the bolts fixing the gearbox side flexible mounting to the rigid support.
Value - daNmFasteningComponentØ  
.(Rigid mount) 5BoltGEARBOX SIDE RUBBER MOUNTM10
- Tighten the nut and the two bolts fixing the flexible mounting to the timing side rigid power unit support to torque.
Value - daNmFasteningComponentØ  
.(Rigid mount on engine) 5BoltFRONT FLEXIBLE MOUNTING BLOCKS, POWER UNITM10
Value - daNmFasteningComponentØ  
.(Rigid mount on engine) 8NutFRONT FLEXIBLE MOUNTING BLOCKS, POWER UNITM12
- Remove the tool and hydraulic lift for supporting and removing the power unit.
DescriptionCodeFunction
.Crossmember1.860.851.003Power unit anchorage beam
- Remove the two brackets secured to the cylinder head.- Fit the engine oil vapour separator and tighten the retaining bolts.- Fit the rigid section of the air pipe from the turbocharger.- Tighten the retaining bolt for the turbocharger union collar to torque.- Tighten the bolt securing the engine oil vapour recovery pipe connection and nut securing the piping to the cylinder head.- Positin the wiring channel and secure to the engine bulkhead using retaining bolts.- Raise the vehicle.- Connect the delivery and return pipes to the power steering pump.- Fit the lower reaction rod in the housing and tighten the bolt fixing the suspension crossmember to torque.- Tighten the nut fixing the reaction rod to the gearbox to torque.- Fit the rigid middle section of the exhaust pipe and tighten the bolts securing it to the rear section to torque.
Value - daNmFasteningComponentØ  
.(Front section flange) 2.6BoltsREAR SILENCER EXHAUSTM8
- Tighten the nuts securing the front section of the exhaust pipe to the turbocharger to torque.
Value - daNmFasteningComponentØ  
.(Flange on turbocharger) 2.6NutREAR SILENCER EXHAUSTM8
- Fit the inner driveshaft in the housing on the differential for the right driveshaft.- Tighten the bolts fixing the steering knuckle to the shock absorber to torque.
Value - daNmFasteningComponentØ  
.(damper strut) 19BoltFRONT HUB STRUTM16
- Tighten the nut fixing the ball joint to the steering rod to torque.
Value - daNmFasteningComponentØ  
.6.9NutADJUSTABLE LINK BALL JOINTSM16
- Fit the brake caliper - bracket assembly and tighten the bolts fixing the bracket to the left disc to torque.
Value - daNmFasteningComponentØ  
.21BoltFRONT BRAKE CALIPER BRACKETM16
- Fit the right driveshaft - intermediate driveshaft assembly.- Tighten the nuts fixing the intermediate driveshaft to the support to torque.- Tighten the bolts fixing the steering knuckle to the shock absorber to torque.
Value - daNmFasteningComponentØ  
.(damper strut) 19BoltsFRONT HUB STRUT-
- Tighten the nut fixing the ball joint to the steering rod to torque.
Value - daNmFasteningComponentØ  
.6.9NutADJUSTABLE LINK BALL JOINTSM16
- Fit the brake caliper - bracket assembly and tighten the bolts fixing the bracket to the disc to torque.
Value - daNmFasteningComponentØ  
.21BoltFRONT BRAKE CALIPER BRACKETM16
1. Use a hammer and chisel to stake the wheel hub drive shaft retaining nut as shown in the figure.- The figure below refers to the 15 quintal version.
Value - daNmFasteningComponentØ  
.37NutFRONT HUBS COMPLETE WITH BEARINGM28
- The figure below refers to the 1800 kg version.
Value - daNmFasteningComponentØ  
.42NutFRONT HUBS COMPLETE WITH BEARINGM33
- Connect the fuel delivery line to the pressure pump and the fuel return line to the tank to the quick-release fittings on the return manifold.- Connect the brake servo vacuum pipe to the vacuum unit- Connect the electrical connections to the junction unit.
DescriptionConnector
.Engine compartment junction unitB001C
DescriptionConnector
.Front/facia couplingD001A
- Position the junction unit in its seat on the mount and fit the protective cover.- Disconnect the electrical connection from the speedometer sensor.
DescriptionConnector
.Speedometer sensorK084
- Fit the air filter casing in the engine compartment.- Tighten the bolt fixing the air filter casing to the bracket joined to the windscreen washer fluid reservoir.- Tighten the bolts fixing the air filter casing mounting bracket.- Connect the voltage regulator electrical connection and the remaining alterantor wiring.
DescriptionConnector
.AlternatorA010A
DescriptionConnector
.AlternatorA010B
- Disconnect the electrical connection for the reversing lights switch.
DescriptionConnector
.Reversing lights switchI020
- Connect the wiring to the starter motor.
DescriptionConnector
.Starter motorA020A
DescriptionConnector
.Starter motorA020B
- Connect the electrical connections for the engine management control unit.
DescriptionConnector
.Engine management control unitM010A
DescriptionConnector
.Engine management control unitM010B
- Fit both heads of the gear selection and engagement cables and secure them to the bracket.- Fit the clutch release cylinder and tighten the retaining bolts to the bracket.- Fit the air supply hose to the turbocharger and connect the two ends to the filter casing and to the actual turbocharger.- Connect the vapour recovery pipe to the air supply hose to the turbocharger.- Connect coolant delivery line and return line to the heater.- Fit the mounting bracket complete with heater plugs control unit.- Tighten the nuts fixing the control unit to the bodyshell.- Connect the electrical connections for the heater plugs control unit.
DescriptionConnector
.Heater plugs control unitM015A
DescriptionConnector
.Heater plugs control unitM015B
DescriptionConnector
.Heater plugs control unitM015C
- Fit the protective cover for the heater plugs control unit and tighten the bolts fixing it to the mounting bracket underneath.- Fit the engine coolant reservoir and tighten the nuts fixing it to the bodyshell.- Connect the coolant delivery pipe to the pump.- Fasten the electrical connection in the housing on the tank.- Connect the band retaining the coolant pipe to the cylinder head.- Fit the crossmember and tighten the crossmember to torque.- Fit the upper crossmember in the engine bay complete with front light clusters.- Tighten the retaining bolts and nuts to torque.
Value - daNmFasteningComponentØ  
.2.9NutsFRONT WING - HEADLAMP SEAT BEAMM8
- Secure the front light clusters to the crossmember.- Tighten the upper light cluster retaining bolts to the crossmember.- Connect the left front light cluster electrical connection.
DescriptionConnector
.Left headlampF010
- With the aid of a second operator, fit the lower crossmember and radiator assembly from underneath the engine bay.- Tighten the bolts securing the radiator mounting beam to torque.
Value - daNmFasteningComponentØ  
.8.5BoltCOOLANT RADIATOR SUPPORT BEAMM12
- Secure the wiring to the lower radiator beam and fasten with collars.- Tighten the upper bolts securing the radiator brackets and fans to the crossmember.
Value - daNmFasteningComponentØ  
.2BoltENGINE RADIATORM8
Value - daNmFasteningComponentØ  
.2BoltENGINE RADIATOR FAN/SM8
- Connect the fan electrical connections and release the wiring from the retaining collars.
DescriptionConnector
.Fan motorN011
DescriptionConnector
.Engine fan motor 2N012
- Connect the recirculation pipe to the engine coolant reservoir.    Op. 7210E10 R.R. FRONT BUMPER    Op. 7055B64 LH OR RH REFLECTOR(ONE) ON REAR BUMPERS - R R- [From both sides]    Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R    Op. 7055B54 UNDER-ENGINE GUARD - R R- Connect the bonnet lid opening cable.- Fit the bonnet catch by screwing in the bolts without tightening.- Fit the front grille and tighten the bolts.- Fit the lower and upper radiator pipes and connect them to the ends of the rigid pipes and radiator.- Fit the air hose from intercooler to intake manifold.- Connect the right front light cluster electrical connection.
DescriptionConnector
.Right headlampF011
- Fit the second section of the air delivery sleeve to the air-air heat exchanger (intercooler).- Fit the power steering fluid reservoir complete with bracket.- Connect the oil hoses to the reservoir and tighten the power steering fluid reservoir bracket bolts to the beam.- Fit the air delivery sleeve to the air-air heat exchanger (intercooler).- Fit the cold intake and intake hose assembly in the engine compartment and tighten the bolts fixing the cold air intake to the upper headlamp holder crossmember.- Connect the intake hose to the air filter casing.- Fit the bonnet lid with the help of a second mechanic, taking care not to damage the paintwork.- Screw in the bolts securing the bonnet lid to the bodyshell without tightening them.- Connect the windscreen washer jet pipe.- Adjust the bonnet lid    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    Op. 0010T70 POWER ASSISTED STEERING FLUID - REPLACE    Op. 7055B54 UNDER-ENGINE GUARD - R R