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

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.
DescriptionConnector
1Fan motorN011
DescriptionConnector
1Engine fan motor 2N012
1. Undo the fixing bolt (1a) and remove the earth lead on the bodyshell (1b).
DescriptionConnector
1bBattery earthC001
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).
DescriptionConnector
1bStarter motorA020A
DescriptionConnector
1bStarter motorA020B
1. Undo the fixing nut.2. Disconnect the earth lead.
DescriptionConnector
2Battery earthC001
1. Undo the fixing nut (1a) and disconnect the positive lead (1b) from battery control unit.
DescriptionConnector
1bBatteryA001A
1. Undo the fixing bolt (1a) for the earth lead on the bodyshell (1b).
DescriptionConnector
1bBattery earthC001
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).
DescriptionConnector
1bHeat-flange relayJ130A
DescriptionConnector
1bHeat-flange relayJ130B
DescriptionConnector
1bHeat-flange relayJ130C
1. Disconnect the electrical connection (1a) and the pipes (1b) from the EGR solenoid valve.
DescriptionConnector
1aEGR solenoid valveL030
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).
DescriptionConnector
3aAir flow meterK041
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).
DescriptionConnector
1aEngine compartment junction unitB001C
DescriptionConnector
1bFront/facia couplingD001A
1. Disconnect the connectors for the engine management control unit.
DescriptionConnector
1Engine management control unitM010A
DescriptionConnector
1Engine management control unitM010B
1. Undo the fixing bolt (1a) and disconnect the earth lead on the bodyshell (1b).
DescriptionConnector
1bBattery earthC001
1. Disconnect the electrical connection for the reversing light switch.
DescriptionConnector
1Reversing lights switchI020
1. Disconnect the electrical connection (1a) for the multi-stage pressure switch (1b).
DescriptionConnector
1a4 stage pressure switchK010
1. Disconnect the electrical connector for the right side ABS sensor.
DescriptionConnector
1Right front wheel sensor for ABSK071
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.
DescriptionConnector
1aSpeedometer sensorK084
    Op. 1080B62 CATALYTIC CONVERTER - R + R1. Disconnect the oil pressure sensor electrical connection.
DescriptionConnector
1Engine oil pressure sensorK028
2. Undo the fixing nuts (2a) and disconnect the leads (2b).
DescriptionConnector
2bAlternatorA010A
DescriptionConnector
2bAlternatorA010B
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.
DescriptionCodeFunction
.Spanner1.850.182.000Wrench 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.
DescriptionCodeFunction
2Crossmember1.860.851.003Power 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 - daNmFasteningComponentØ  
.(Flexible block on rigid mount) 5NutGEARBOX SIDE RUBBER MOUNTM10 X 1.25
- Tighten the fastenings securing the flexible mounting to the timing side rigid support to torque.
Value - daNmFasteningComponentØ  
.(Flexible block on rigid mount) 8BoltFRONT FLEXIBLE MOUNTING BLOCKS, POWER UNITM12 X 1.25
- Remove the tool and hydraulic lift for supporting and removing the power unit.
DescriptionCodeFunction
.Crossmember1.860.851.000Power 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 - daNmFasteningComponentØ  
.6.9NutADJUSTABLE LINK BALL JOINTSM16
- 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 - daNmFasteningComponentØ  
.(damper strut) 19BoltFRONT HUB STRUTM16
- 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 - daNmFasteningComponentØ  
.21BoltFRONT BRAKE CALIPER BRACKETM16
- 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.
DescriptionConnector
.Engine oil pressure sensorK028
- 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.
DescriptionConnector
.Speedometer sensorK084
- 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.
DescriptionConnector
.Right front wheel sensor for ABSK071
- Connect the electrical connection for the multi-stage pressure switch.
DescriptionConnector
.4 stage pressure switchK010
- Connect the electrical connection for the reversing light switch.
DescriptionConnector
.Reversing lights switchI020
- Tighten the fixing bolt and connect the earth on the bodyshell.
DescriptionConnector
.Battery earthC001
- Connect the electrical connections for the engine management control unit.
DescriptionConnector
.Engine management control unitM010A
DescriptionConnector
.Engine management control unitM010B
- 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 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.
DescriptionConnector
.Air flow meterK041
- 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.
DescriptionConnector
.EGR solenoid valveL030
- Connect the electrical connections to the heat flange relay.
DescriptionConnector
Heat-flange relayJ130A
DescriptionConnector
Heat-flange relayJ130B
DescriptionConnector
Heat-flange relayJ130C
- 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 - daNmFasteningComponentØ  
.8.5BoltCOOLANT RADIATOR SUPPORT BEAMM12
- 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.
DescriptionConnector
.Battery earthC001
- 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.
DescriptionConnector
.Starter motorA020A
DescriptionConnector
.Starter motorA020B
- 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.
DescriptionConnector
.Battery earthC001
- Connect the electrical connections for the fan.
DescriptionConnector
.Fan motorN011
DescriptionConnector
.Engine fan motor 2N012
- 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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