312000268 - 1004B12 POWER UNIT WITH MANUAL GEARBOX - R+R FOR VERSIONS WITH A/C

Removing ( Refitting )     Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE - Position the vehicle on a lift.- Disconnect the negative battery terminal.

	Description	Connector
-	Battery	See A001 BATTERY

- Position a suitable container for collecting the coolant.    Op. 0010T20 ENGINE COOLANT - CHANGE     Op. 5530B10 BATTERY - R+R     Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R     Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R + R    Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 4410D22 BRACKET FIXING FRONT SUSPENSION CROSSMEMBER TO BODYSHELL (ONE), LEFT OR RIGHT - R.R.     Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.     Op. 7210E10 R.R. FRONT BUMPER     Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.     Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.     Op. 1088D10 RADIATOR COOLANT OUTLET HOSE - R.R.     Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.     Op. 5540B70 LEFT FRONT LIGHT CLUSTER WITH DIRECTION INDICATOR - R.R.    Op. 5540B71 RIGHT FRONT LIGHT CLUSTER WITH DIRECTION INDICATOR - R.R.    Op. 7210A02 FRONT END ASSEMBLY - R.R.     Op. 1076B20 REAR EXHAUST SILENCER - R + R     Op. 1076B40 CENTRE EXHAUST PIPE - R.R.     Op. 1008C30 POWER UNIT LOWER REACTION LINK - R.R. 1. Undo ]nut (1a) and disconnect the engine earth braid on gearbox (1b).2. Disconnect reversing switch (2a) and release the associated wiring from retaining bracket (2b).

	Description	Connector
2a	Reversing light switch	See I020 REVERSING LIGHTS SWITCH

1. Unscrew stroke adjustment device (1a) and disconnect clutch cable (1b) from lever (1c). 1. Open retaining bands (1a) and disconnect heater supply and return pipes (1b), heater side. 1. Prise up the head of the gear selector cable.2. Prise up the head of the gear engagement cable.3. Undo retaining bolts (3a) on the gearbox from gear selection-engagement cables mounting bracket (3b). 1. Discharge the fuel pressure from the common rail, using the specific tool.

Tool	Description	Function	Validity
1.870.684.000	Quick coupling connector	Pressure exhaust on single fuel manifold pipe	1.2 8V1.4 16V

- Remove the tool at the end of the operation.

Tool	Description	Function	Validity
1.870.684.000	Quick coupling connector	Pressure exhaust on single fuel manifold pipe	1.2 8V1.4 16V

1. Adjust the quick coupling and disconnect the pipe from the fuel supply to common rail. 1. Open retaining clip (1a) and disconnect fuel vapour enablement solenoid pipe (1b). 1. Undo nut (1a) and disconnect starter motor cable (1b) from battery cable (1c), battery terminal side. 1. Disconnect the front/engine wiring electrical coupling.

	Description	Connector
1	Front/engine coupling	See D004 FRONT/ENGINE COUPLING

1. Undo the nut securing the steering rod head to the wheel hub. 1. Using tool (1a) release steering rod (1b) from wheel hub (1c).

Tool	Description	Function	Validity
1.871.000.700	Extractor	Separation of steering track rod end from steering knuckle	1.2 8V1.4 16V

- Carry out the same operation for the remaining side. 1. Undo bolt (1a) and remove wheel rpm sensor (1b) from its seat.- Carry out the same operation for the remaining side. 1. Release brake pipe (1a) and the ABS electrical wiring and brake wear cable on wheel (1b) from the retaining clips.- Carry out the same operation for the remaining side. 1. Undo the bolts securing the wheel hub to the wheel strut.- Carry out the same operation for the remaining side. 1. Using a special tool, adjust the sliding joint to prise up the driveshaft from its housing on the gearbox.- Carry out the same operation for the remaining side. 1. Position a suitable bracket (1a) on the gear casing and secure it with a bolt (1b).

The anchorage point is close to the gearbox oil filler cap.

1. Position a suitable bracket (1a) on the compressor and secure it with a bolt (1b). - Using a hydraulic lift, install the tool with chains and hooks.

Tool	Description	Function	Validity
1.871.001.700	Balance	Removing-refitting power unit	all versions

1. Anchor the hooks at front points (1a) and (1b). 1. Anchor the hooks at rear points (1a) and (1b). 1. Undo the bolt securing the flexible block to the engine mounting, gearbox side. 1. Undo retaining bolts (1a) and remove engine support (1b), gearbox side. 1. Undo nuts (1a) on body and (1b) on engine mount and remove flexible block (1c), gearbox side. - Remove the engine from its housing with the help of a second mechanic.- Whilst moving the engine, take care not to damage part of the bodywork and/or neighbouring parts.- Once removed, place the engine on a suitable footboard and secure it. Refitting ( Removing ) - Place the engine in position. 1. Position flexible block (1a), engine side, and tighten nuts (1b) to the recommended torque on body and (1c) on engine mounting.

Component	Fastening	dia	Value (daNm)	Validity
Engine side flexible block (on body)	Nut	M10x1.25	5.0	T.i.T

Component	Fastening	dia	Value (daNm)	Validity
Engine side flexible block (on engine)	Nut	M10x1.25	5.0	T.i.T

1. Place engine mounting (1a) in position, gearbox side, and tighten retaining bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side engine mounting (on gearbox)	Bolt	M10x1.25	5.0	T.i.T

1. Tighten the retaining bolt securing the flexible block to the engine mount to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side flexible block (on mounting)	Bolt	M12x1.25	8.0	T.i.T

- Release the engine from the retaining hooks used for removal. 1. Remove the temporary bracket, fitted to the compressor, used as a support point. 1. Remove the temporary bracket, fitted to the gearbox, used as a support point. - Position the driveshaft, right and left, in its housing on the gearbox. 1. Tighten the main retaining bolts securing the wheel hub to the wheel strut, to the recommended torque.- Carry out the same operation for the remaining side.

Component	Fastening	dia	Value (daNm)	Validity
Shock absorber (on steering knuckle)	Nut	M10x1.25	7.5	all versions

- Connect the brake pipe and the ABS electrical wiring and brake wear cable on wheel to the retaining clips.- Carry out the same operation for the remaining side.- Place the wheel rpm sensor in position and tighten the bolts.- Carry out the same operation for the remaining side.- Fit the steering rod to the wheel hub.- Carry out the same operation for the remaining side. 1. Tighten the nut securing the steering rod head to the wheel hub to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Steering track rod end to steering knuckle	Nut	M10x1.25	4.0	all versions

1. Connect the front/engine wiring electrical coupling.

	Description	Connector
1	Front/engine coupling	See D004 FRONT/ENGINE COUPLING

- Connect the starter motor lead to the battery cable and tighten the nut.- Connect the pipe to the fuel vapour enablement solenoid- Connect the pipe from the fuel supply to the common rail.. 1. Position the head of the gear selector cable.2. Position the head of the gear engagement cable.3. Tighten retaining bolts (3a) on the gearbox from the gear selection-engagement cables mounting bracket (3b), to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Join between gearbox and engine (gearbox side)	Bolt	M12x1.25	8.0	all versions

- Connect the heater water supply and return pipes, heater side, and secure them using the retaining bands.- Position the clutch cable on the levers and tighten the stroke adjustment device. 1. Position the engine earth braid on gearbox (1a) and tighten nut (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox earth	Nut	M8	1.5	all versions

2. Connect reversing switch (2a) and release the associated wiring from retaining bracket (2b).

	Description	Connector
2a	Reversing light switch	See I020 REVERSING LIGHTS SWITCH

    Op. 1008C30 POWER UNIT LOWER REACTION LINK - R.R.    Op. 1076B40 CENTRE EXHAUST PIPE - R.R.     Op. 1076B20 REAR EXHAUST SILENCER - R + R     Op. 7210A02 FRONT END ASSEMBLY - R.R.     Op. 5540B71 RIGHT FRONT LIGHT CLUSTER WITH DIRECTION INDICATOR - R.R.    Op. 5540B70 LEFT FRONT LIGHT CLUSTER WITH DIRECTION INDICATOR - R.R.    Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.     Op. 1088D10 RADIATOR COOLANT OUTLET HOSE - R.R.     Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.     Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.     Op. 7210E10 R.R. FRONT BUMPER     Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.     Op. 4410D22 BRACKET FIXING FRONT SUSPENSION CROSSMEMBER TO BODYSHELL (ONE), LEFT OR RIGHT - R.R.     Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R + R    Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R     Op. 5530B10 BATTERY - R+R - Connect the negative battery terminal.

	Description	Connector
-	Battery	See A001 BATTERY

    Op. 0010T20 ENGINE COOLANT - CHANGE     Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE - Remove the vehicle from the lift.