323002051 - 1004B12 POWER UNIT WITH MANUAL GEARBOX - R+R FOR VERSIONS WITH A/C

Removing ( Refitting )     Op. 5530B10 BATTERY - 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. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE     Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.     Op. 0010T20 ENGINE COOLANT - CHANGE     Op. 0010T40 CHANGE MANUAL GEARBOX OIL     Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 7210E10 R.R. FRONT BUMPER 1. Undo the brake/clutch fluid reservoir cap and tighten the tool.

Tool	Description	Function	Validity
2000001400	Plug	Brake/ clutch system vacuum

1. Loosen the band (1a) and disconnect the heat exchanger flexible air supply pipe (1b).2. Loosen the band (2a) and disconnect the throttle casing flexible air supply pipe (2b).3. Undo the bolt fixing the heat exchanger rigid air supply pipe to the front end. 1. Undo the bolt (1a) fixing the heat exchanger rigid air inlet pipe (1b) to the front end.2. Undo the bolt (2a) fixing the throttle casing rigid air supply pipe (2b) to the front end.3. Undo the bolts (3a) and remove the air-air heat exchanger assembly (3b). 1. Undo the bolt (1a) fixing the flange for the air conditioning compressor inlet and supply pipes (1b). 1. Disconnect the rapid connector for the radiator lower coolant outlet pipe. 1. Disconnect the electrical connection for the reversing light switch.

	Description	Connector
1	Reversing light switch	See I020 REVERSING LIGHTS SWITCH

2. Undo the bolt (2a) and disconnect the battery earth lead (2b) from the engine.

	Description	Connector
2b	Battery earth on engine	See C002 BATTERY EARTH ON ENGINE

    Op. 5520C20 HEATER PLUGS CONTROL UNIT - R.R 1. Disconnect the rapid connectors for the heater supply and return pipes.2. Disconnect the single-acting valve from the brake servo. 1. Disconnect the gear selector and engagement cables.2. Retract the cursor and disconnect the gear selector and engagement cables from the bracket. 1. Disconnect the fuel supply pipe rapid connector from the fuel filter.2. Disconnect the intermediate rapid connector for the return pipe to the fuel tank. 1. Disconnect the vacuum pipe from the turbocharger vane control actuator.2. Disconnect the hose from the rigid vacuum pipe. 1. Disconnect the electrical connection for the injection control unit.

	Description	Connector
1	Engine management control unit	See M010 ENGINE MANAGEMENT ECU

2. Disconnect the engine coupling.

	Description	Connector
2	Engine cables/engine services cable coupling	See D29 ENGINE CABLES/ENGINE SERVICES CABLE COUPLING

3. Disconnect the electrical connection for the Lambda sensor and open one of the clips to release the wiring.

	Description	Connector
3	Lambda sensor on catalytic converter	See K017 LAMBDA SENSOR ON CATALYZER

1. Disconnect the electrical connection from the turbocharger vane control actuator solenoid valve.

	Description	Connector
1	Turbine variable geometry control solenoid	See L036 TURBINE VARIABLE GEOMETRY CONTROL SOLENOID VALVE

1. Disconnect the electrical connection for the fan.

	Description	Connector
1	Engine fan motor	See N011 FAN MOTOR

2. Disconnect the resistor electrical connection.

	Description	Connector
2	Engine fan adjustment resistance	See O010 ENGINE FAN ADJUSTMENT RESISTANCE - 1

3. Undo the split pins (3a) and remove the fan (3b). 1. Unscrew the nut, fit the tool and disconnect the left steering link from the strut.

Tool	Description	Function	Validity
1871000700	Extractor	Extracting steering rod from strut

2. Undo the bolts securing the left front shock absorber to the strut.3. Undo the bolt and remove the ABS sensor. - Move back the left half-axle from the differential.- Proceed in the same way for the right side. 1. Undo the bolts (1a) securing the intermediate driveshaft support (1b). - Withdraw the right half-axle complete with intermediate driveshaft from the differential and secure to the steering box.1. Support the power unit using a hydraulic hoist (1a) and the tool (1b) connected to the mounting brackets (1c) on the engine.

Tool	Description	Function	Validity
1871001700	Balance	Removing/ refitting power unit

- Postion a suitable footboard beneath the power unit.1. Undo the power steering pump supply pipe connector, remove one of the bands and release the supply pipe.    Op. 1008b10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE     Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE - Slowly lower the power unit with the hydraulic hoist until it rests on the board positioned previously. Refitting ( Removing ) - Fit the support tools to the power unit.- Place the power unit in its housing using the hydraulic hoist.    Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE     Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE - Remove the hydraulic hoist and tool used for supporting the power unit.- Place the left half-axle back in its housing.- Tighten the new bolts fixing the left front shock absorber to the steering knuckle to the recommended torque.

To tighten to torque, position the torque wrench on the nut and not on the bolt.

Component	Fastening	dia	Value (daNm)	Validity
Front shock absorber - strut side	Bolt (to be replaced)	M12	10.3 ÷ 12.6 + 45°

- Connect the left steering links to the knuckle and tighten the nut to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Steering rod to pillar	Nut	M10	3.6 ÷ 4.4

- Connect the ABS sensor to the knuckle and secure it using the bolt.- Proceed in the same way for the right side.- Tighten the bolts fixing the intermdiate driveshaft to the mounting to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Intermediate driveshaft bearing support	Bolt	M8	2.0 ÷ 2.4	1.3 Multijet

- Place the fan in its housing and secure it using the split pins.- Connect the resistor electrical connection.- Connect the electrical connection for the fan.- Connect the electrical connection of the turbocharger vane control actuator solenoid valve.- Connect the electrical connection for the Lambda sensor.- Connect the engine coupling.- Connect the electrical connection for the injection control unit.- Connect the hose to the rigid vacuum pipe.- Connect the vacuum pipe to the turbocharger vane control actuator.- Connect the intermediate rapid connector for the return pipe to the fuel tank.- Connect the fuel supply pipe rapid connector to the fuel filter.- Introduce the two quick-fits for hoses in the openings in the bracket keeping the cursors retracted and inserting them fully into the seats using manual pressure; release the cursors.- Connect the ends of the gear selection-engagement cables to the ends of the gear lever.- Connect the single-acting valve to the brake servo.- Connect the rapid connectors for the heater supply and return pipes.    Op. 5520C20 HEATER PLUGS CONTROL UNIT - R.R - Connect the hose to the coaxial clutch control actuator three-way fitting.- Place the battery earth lead back in position.- Connect the electrical connection for the reversing light switch.- Connect the rapid connector for the lower coolant outlet pipe to the radiator.- Tighten the bolt for the connector for the air conditioning compressor inlet and supply pipes to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Air conditioning pipe connector (compressor/air conditioning) on compressor	Bolt	M6	0.7 ÷ 1.1

- Place the air/air heat exchanger assembly in its housing and secure it using the bolts.- Tighten the bolt fixing the throttle casing rigid air supply pipe to the front end.- Tighten the bolt fixing the heat exchanger rigid air inlet pipe to the front end.- Tighten the bolt fixing the heat exchanger rigid air supply pipe to the front end.- Connect the flexible air supply pipe to the throttle casing.- Connect the flexible air supply pipe to the heat exchanger.    Op. 7210E10 R.R. FRONT BUMPER     Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - 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. 5530B10 BATTERY - R+R     Op. 0010T71 POWER STEERING FLUID CHECK LEVEL AND TOP UP IF NECESSARY     Op. 0010T40 CHANGE MANUAL GEARBOX OIL     Op. 0010T20 ENGINE COOLANT - CHANGE     Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE