323002856 - 1004B24 POWER UNIT WITH MANUAL GEARBOX WITH HYDRAULIC SELECTION - R.R.

Removing ( Refitting ) - Position the vehicle on a lift.    Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.     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. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R.    Op. 1076B20 REAR EXHAUST SILENCER - R + R     Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R     Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 7210E10 R.R. FRONT BUMPER 1. Loosen the band and disconnect the rigid intermediate pipe between the heat exchanger and the throttle body, throttle body side.2. Undo the fixing nut on the engine block.- Release the rigid intermediate pipe from the vehicle.3. Undo the bolts (3a) and disconnect the pipe (3b) from the turbocharger.4. Undo the bolts (4a) and (4b) securing the heat exchanger rigid inlet and outlet pipes.5. Unscrew the radiator supporting crossmember bolts.6. Undo the bolts fixing the heat exchanger.7. Remove the heat exchanger complete with radiator supporting crossmember and pipes. 1. Undo the bolt (1a) and disconnect the pipes (1b) from the air conditioning compressor. 1. Loosen the bands and disconnect the upper hose (1a), the lower hose (1b) and the pipe from the supply reservoir (1c) from the radiator. 1. Undo the nut (1a) and disconnect the battery earth lead (1b) from the engine.

	Description	Connector
1b	BATTERY EARTH ON ENGINE	See C002 BATTERY EARTH ON ENGINE

- Disconnect the electrical connection for the robotized gearbox control unit, vehicle wiring side.

	Description	Connector
-	ROBOTIZED GEARBOX CONTROL UNIT	See M054 ROBOTIZED TRANSMISSION CONTROL UNIT

- Disconnect the electrical connections for the heater plugs control unit, engine wiring side.

	Description	Connector
-	GLOW PLUG PREHEATING CONTROL UNIT	See M015 PLUG PREHEATING CONTROL UNIT

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 fuel supply pipe rapid connector from the fuel filter.2. Disconnect the intermediate rapid connector for the return pipe to the fuel tank.3. Loosen the band and disconnect the degassing pipe from the engine coolant reservoir.- Undo the cap and, using a syringe, draw off the power assisted stering system fluid from the reservoir; collect the fluid in a suitable container.4. Loosen the band and disconnect the pipe from the reservoir to the power steering pump, power assisted steering pump side.5. Disconnect the engine coupling.

	Description	Connector
-	ENGINE CABLE/ENGINE SERVICE CABLE COUPLING	See D029 ENGINE CABLES/ENGINE SERVICES CABLE COUPLING

6. Connect the electrical connection for the injection control unit.

	Description	Connector
-	ENGINE MANAGEMENT CONTROL UNIT	See M010 ENGINE MANAGEMENT ECU

7. Disconnect the electrical connection for the Lambda sensor.

	Description	Connector
-	FUEL PUMP AND LEVEL GAUGE	See N040 FUEL PUMP AND LEVEL GAUGE

8. Undo the connector and disconnect the supply pipe from the pump to the power assisted steering box, pump side. 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 from the turbocharger vane control actuator solenoid valve.

	Description	Connector
1	VARIABLE GEOMETRY TURBINE CONTROL FAN	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 HEATING COIL - 1	See O010 ENGINE FAN ADJUSTMENT RESISTANCE - 1

3. Remove the circlips (3a) and remove the fan (3b). - Work on both sides of the vehicle.1. Unscrew the nut, fit the tool and disconnect the steering link from the strut.

Tool	Description	Function	Validity
1871000700	Extractor	Extracting steering rod from strut

2. Undo the bolts securing the front shock absorber to the steering knuckle.3. Undo the bolt and remove the ABS sensor. 1. Undo the bolts (1a) securing the intermediate driveshaft support (1b).- Retract the brake caliper and extract the driveshafts from the differential.- Secure the driveshafts to the bodyshell. - Release the remaining fastenings for the pipes/connections.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. - Undo the bolts fixing the gearbox side flexible mounting to the rigid support.- Undo the nuts fixing the timing side flexible mounting to the rigid support.- Slowly lower the power unit with the hydraulic hoist until it rests on the board positioned previously.- Remove the hydraulic lift.- Raise the vehicle carefully and remove the power unit. Refitting ( Removing ) - Position the power unit and lower the vehicle.- Support the power unit using a hydraulic hoist and the special tool connected to the brackets on the engine.

Tool	Description	Function	Validity
1871001700	Balance	Removing/ refitting power unit

- Place the power unit in position and tighten the nuts and bolts securing the gearbox and timing side flexible mountings to the rigid supports, as described in the procedures:    Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE and    Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE - Remove the hydraulic hoist and tool used for supporting the power unit.- Work on both sides of the vehicle.- Fit the driveshaft in place on the differential.- Tighten the new bolts securing the front shock absorber to the strut 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 steering link 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.- 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

- Refit the fan in its seat and secure with the circlips.- Connect the pipe from the power assisted steering pump, pump side and tighten the band.- Connect the delivery pipe to the power steering pump and tighten the connector.- Connect the degassing pipe to the engine coolant reservoir and tighten the band.- Connect the resistor electrical connection.

	Description	Connector
-	ENGINE FAN ADJUSTMENT HEATING COIL - 1	See O010 ENGINE FAN ADJUSTMENT RESISTANCE - 1

- Connect the electrical connection for the fan.

	Description	Connector
-	ENGINE FAN MOTOR	See N011 FAN MOTOR

- Connect the electrical connection of the turbocharger vane control actuator solenoid valve.

	Description	Connector
-	VARIABLE GEOMETRY TURBINE CONTROL SOLENOID VALVE	See L036 TURBINE VARIABLE GEOMETRY CONTROL SOLENOID VALVE

- Connect the electrical connection for the Lambda sensor.

	Description	Connector
-	LAMBDA SENSOR	See K040 LAMBDA SENSOR

- Connect the engine coupling.

	Description	Connector
-	ENGINE CABLE/ENGINE SERVICE CABLE COUPLING	See ENGINE CABLES/ENGINE SERVICES CABLE COUPLING

- Connect the electrical connection for the injection control unit.

	Description	Connector
-	ENGINE MANAGEMENT CONTROL UNIT	See M010 ENGINE MANAGEMENT ECU

- 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.- Connect the single-acting valve to the brake servo.- Connect the rapid connectors for the heater supply and return pipes.- Secure the electrical connection for the robotized gearbox control unit.

	Description	Connector
-	ROBOTIZED GEARBOX CONTROL UNIT	See M054 ROBOTIZED TRANSMISSION CONTROL UNIT

- Connect the electrical connections for the heater plugs control unit.

	Description	Connector
-	GLOW PLUG PREHEATING CONTROL UNIT	See M015 PLUG PREHEATING CONTROL UNIT

- Connect the upper hose, the lower hose and the supply reservoir pipe to the radiator and tighten the bands.- Connect the battery earth lead and tighten the nut.

	Description	Connector
-	BATTERY EARTH ON ENGINE	See C002 BATTERY EARTH ON ENGINE

- Connect the pipes to the compressor and tighten the fixing bolt.- Place the heat exchanger in position complete with radiator supporting crossmember and pipes.- Tighten the bolts fixing the radiator supporting crossmember and pipes.- Tighten the bolts fixing the heat exchanger.- Place the heat exchanger inlet and outlet pipes in position and tighten the bolts securing the rigid pipes.- Connect the pipe to the turbocharger and tighten the fixing bolts.- Connect the rigid intermediate pipe between the heat exchanger and the throttle body and tighten the band.- Tighten the fixing nut on the engine block.    Op. 7210E10 R.R. FRONT BUMPER     Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R     Op. 1076B20 REAR EXHAUST SILENCER - R + R     Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - 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     Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. - Remove the vehicle from the lift.