323002855 - 1004B10 POWER UNIT WITH MANUAL GEARBOX - R.R

Removing ( Refitting ) - Position the vehicle on a lift.    Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.     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. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE     Op. 0010T71 POWER STEERING FLUID CHECK LEVEL AND TOP UP IF NECESSARY     Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.     Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.     Op. 1088B32 ENGINE COOLING RADIATOR SUPPORTING CROSSMEMBER - R.R.    Op. 7210E10 R.R. FRONT BUMPER     Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.     Op. 1088D09 PIPE BETWEEN SUPPLY RESERVOIR AND ENGINE COOLANT RADIATOR - R.R.    Op. 1088D10 RADIATOR COOLANT OUTLET HOSE - R.R.     Op. 1088D14 UPPER RADIATOR COOLANT INLET HOSE - R.R.     Op. 1048B18 INTERMEDIATE AIR SUPPLY PIPE FROM TURBOCHARGER TO HEAT EXCHANGER - R.R.    Op. 1048B19 TURBOCHARGER AIR OUTLET HOSE -R.R.    Op. 1048B20 AIR SUPPLY HOSE FROM HEAT EXCHANGER TO RIGID PIPE - REPLACE     Op. 1048B25 INTERMEDIATE RIGID PIPE BETWEEN HEAT EXCHANGER AND THROTTLE BODY - R R    Op. 1048B30 AIR SUPPLY HOSE FROM RIGID PIPE TO THROTTLE BODY - REPLACE    Op. 1016A10 SOUND-PROOFING COVER - R.R     Op. 5530B10 BATTERY - R+R     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R.    Op. 1076B74 FRONT EXHAUST SILENCER WITH FLEXIBLE SECTION - R.R.    Op. 4130B34 SUPPLY PIPE FROM FLUID RESEVIOR TO POWER STEERING PUMP - R.R.    Op. 4130B10 POWER STEERING FLUID RESERVOIR - R.R.    Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 2710A14 RIGHT HAND DRIVE SHAFT WITH JOINTS - R+R 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. 1. Loosen the band and disconnect the left driveshaft from the differential internal driveshaft. 1. Unscrew the brake fluid reservoir cap and fit the tool.

Tool	Description	Function	Validity
2000001400	Plug	Brake/ clutch system vacuum

1. Loosen the band and disconnect the brake servo vacuum pipe from the air intake chamber.2. Disconnect the fuel return pipe quick coupling, pressure regulator side.- Open the retaining clips and move the pipes disconnected previously aside. 1. Disconnect the quick coupling for the fuel supply pipe, fuel manifold pipe side.2. Disconnect the quick coupling for the fuel vapour recovery pipe, air chamber side.- Open the retaining clips and move the pipes disconnected previously aside. 1. Undo the bolts and disconnect the coolant fluid pipes from the air conditioning compressor.- Release the high pressure pipe from the retaining clip. 1. Undo the bolt securing the coolant fluid pipe. 1. Undo connector (1a) and disconnect supply pipe (1b) from the pump to the power steering box. 1. Disconnect the engine intermediate coupling.

	Description	Connector
1	Engine cables/engine services cable coupling	See D029 ENGINE CABLES/ENGINE SERVICES CABLE COUPLING

2. Disconnect the electrical connection for the injection/ignition control unit.

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

- Release the wiring from the retaining clips. 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 and disconnect the battery earth lead.

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

3. Push the clip and disconnect the hose from the clutch release coaxial actuator. 1. Disconnect the gear selector and engagement cables.2. Move locking slides (2a) backwards and remove gear selector and engagement cables (2b). 1. Disconnect the quick couplings for the coolant supply and return pipes, heater side.     Op. 1008A45 GEARBOX SIDE RIGID SUPPORT REINFORCEMENT1. Fit the power unit mounting brackets on the gearbox as illustrated. - Undo the retaining bolts and remove the air conditioning compressor pulley guard.1. Fit the power unit mounting bracket on the compressor support as illustrated. 1. Fit the power unit mounting bracket, exhaust manifold side as illustrated. 1. Support the power unit using a hydraulic hoist and the tool connected to the mounting brackets.

Tool	Description	Function	Validity
1871001700	Balance	Removing/ refitting power unit

- Undo the bolts securing the flexible mounting to the gearbox side rigid power unit support, with reference to    Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE     Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE - Position a suitable footboard beneath the power unit.- Move the power unit extremely carefully and support it on the footboard that was put in place earlier.- Ensure that the power unit is well supported and stable on the footboard, then remove the hydraulic hoist.- Raise the vehicle carefully and remove the power unit. Refitting ( Removing ) - Fit the support tools to the power unit.- Place the power unit on a suitable footboard positioned under the vehicle engine compartment.- Carefully lower the vehicle so that the power unit is positioned inside the engine compartment.- Use a hydraulic hoist to raise the power unit and move it to the fitting position.     Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE     Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE - Remove the hydraulic hoist and the equipment used for supporting the power unit.    Op. 1008A45 GEARBOX SIDE RIGID SUPPORT REINFORCEMENT- Position the air conditioning compressor pulley guard and screw in the retaining bolts.- Connect the quick couplings for the coolant supply and return pipes, heater side.- Working in the engine compartment, introduce the two quick-fits for the gear selector and engagement cables in the openings in the bracket, keeping the slides retracted and inserting them fully into the seats using manual pressure until they are attached.Release the slides.- Using manual pressure, connect the ends of the gear selection and engagement cables to the ball joints for the levers on the gearbox.- Adjust the clip and connect the hose to the clutch release coaxial actuator.- Connect the battery earth lead to the gearbox and tighten the bolt.

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

- Connect the electrical connection for the reversing light switch.

	Description	Connector
-	REVERSING LIGHTS SWITCH	See I020 REVERSING LIGHTS SWITCH

- Connect the electrical connection for the injection/ignition control unit.

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

- Connect the engine intermediate coupling.

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

- Secure the wiring to the retaining clips.- Connect the supply pipe from the pump to the power steering box, pump side, and screw in the connector to the recommended torque.- Tighten the bolt securing the coolant fluid pipe to the alternator mounting.- Connect the coolant fluid pipes to the air conditioning compressor and tighten the bolts.- Attach the high pressure pipe to the retaining clip.- Refit the fuel vapour return pipe in its seat, connect the quick coupling, air chamber side, and close the retaining clips.- Refit the fuel vapour supply pipe in its seat, connect the quick coupling, fuel manifold pipe side, and close the retaining clips.- Refit the fuel vapour return pipe in its seat, connect the quick coupling, pressure regulator side, and close the retaining clips.- Place the brake servo vacuum pipe in position, connect it to the air chamber using the band and close the retaining clips.- Connect the left driveshaft to the differential internal driveshaft and tighten the band.- Tighten the new bolts securing the left front shock absorber to the strut to the recommended torque.

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 strut 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 strut and secure it using the bolt.     Op. 2710A14 RIGHT HAND DRIVE SHAFT WITH JOINTS - R+R     Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 4130B10 POWER STEERING FLUID RESERVOIR - R.R.    Op. 4130B34 SUPPLY PIPE FROM FLUID RESEVIOR TO POWER STEERING PUMP - R.R.    Op. 1076B74 FRONT EXHAUST SILENCER WITH FLEXIBLE SECTION - R.R.    Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R.    Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 5530B10 BATTERY - R+R     Op. 1016A10 SOUND-PROOFING COVER - R.R     Op. 1048B30 AIR SUPPLY HOSE FROM RIGID PIPE TO THROTTLE BODY - REPLACE    Op. 1048B25 INTERMEDIATE RIGID PIPE BETWEEN HEAT EXCHANGER AND THROTTLE BODY - R R    Op. 1048B20 AIR SUPPLY HOSE FROM HEAT EXCHANGER TO RIGID PIPE - REPLACE     Op. 1048B19 TURBOCHARGER AIR OUTLET HOSE -R.R.    Op. 1048B18 INTERMEDIATE AIR SUPPLY PIPE FROM TURBOCHARGER TO HEAT EXCHANGER - R.R.    Op. 1088D14 UPPER RADIATOR COOLANT INLET HOSE - R.R.     Op. 1088D10 RADIATOR COOLANT OUTLET HOSE - R.R.     Op. 1088D09 PIPE BETWEEN SUPPLY RESERVOIR AND ENGINE COOLANT RADIATOR - R.R.    Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.     Op. 7210E10 R.R. FRONT BUMPER     Op. 1088B32 ENGINE COOLING RADIATOR SUPPORTING CROSSMEMBER - R.R.    Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.     Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.     Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.     Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 0010T71 POWER STEERING FLUID CHECK LEVEL AND TOP UP IF NECESSARY     Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE     Op. 0010T40 CHANGE MANUAL GEARBOX OIL     Op. 0010T20 ENGINE COOLANT - CHANGE     Op. 0010T64 BRAKE AND/OR CLUTCH FLUID CHECK LEVEL AND TOP UP AS NECESSARY     Op. 0010T65 HYDRAULIC BRAKE SYSTEM - BLEED AIR     Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR     Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. - Remove the vehicle from the lift.