74556 - 1004B10 POWER UNIT with manual gearbox - R.R.

Removing ( Refitting ) - Position the vehicle on a lift.- Make sure that the ignition key is in the OFF position, then open the boot, remove the cover on the left hand side and disconnect the negative battery lead.1. Undo the bolt (1a) fixing the steering column (1b) to the steering box pinion.2. Undo the fixing nuts (1a) and remove the protective boot (2b) from the vehicle floor.     See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.    See in Op. 5040A10 Air conditioning coolant circuit - Drying and Repressurizing    See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.- Position a suitable container for collecting the engine coolant.- Raise the lift.1. Disconnect the lower radiator pipe.

    See in Op. 4450B02 Left FRONT WHEEL (one) - R.R.    See in Op. 4450B04 Right FRONT WHEEL (one) - R.R.- Raise the lift    See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.    See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.    See in Op. 7210E10 FRONT BUMPER- Lower the lift    See in Op. 1048B44 RIGID air supply PIPE from heat exchanger to intake manifold - R.R.    See in Op. 1016A40 Ignition COIL COVER on cylinder head - R.R.    See in Op. 1048A50 air inlet pipe to turbocharger - r + r    See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R.    See in Op. 1048A10 COMPLETE AIR FILTER -R.R.    See in Op. 1048A54 TURBOCHARGER air inlet HOSE from rigid pipe - R.R.1. Undo the fixing nuts (1a) and remove the bonnet lock (1b) from the housing in the crossmember.2. Undo the lower bolt (2a) and remove the lock reinforcement bracket (2b).

1. Undo the retaining bolts.2. Remove the front crossmember.

1. Undo the fixing bolt on the compressor (1a) and the bolt fixing the flange (1b) and remove the climate control system coolant return pipe (1c).

- Disconnect the electrical connections for the horns.

	Description	Connector
.	High tone horn	P010

	Description	Connector
.	High tone horn	P010

	Description	Connector
.	Low tone horn	P011

	Description	Connector
.	Low tone horn	P011

1. Disconnect the electrical connections for the engine cables/fan-radiator cables coupling.

	Description	Connector
1a	Front/radiator coupling	D009A

	Description	Connector
1b	Front/radiator coupling	D009B

2. Disconnect the electrical connection from the air conditioning system pressure switch.

	Description	Connector
2	Linear sensor (for climate control)	K120

3. Undo the bolt fixing the air conditioning system pipe to the drier filter.

1. Undo the nut (1a) and disconnect the earth lead (1b) from the bodyshell.

1. Lift up the retaining spring (1a) and release the oil pipe (1b) for the hydraulic clutch release cylinder.

1. Open the protective cover (1a), loosen the nut (1b) and disconnect the starter motor supply lead (1c).

	Description	Connector
1c	Starter motor	A020A

1. Undo the three nuts (1a) fastening the flexible cables mounting bracket to the gearbox and the nut (1b) securing the starter motor earth lead mounting bracket.2. Press the two tabs (2a) and lift up the head (2b) until it is released from the ball joint.- Carry out this operation on the other flexible cable.3. Position the bracket, complete with flexible cables, outside of the working area.

1. Disconnect the electrical connection for the engine management control unit.

	Description	Connector
1	Engine management control unit	M010A

2. Disconnect the electrical connection from the fuel vapour recovery solenoid valve.

	Description	Connector
2	Fuel vapour recovery solenoid valve	L010

3. Disconnect the vacuum intake pipe from the brake servo.4. Disconnect the fuel vapour intake pipe from the intake chamber.

1. Disconnect the engine coolant supply pipe (1a) and return pipe (1b) from the passenger compartment heater.

1. Release the fastening band (1a) and remove the turbocharger engine coolant return pipe (1b).2. Disconnect the fuel supply pipe (2a) and the return pipe (2b) from the fuel manifold.3. Release the fuel pipes from the band on the intake chamber.4. Disconnect the electrical connection for the engine/dashboard cable loom coupling.

	Description	Connector
4	Front/dashboard coupling	D001

1. Undo the bolt (1a), loosen the bolt (1b) and rotate the reaction rod connecting rod.

1. Release the fastening band (1a) and disconnect the engine coolant pipe (1b) on the cylinder head.

1. Remove the protective cover (1a), undo the power assisted steering fluid reservoir cap (1b) and draw off the fluid in the reservoir using a special syringe.

1. Disconnect the supply pipe from the reservoir to the power assisted steering pump.2. Disconnect the fluid return pipe from the power assisted steering box.

1. Loosen the bolts fixing the brake caliper to the hub.2. Remove the brake pipe retaining band.3. Disconnect the electrical connection for the brake pad wear sensor.

	Description	Connector
3	Left brake pad wear sensor (switch)	K020

	Description	Connector
3	Right brake pad wear sensor (switch)	K021

Take great care not to damage the brake fluid pipes and the electrical leads for the sensors, if necessary, release them from the bands on the steering knuckles.

- Undo the retaining bolt and remove the ABS flywheel sensor.1. Undo the retaining bolt.2. Undo the upper fixing nut (2a) and disconnect the end of the anti-roll bar connecting rod (2b).3. Undo the fixing nut (3a) and move the accelerometer sensor (3b), complete with mounting bracket, aside.

1. Undo the fixing bolts.2. Separate the two heads from the suspension housing.

3. Remove the fixing bolts (3a) and remove the brake caliper (3b).

- Repeat the operations on the brake caliper and the suspension damper on the opposite side.- Disconnect the electrical connection for the bodyshell accelerometer sensor (left side).

	Description	Connector
.	Left front vertical acceleration sensor	K006

	Description	Connector
.	Right front vertical acceleration sensor	K007

    See in Op. 1076B70 EXHAUST PIPE BETWEEN PRECATALYZER AND CATALYZER - R.R.1. Undo the nut fixing the engine support to the flexible mounting.2. Undo the bolts fixing the engine support to the gearbox.3. Remove the engine support from the engine compartment.4. Disconnect the electrical connection on the gearbox for the reverse gear engagement sensor.

1. Position the tool for supporting the power unit-chassis assembly (1a), complete with hydraulic jack, under the housings in the power unit support frame (1b).

	Description	Code	Function
1a	Power unit support frame	1.870.835.000	Removing power unit-chassis

1. Undo the bolts fixing the front supports.2. Undo the bolts (2a) fixing the rear supports and the bolts (2b) fixing the brackets.3. Remove the brackets.

- Lower the power unit-chassis assembly moving it away from the vehicle.1. Disconnect the pipes from the power assisted steering system cooling coil.2. Disconnect the heat exchanger air intake pipe.3. Release the supercharging by-pass solenoid valve from the bracket.

- Remove the engine cooling radiator complete with fan, heat exchanger, condenser and power assisted steering system cooling coil.1. Disconnect the band fastening the left driveshaft to the intermediate driveshaft and release the driveshaft.2. Disconnect the power steering fluid supply pipe.

1. Disconnect the band fastening the right driveshaft to the differential and release the driveshaft.

- Remove the engine support connecting rod.1. Fit a suitable size bracket on the timing side.

Position suitable to washers to prevent damage to the flexible mounting.

2. Fit a suitable size bracket on the gearbox side.3. Secure the chain and hook assembly to the brackets fitted previously and to the hydraulic lifting device.

1. Undo the nut (1a) fixing the timing side engine support (1b) to the supporting crossmember.

1. Undo the nut (1a) fixing the rear engine support (1b) to the supporting crossmember.

- Raise the power unit.- Position the power unit on a special support and remove the hoist, making sure that the unit is properly balanced. Refitting ( Removing ) - Position the power unit-chassis support tool on the hydraulic jack, then position the power unit support frame on the power unit-chassis assembly support tool by the seats.

	Description	Code	Function
.	Power unit support frame	1.870.835.000	Removing power unit-chassis

- Secure the power unit with chains for hoisting to the hydraulic lifting device.- Position the power unit on the chassis, fitting the timing side engine support and the rear support on the flexible mounting bearings.- Tighten the nut fixing the rear engine support to the supporting crossmember.

	Value - daNm	Fastening	Component	Ø
.	(to crossmember) 5	Nut	RIGID REAR SUPPORT POWER UNIT	M10 X 1.25

- Tighten the nut fixing the timing side engine support to the supporting crossmember.

	Value - daNm	Fastening	Component	Ø
.	(to crossmember) 5	Nut	RIGID ENGINE MOUNT, TIMING SIDE	M10 X 1.25

- Release the engine from the supporting chains.- Remove the brackets positioned for attaching the power unit supporting hooks.- Position the connecting rod for the reaction rod and tighten the fixing bolt.

	Value - daNm	Fastening	Component	Ø
.	(to engine support) 5	Bolt	POWER UNIT REACTION ROD	M10 X 1.25

- Fit the three-lobe joints for the driveshafts in their housings in the differential and the intermediate shaft.- Fit the boots on both sides and secure the retaining bands.- Fit the engine cooling radiator complete with fan, heat exchanger, condenser and power assisted steering system cooling coil.- Connect the power steering fluid supply pipe.- Connect the pipes to the power assisted steering system cooling coil.- Connect the heat exchanger air intake pipe.- Attach the supercharging by-pass solenoid valve from the bracket.- Raise the power unit-chassis until the front and rear flexible supports correspond with the housings in the bodyshell.- Fit the brackets and tighten the fixing bolts.- Tighten the rear support fixing bolts.    See in Op. 1076B70 EXHAUST PIPE BETWEEN PRECATALYZER AND CATALYZER - R.R.- Position the engine suport and secure it to the bell housing.

	Value - daNm	Fastening	Component	Ø
.	(on gearbox) 5	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10 X 1.25

- Tighten the nut fixing the engine support to the flexible mounting.

	Value - daNm	Fastening	Component	Ø
.	(on flexible mounting) 5	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10 X 1.25

- Connect the electrical connection on the gearbox for the reversing lights switch.- Position the bracket complete with bodyshell accelerometer sensor (left side) and secure it using the bolt.- Fit the brake caliper on both sides and screw in the fixing bolts without tightening them.- Connect the two ends of the suspension on both sides and secure them using the fastening bolts.

	Value - daNm	Fastening	Component	Ø
.	3.4	Bolt	FRONT SHOCK ABSORBERS (S.M.)	M8

- Tighten the upper nut securing the anti-roll bar connecting rod on both sides.

	Value - daNm	Fastening	Component	Ø
.	5.5	Nut	FRONT ANTI-ROLL BAR JOINTS	M10 X 1.25

- Tighten the bolt fixing the fork to the steering knuckle on both sides.

	Value - daNm	Fastening	Component	Ø
.	(to the lower front rod) 9	Bolt	FRONT DAMPER FORK ON WISHBONE	M12 x 1.25

- Position the bracket complete with accelerometer sensor on both sides and secure it using the bolt.- Fit the ABS sensor on both sides and position the cable in the special cable duct.- Connect the electrical connection for the brake pad wear sensor.

	Description	Connector
3	Left brake pad wear sensor (switch)	K020

	Description	Connector
3	Right brake pad wear sensor (switch)	K021

Take great care not to damage the brake fluid pipes and the sensor electrical cables.

- Fasten the brake pipe retaining band.- Tighten the bolts fixing the brake caliper to the hub.- Connect the supply pipe from the reservoir to the power assisted steering pump.- Connect the fluid return pipe to the power assisted steering box.- Lower the lift.- Connect the engine coolant pipe to the cylinder head.- Position the connecting rod for the reaction rod and tighten the fixing bolts.

	Value - daNm	Fastening	Component	Ø
.	(to bracket on bodyshell) 5	Bolt	POWER UNIT REACTION ROD	M10 X 1.25

	Value - daNm	Fastening	Component	Ø
.	(to engine support) 5	Bolt	POWER UNIT REACTION ROD	M10 X 1.25

- Connect the electrical connection for the engine/dashboard cable loom coupling.

	Description	Connector
.	Front/dashboard coupling	D001

- Connect the fuel supply and return pipe to the fuel manifold and secure the fuel pipes to the band on the intake chamber.- Connect the turbocharger engine coolant return pipe.- Connect the engine coolant supply pipe and return pipe to the passenger compartment heater.- Connect the electrical connection for the engine management control unit.

	Description	Connector
.	Engine management control unit	M010A

- Connect the electrical connection from the fuel vapour recovery solenoid valve to the intake.

	Description	Connector
.	Fuel vapour recovery solenoid valve	L010

- Connect the vacuum intake pipe to the brake servo.- Connect the fuel vapour intake pipe to the intake chamber.- Position the mounting bracket for the gearbox flexible control cables and secure it using the fixing nuts.

	Value - daNm	Fastening	Component	Ø
.	(on bellhousing) 1.7	Nut	MANUAL GEARBOX LEVER SUPPORT (F)	M8

- Connect the ends of the flexible cables to the ball joints.- Fasten the mounting bracket for the starter motor earth lead using the nut.- Connect the starter motor supply lead, then reposition the protective cover.

	Description	Connector
.	Starter motor	A020A

- Fit the oil pipe for the hydraulic clutch release cylinder and secure it using the retaining spring.- Connect the earth lead to the bodyshell.- Tighten the bolt fixing the air conditioning system pipe to the drier filter.- Connect the electrical connection to the air conditioning system pressure switch.

	Description	Connector
.	Linear sensor (for climate control)	K120

- Connect the electrical connections for the engine cables/fan-radiator cables coupling.

	Description	Connector
.	Front/radiator coupling	D009A

	Description	Connector
.	Front/radiator coupling	D009B

- Connect the electrical connections for the horns.

	Description	Connector
.	High tone horn	P010

	Description	Connector
.	High tone horn	P010

	Description	Connector
.	Low tone horn	P011

	Description	Connector
.	Low tone horn	P011

- Position the air conditioning system coolant return pipe and tighten the fixing bolt on the compressor and the flange fixing bolt.- Fit the upper front crossmember and tighten the fixing bolts.- Fit the bonnet lock on the crossmember complete with reinforcement bracket.    See in Op. 1048A54 TURBOCHARGER air inlet HOSE from rigid pipe - R.R.    See in Op. 1048A10 COMPLETE AIR FILTER -R.R.    See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R.    See in Op. 1048A50 air inlet pipe to turbocharger - r + r    See in Op. 1016A40 Ignition COIL COVER on cylinder head - R.R.    See in Op. 1048B44 RIGID air supply PIPE from heat exchanger to intake manifold - R.R.- Raise the lift    See in Op. 7210E10 FRONT BUMPER    See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.    See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.- Lower the lift    See i

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