POWER UNIT WITH MANUAL GEARBOX - R.R

Operation 1004B10 · POWER UNIT ASSEMBLY

2.2 JTS

Removing

- Position the vehicle on a lift.

- Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).

Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE

Op. 7210A18 R.R FRONT CROSSMEMBER

- Using a suitable syringe, draw off the power assisted steering fluid from the reservoir.

Op. 4130B40 SUPPLY PIPE FROM PUMP TO POWER STEERING BOX - R.R.

1. Loosen the band and disconnect the supply pipe from the power assisted steering fluid reservoir to the pump, power assisted steering pump side.

2. Disconnect the rapid connector for the return pipe from the heat exchanger pipe to the power assisted steering fluid reservoir, heat exchanger side.

3. Undo the bolts (3a) and remove the power assisted steering fluid reservoir (3b) complete with pipes (3c).

4. Loosen the band and disconnect the coolant return pipe, cylinder head side.

1. Disconnect the rapid connector for the power assisted steering system heat exchanger inlet pipe, heat exchanger side.

2. Remove the heat exchanger pipe (2a) after having released it from the securing band (2b).

1. Undo the bolt (1a) and disconnect the inlet/outlet pipes from the air conditioning compressor (1b).

Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.

2. Undo the nut (2a) and disconnect the air conditioning pipes intermediate flange (2b).

Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.

3. Remove the air condtioning system pipes.

Op. 5530B10 BATTERY - R+R

1. Disconnect the electrical connections from the injection/ignition system control unit.

2. Undo the bolts (2a) and remove the battery drip tray (2b) complete with injection/ignition system control unit (2c).

1. Open the junction unit cover, rotate the junction unit and disconnect the electrical connection (connector A).

1. Loosen the band and disconnect the brake servo vacuum intake pipe, air chamber side.

1. Disconnect the rapid connector for the fuel vapour pipe intermediate coupling.

2. Disconnect the rapid connector for the fuel supply pipe, multiple connector side.

- Discharge the fuel supply system pressure.

1. Disconnect the electrical connection for the left upper Lambda sensor.

2. Disconnect the electrical connection for the right upper Lambda sensor.

3. Disconnect the electrical connection for the left rear Lambda sensor to the catalytic converter.

4. Disconnect the electrical connection for the right rear Lambda sensor to the catalytic converter.

Mark the electrical connections for disconnect them so that they can be correctly refitted.

1. Disconnect the rapid connectors for the air conditioning system heater coolant inlet and outlet pipes.

1. Loosen the collar and disconnect the supply pipe from the engine coolant reservoir.

- Replace the brake-clutch fluid reservoir plug using the tool.

1. Release the retaining clip (1a) and disconnect the pipe (1b) between the damper and the clutch operating cylinder (1b), operating cylinder side.

2. Undo the bolt (2a) and disconnect the earth lead (2b) (connector B) from the gearbox.

1. Disconnect the electrical connection from the reversing light switch.

1. Disconnect the gear selector cable.

2. Disconnect the gear engagement cable.

1. Unscrew the bolts (1a) and move aside the bracket (1b) complete with gear selection and engagement cables (1c).

Op. 4450B12 FRONT WHEELS (TWO) - R+R

Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R

1. Undo the bolts (1a) and move the brake caliper assemblies (1b) to the side and secure them appropriately.

1. Undo the nuts fixing the steering rods to the front steering knuckles.

2. Disconnect the steering rods (2a) from the front steering knuckle using the tool (2b).

1. Undo the nuts (1a) and disconnect the front suspension upper track control arms (1b) from the steering knuckles (1c).

1. Undo the pins (1a) and remove the front brake discs (1b).

1. Undo the nuts (1a) and disconnect the lower track control arms (1b) from the steering knuckles.

1. Remove the left front wheel steering knuckle (1a) complete with driveshaft (1b).

Collect the gearbox oil that comes out in a suitable container.

1. Loosen the bolts fixing the intermediate driveshaft to the mounting.

2. Remove the right front wheel steering knuckle (2a) complete with driveshaft (2b) and intermediate driveshaft (2c).

- Position a hydraulic jack under the engine crankcase sump.

1. Undo the bolts fixing the power unit lower reaction rod, engine crankcase sump side.

1. Undo the bolts fixing the power unit rear support flexible mounting, rigid support side.

- Remove the hydraulic jack under the engine crankcase sump.

1. Support the power unit using a hydraulic hoist (1a) and the tool (1b) connected to the mounting brackets (1c).

1. Undo the bolts (1a), (1b) and remove the flexible mounting for the power unit timing side front support (1c) complete with power assisted steering fluid reservoir mounting bracket (1d).

1. Undo the bolts (1a), (1b), then remove the gearbox side support flexible mounting (1c).

1. Using the hydraulic hoist, remove the power unit from the engine compartment and place it on a suitable support.

- Release the power unit from the support tools.

Refitting

- Secure the power unit using the support tools.

- Place the power unit in its housing using the hydraulic hoist.

1. Place the gearbox side support flexible mounting (1a) in its housing and secure it tightening the bolts (1b) and the new bolts (1c) to the recommended torque.

1. Place the timing side power unit front support flexible mounting (1a) in its housing complete with power assisted steering fluid reservoir mounting bracket (1b) and secure it tightening the bolts (1c) and (1d) to the recommended torque.

- Remove the hydraulic hoist and tool used for supporting the power unit safely.

- Position a hydraulic jack under the engine crankcase sump.

1. Tighten the bolts fixing the power unit rear support flexible mounting, rigid support side to the recommended torque.

1. Tighten the bolts fixing the power unit lower reaction rod, engine crankcase sump side to the recommended torque.

- Remove the hydraulic jack under the engine crankcase sump.

- Place the right front wheel steering knuckle in its housing complete with driveshaft and intermediate driveshaft.

- Tighten the bolts fixing the intermdiate driveshaft to the mounting to the recommended torque.

- Place the left front wheel steering knuckle in its housing complete with driveshaft.

1. Connect the lower track control arms (1a) to the steering knuckles and secure them tightening the nuts (1b) to the recommended torque.

1. Position the front brake discs (1a) in their housings and secure them tightening the pins (1b) to the recommended torque.

1. Connect the front suspension upper track control arms (1a) to the steering knuckles (1b) and secure them tightening the nuts (1c) to the recommended torque.

1. Connect the steering links (1a) to the front steering knuckles and secure them tightening the new nuts (1b) to the specified torque.

1. Position the brake caliper assemblies (1a) in their housings and secure them tightening the bolts (1b) to the recommended torque.

Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R

Op. 4450B12 FRONT WHEELS (TWO) - R+R

1. Refit the bracket (1a) complete with gear selection and engagement cables (1b) and secure them tightening the bolts (1c) to the recommended torque.

- Connect the gear selector and engagement cables.

- Connect the electrical connection to the reversing light switch.

- Connect the earth lead to the gearbox and secure it using the bolt.

- Connect the pipe between the damper and clutch operating cylinder, operating cylinder side and secure it using the retaining clip.

- Replace the tool with the brake-clutch fluid reservoir plug.

- Connect the coolant return pipe to the engine coolant reservoir and tighten the collar.

- Connect the rapid connectors for the air conditioning system heater coolant inlet and outlet pipes.

- Connect the electrical connections for the Lambda sensors.

- Connect the rapid connector for the fuel supply pipe, multiple connector side.

- Connect the rapid connector for the fuel vapour pipe intermediate coupling.

- Connect the brake servo vacuum intake pipe, air chamber side and tighten the band.

- Connect the electrical connection, place the junction unit in its housing and close the cover.

- Place the battery drip tray complete with injection/ignition system control unit in its housing and secure it using the bolts.

- Connect the electrical connections to the injection/ignition system control unit.

Op. 5530B10 BATTERY - R+R

- Place the air conditioning system pipes in their housings.

- Connect the air conditioning pipes intermediate flange and tighten the nut to the recommended torque.

- Connect the air conditioning compressor inlet/outlet pipes and secure them by tightening the bolt to the recommended torque.

- Place the heat exchanger in position and fasten it with the band.

- Connect the rapid connector for the power assisted steering system heat exchanger inlet pipe, heat exchanger side.

- Connect the coolant return pipe, cylinder head side, and tighten the band.

- Place the power assisted steering fluid reservoir complete with pipes in its housing and secure it using the bolts.

- Connect the rapid connector for the return pipe from the heat exchanger pipe to the power assisted steering fluid reservoir, heat exchanger side.

- Connect the supply pipe from the fluid reservoir to the power assisted steering pump, power assisted steering pump side, and tighten the band.

Op. 4130B40 SUPPLY PIPE FROM PUMP TO POWER STEERING BOX - R.R.

Op. 7210A18 R.R FRONT CROSSMEMBER

- Connect the negative battery terminal.

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 0010T41 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY

Op. 0010T64 BRAKE AND/OR CLUTCH FLUID CHECK LEVEL AND TOP UP AS NECESSARY

Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR

Op. 0010T71 POWER STEERING FLUID CHECK LEVEL AND TOP UP IF NECESSARY

Op. 0010T75 HYDRAULIC POWER STEERING SYSTEM BLEED AIR

Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE

- Remove the vehicle from the lift.

3.2 JTS

Removing

Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 0010T40 CHANGE MANUAL GEARBOX OIL

Op. 4450B12 FRONT WHEELS (TWO) - R+R

Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 7055B65 ENGINE COMPARTMENT DUST COVER IN LEFT FRONT WHEEL ARCH - R.R.

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 7210E10 R.R. FRONT BUMPER

Op. 5530B10 BATTERY - R+R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5540B81 LEFT GAS DISCHARGE LIGHT CLUSTER - R.R.

Op. 5540B82 RIGHT GAS DISCHARGE LIGHT CLUSTER - R.R.

Op. 7210A15 R.R. FRONT WING/HEADLAMP HOUSING CROSSMEMBER

Op. 7210A18 R.R FRONT CROSSMEMBER

- Open the clips securing the wiring to the engine cooling radiator assembly.

- Draw off the power assisted steering fluid from the reservoir using a suitable syringe.

1. Loosen the band and disconnect the flexible power assisted steering fluid pipe from the pump intake connector and collect the remaining fluid in a suitable container.

2. Undo the nut securing the air conditioning refrigerant fluid return pipe intermediate flange.

1. Open the cover for the fuse and relay box and disconnect connection (1a) and connection (1b) and release the relay (1c) from its housing.

1. Undo the nut and disconnect the earth lead.

1. Disconnect the electrical connection for the left head Lambda sensor on the precatalyzer.

1. Disconnect the engine coolant hose from the radiator upper connector.

2. Undo the nuts and disconnect the air conditioning system refrigerant pipes from the condenser.

1. Disconnect the engine coolant hose from the radiator lower connector.

- Remove the engine cooling radiator assembly.

1. Undo the fixing bolts and remove the two engine coolant radiator assembly supports.

1. Undo the bolt and disconnect the supply and return pipes from the air conditioning compressor and remove them.

1. Undo the bolt for the connector and disconnect the power assisted steering fluid supply pipe from the pump.

1. Undo the bolt fixing the power assisted steering fluid rigid supply pipe to the suspension crossmember.

2. Open the clips securing the engine coolant pipe.

3. Undo the bolts fixing the power assisted steering fluid rigid supply pipe to the suspension crossmember and move it to one side.

1. Unscrew the anti-theft siren fixing bolts and move it to one side.

- Undo the brake/clutch fluid reservoir plug and tighten the cap.

1. Undo the nut fixing the starter motor and alternator supply leads to the battery positive.

1. Lift up the fastening clip and disconnect the clutch fluid pipe from the three-way connector.

2. Disconnect the electrical connection for the reversing switch.

3. Undo the bolt and release the earth lead from the gearbox.

4. Loosen the band and disconnect the engine cooling system supply pipe from the pump rigid intake pipe.

5. Lift up the gear selector lever and lock it in the position illustrated using a suitable peg.

1. Disconnect the terminals of the cables from the levers for the gear selection-engagement assembly.

2. Adjusting the clips (2a), remove the gear selection-engagement cables (2b) from the reaction bracket.

1. Loosen the band and disconnect the degassing pipe from the engine coolant reservoir.

2. Undo the nuts securing the engine coolant reservoir and remove it.

1. Loosen the band and disconnect the brake servo vacuum pipe from the intake chamber.

2. Disconnect the electrical connection for the Lambda sensor upstream of the catalytic converter, right head.

1. Disconnect the water supply and return pipes from the heater.

1. Disconnect the electrical connection for the flow meter.

2. Loosen the bands (2a) and remove the chamber corrugated air hose (2b) complete with flow meter.

1. Disconnect the electrical connection for the throttle casing.

1. Disconnect the electrical connection for the air pressure sensor on the intake chamber.

2. Disconnect the rapid connector for the engine oil vapour recovery pipe from the right cylinder head.

3. Disconnect the electrical connection for the intake chamber fuel vapour flow enablement solenoid.

4. Disconnect the rapid connector for the fuel vapour pipe from the intake chamber fuel vapour flow enablement solenoid.

1. Undo the bolts fixing the wiring bracket to the intake chamber.

2. Undo the bolts fixing the intake chamber and remove it.

- Undo the nut fixing the power assisted steering fluid return pipe.

1. Disconnect the rapid connector for the fuel return pipe from the three-way connector.

2. Disconnect the rapid connector for the fuel supply pipe from the spherical connector.

3. Undo the bolts fixing the right head catalytic preconverter to the front exhaust pipe.

1. Undo the bolts fixing the left head catalytic preconverter to the front exhaust pipe.

1. Undo the fastenings securing the catalyzer assembly to the mounting bracket.

2. Undo the bolts securing the catalyzer assembly mounting bracket to the bodyshell and remove it.

- Remove the gaskets.

1. Undo the nuts fixing the front exhaust pipes to the catalytic converter flange and then remove them.

1. Mark the position of the two flanges connecting the rear drive idler casing to the propeller shaft.

2. Undo the bolts fixing the two flanges connecting the rear drive idler casing to the propeller shaft.

1. Undo the nut fixing the left steering rod to the steering knuckle.

2. Disconnect the left steering rod (2a) from the steering knuckle using the tool (2b).

1. Undo the lower bolt securing the forkv to the lower track control arm.

2. Undo the nut and disconnect the left front steering knuckle from the upper track control arm.

- Retract the left front driveshaft to release it from the differential. Secure the steering knuckle to the upper track control arm.

1. Remove the two stakings and undo the nut (1a) securing the right front hub to the driveshaft using the tool (1b) for counter-torque.

1. Undo the nut fixing the right steering rod to the steering knuckle.

2. Disconnect the right steering rod (2a) from the steering knuckle using the tool (2b).

1. Undo the nut fixing the joint for the anti-roll bar to the right front shock absorber fork.

2. Undo the two bolts fixing the fork to the shock absorber and to the lower wishbone and remove it.

3. Undo the nut fixing the right front steering knuckle to the upper track control arm.

- Undo the bolt fixing the brake disc to the wheel hub.

1. Use the tool to move the driveshaft back from the right front wheel hub.

1. Disconnect the right front driveshaft from the differential and remove it.

- Position a hydraulic jack underneath the gearbox to remove the two lower reaction rods as described below.

1. Undo the fastenings securing the engine side lower reaction rod to the front suspension frame and to the oil sump and remove it.

1. Undo the fastenings securing the gearbox side lower reaction rod to the front suspension frame and to the gearbox and remove it.

- Remove the hydraulic jack positioned previously underneath the gearbox

1. Support the power unit using a hydraulic hoist (1a) and the tool (1b) connected to the brackets (1c).

1. Undo the bolts fixing the rigid power unit support to the gearbox.

2. Undo the bolts (2a) fixing the flexible mounting to the rigid support; remove the rigid support (2b) from the gearbox.

3. Undo the bolts (3a) securing the flexible mounting (3b) to the bodyshell and remove it.

1. Undo the bolts fixing the power unit flexible mounting, timing side and remove it.

1. Using the hydraulic hoist, remove the power unit from the engine compartment and place it on a suitable bench.

- Release the power unit from the support tools.

Refitting

- Replace the power unit in the engine compartment using a hydraulic hoist.

- Place the timing side power unit flexible mounting in its housing and secure it tightening the bolts to the recommended torque.

- Place the flexible mounting in its housing and secure it to the bodyshell and to the gearbox side power unit rigid support tightening the bolts to the recommended torque.

- Remove the hydraulic hoist using the engine lifting tool.

- Place the gearbox side lower reaction rod in its housing and secure it to the suspension frame and to the gearbox tightening the bolts to the recommended torque.

- Place the engine side lower reaction rod in its housing and secure it to the suspension frame and to the oil sump tightening the bolts to the recommended torque.

- Tighten the bolt fixing the front brake disc to the wheel hub.

- Place the right front driveshaft back in its housing.

- Tighten the nut fixing the right front steering knuckle to the upper track control arm to the recommended torque.

- Place the right front shock absorber fork in position and secure it to the lower wishbone and to the shock absorber tightening the bolts to the recommended torque.

- Connect the anti-roll bar to the right shock absorber fork and secure it tightening the nut to the recommended torque.

- Connect the right steering link to the steering knuckle and secure by tightening the nut to the specified torque.

- Using the counter-torque tool used for the removal, tighten a new nut securing the right front hub to the driveshaft to the recommended torque.

- Stake the nut collar twice.

- Place the left front driveshaft back in its housing.

- Connect and tighten the nut fixing the left front steering knuckle to the upper track control arm to torque.

- Connect and tighten the bolt fixing the left front shock absorber fork to the lower track control arm to torque.

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

- Refit the propeller shaft in its seat, aligning the reference marks made on removal.

- Tighten the front constant velocity joint bolts to the PTU to the specified torque in a cross sequence.

- Place the front drainage pipes complete with seals in their housings and connect them to the catalytic converters tightening the nuts to the recommended torque.

- Place the catalyzer mounting bracket in its housing and secure it using the bolts.

- Connect the catalyzers to the mounting bracket using the nuts.

- Tighten the bolts fixing the left head catalytic preconverter to the front exhaust pipe to the recommended torque.

- Tighten the bolts fixing the right head catalytic preconverter to the front exhaust pipe to the recommended torque.

- Connect the fuel supply pipe rapid connector.

- Connect the fuel return pipe rapid connector.

- Tighten the nut fixing the power assisted steering fluid return pipe to the bracket.

- Fit the intake chamber and secure it using the bolts.

- Connect the rapid connector for the fuel vapour pipe to the solenoid.

- Connect the electrical connection for the fuel vapour solenoid.

- Connect the rapid connector for the oil vapour recovery pipe to the right cylinder head.

- Connect the electrical connection for the air pressure sensor on the intake chamber.

- Connect the electrical connection for the throttle casing.

- Place the corrugated hose complete with flow meter back in its housing and tighten the bands.

- Connect the electrical connection for the flow meter.

- Connect the heater supply and return pipes.

- Connect the electrical connections for the Lambda sensors upstream of the catalytic preconverters.

- Connect and fasten the brake servo vacuum pipe using the band, intake chamber side.

- Place the engine coolant reservoir back in its housing and secure it using the nuts.

- Connect the degassing pipe to the engine coolant reservoir and fasten it using the band.

- Connect the ends of the gear selection-engagement cables to the gear selection-engagement levers.

- Fasten the gear selection-engagement cables to the reaction bracket using the retaining clips.

- Remove the peg locking the gear selector lever.

- Connect the system supply pipe using the band, pump rigid inlet pipe side.

- Connect the earth lead to the gearbox and secure it using the bolt.

- Connect the electrical connection for the reversing switch.

- Connect the clutch fluid pipe and fasten it using the clip, three-way connector side.

- Connect the starter motor supply lead and secure it using the nut.

- Place the anti-theft siren in its housing and secure it using the bolts.

- Place the power assisted steering box rigid fluid pipe in its housing and secure it to the suspension crossmember using the bolts.

- Connect the connector for the fluid supply pipe to the power steering pump.

- Connect the supply and return pipes to the air conditioning compressor and secure them using the bolt.

- Place the engine cooling radiator assembly supports in their housings and secure them using the bolts.

- Connect the lower engine coolant hose to the radiator.

- Connect the air conditioning system refrigerant pipes to the condenser using the nuts.

- Connect the upper engine coolant hose to the radiator.

- Connect the earth lead to the bodyshell and secure it using the nut.

- Place the wiring in its housing in the fuse and relay box and connect the connections.

- Connect the air conditioning coolant return pipe intermediate flanges and secure them using the nut.

- Connect the flexible pipe to the power assisted steering pump intake and secure it using the band.

Op. 7210A18 R.R FRONT CROSSMEMBER

Op. 7210A15 R.R. FRONT WING/HEADLAMP HOUSING CROSSMEMBER

Op. 5540B82 RIGHT GAS DISCHARGE LIGHT CLUSTER - R.R.

Op. 5540B81 LEFT GAS DISCHARGE LIGHT CLUSTER - R.R.

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5530B10 BATTERY - R+R

Op. 7210E10 R.R. FRONT BUMPER

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. 7055B65 ENGINE COMPARTMENT DUST COVER IN LEFT FRONT WHEEL ARCH - R.R.

Op. 4450B12 FRONT WHEELS (TWO) - R+R

Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 0010T40 CHANGE MANUAL GEARBOX OIL

Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR

2.4 JTD 20v

Removing

- Position the vehicle on a lift.

Op. 5530B10 BATTERY - R+R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 1016A10 SOUND-PROOFING COVER - R.R

Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE

Op. 4450B12 FRONT WHEELS (TWO) - R+R

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

Op. 7210E10 R.R. FRONT BUMPER

Op. 5540B70 LEFT FRONT LIGHT CLUSTER WITH DIRECTION INDICATOR - R.R.

Op. 5540B71 RIGHT FRONT LIGHT CLUSTER WITH DIRECTION INDICATOR - R.R.

Op. 7210A15 R.R. FRONT WING/HEADLAMP HOUSING CROSSMEMBER

- Undo the radiator coolant drain plug.

Collect the coolant in a suitable container.

1. Disconnect the rapid connector for the radiator upper water inlet hose.

2. Disconnect the power steering system pipe rapid connector from the power steering system heat exchanger.

1. Undo the bolts (1a) and disconnect the coolant inlet/ outlet pipes (1b) from the air conditioning condenser.

Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.

2. Loosen the band and disconnect the air outlet hose from the supercharging air/air heat exchanger.

1. Loosen the band and disconnect the air outlet hose from the supercharging air/air heat exchanger.

2. Disconnect the rapid connector for the radiator coolant outlet lower hose.

1. Disconnect the power steering system pipe rapid connector from the power steering system heat exchanger.

2. Disconnect the electrical connections (2a) and (2b) from the engine cooling fan resistors.

3. Disengage the relay from the support bracket on the engine cooling fans.

- Remove the heat shields from the engine cooling fans.

- Disconnect the electrical connections for the radiator cooling fans.

1. Undo the bolts (1a) and disconnect the engine oil inlet and outlet pipes (1b), engine oil cooling radiator side.

Collect the engine oil that comes out in a suitable container.

1. Loosen the bands and remove the flow meter hose from the turbocharger.

1. Remove the air filter assembly.

- Disconnect the power steering fluid inlet and outlet pipes.

Collect the coolant in a suitable container.

1. Undo the bolts (1a) and remove the power assisted steering fluid reservoir (1b) complete with pipes (1c).

2. Undo the bolt (2a) and remove the power assisted steering fluid reservoir mounting bracket (2b).

1. Undo the bolts (1a) and disconnect the engine oil inlet and outlet pipes from engine oil cooling radiator (1b).

- Position a hydraulic jack underneath the engine cooling radiator.

- Undo the bolts fixing the engine cooling radiator mounting brackets to the front suspension crossmember.

- Remove the engine cooling radiator mounting brackets.

- Remove the engine cooling radiator complete with heat exchanger and air conditioning condenser.

Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R

1. Undo the bolts fixing the power unit lower reaction rod, engine crankcase sump side.

1. Undo the bolts fixing the power unit rear support flexible mounting, rigid support side.

Op. 7210A18 R.R FRONT CROSSMEMBER

- Open the junction unit cover.

- Release the clips and rotate the junction unit.

1. Disconnect the electrical connection.

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

2. Disconnect the electrical connection from the reversing light switch.

3. Undo and remove the reversing light switch.

4. Release the retaining clip (4a) and disconnect the pipe between the damper and the clutch operating cylinder (4b), operating cylinder side.

Collect the brake/ clutch fluid that comes out in a suitable container.

1. Disconnect the gear selector cable.

2. Disconnect the gear engagement cable.

1. Open the clips (1a) and release the gear selector and engagement cables (1b) from the mounting bracket.

1. Disconnect the rapid connectors for the air conditioning system heater coolant inlet and outlet pipes.

1. Undo the bolts (1a) and remove the rigid air inlet pipe on the throttle body (1b) complete with hose.

2. Disconnect the rapid connector for the vacuum intake pipe from the vacuum pump.

1. Loosen the band (1a), unscrew bolt (1b) and disconnect the power assisted steering fluid pipe from the reservoir to the power assisted steering pump (1c), power assisted steering pump side.

2. Undo the connector (2a) and disconnect the supply pipe from the pump to the power assisted steering box (2b), power steering pump side.

1. Disconnect the fuel supply pipe rapid connector, pressure pump side.

2. Disconnect the rapid connector for the fuel return pipe, fuel return manifold side.

1. Undo nut (1a), raise the glow plug preheating control unit (1b) enough to disconnect electrical connections (1c), and then remove it.

Op. 0010T40 CHANGE MANUAL GEARBOX OIL

1. Undo the connector (1a) and disconnect the rigid pipe (1b), flexible pipe side.

2. Withdraw the hose retaining clip.

1. Disconnect the electrical connection for the brake pad wear sensor.

2. Undo the bolts (2a) and remove the front brake calipers (2b) from the relative steering knuckles.

1. Undo the pins (1a) and remove the front brake discs (1b).

1. Undo the nuts (1a) and disconnect the front suspension upper wishbones (1b) from the relative steering knuckles.

1. Undo the nuts (1a) and disconnect the front suspension lower wishbones (1b) from the relative steering knuckles.

1. Undo the nuts fixing the steering rods to the front steering knuckles.

2. Disconnect the steering rods (2a) from the front steering knuckle using the tool (2b).

1. Unscrew bolts (1a) and remove the front wheel rpm sensors (1b) from the steering knuckles.

1. Disconnect the left driveshaft from the gearbox and remove the steering knuckle assembly (1a) and the driveshaft (1b).

1. Loosen the bolts fixing the intermediate driveshaft to the mounting.

2. Remove the right front wheel steering knuckle (2a) complete with driveshaft (2b) and intermediate driveshaft (2c).

- Postion a suitable footboard beneath the power unit.

- Lower the vehicle until the power unit is resting on the footboard.

1. Undo the bolts (1a), (1b), then remove the power unit timing side front support flexible mounting (1c).

- Fit two suitable brackets on the power unit rigid support, timing system side.

- Use a hydraulic hoist with suitable chains connected to the special brackets to support the power unit.

1. Undo the bolts fixing power unit gearbox side rigid support to the manual gearbox.

2. Undo the bolts fixing the gearbox side support flexible mounting to the bodyshell.

3. Remove the gearbox side support flexible mounting (3a), complete with rigid support (3b).

- Using the hydraulic hoist, remove the power unit from the engine compartment and place it on a suitable work bench.

Refitting

- Replace the power unit in the engine compartment using a hydraulic hoist.

1. Remove the gearbox side support flexible mounting (1a), complete with rigid support (1b).

2. Tighten the bolts fixing the gearbox side support flexible mounting to the bodyshell to the recommended torque.

3. Tighten the bolts fixing the power unit gearbox side rigid support to the gearbox to the recommended torque.

- Postion a suitable footboard beneath the power unit.

- Lower the vehicle until the power unit is resting on the footboard.

- Remove the hydraulic hoist and chains used to support the power unit safely.

- Remove the brackets on the power unit rigid support, timing system side.

1. Place the timing side power unit front support flexible mounting (1a) in its housing and secure it tightening the bolts (1b), (1c) and (1d) to the recommended torque.

- Place the right front wheel steering knuckle in its housing complete with driveshaft and intermediate driveshaft.

- Tighten the bolts fixing the intermdiate driveshaft to the mounting to the recommended torque.

- Place the left front wheel steering knuckle in its housing complete with driveshaft.

- Refit the front wheel rpm sensors in their housings on the steering knuckles and secure by the tightening bolts to the specified torque.

- Connect the steering rods to the front steering knuckles and secure them tightening new nuts to the specified torque.

1. Connect the lower track control arms (1a) to the steering knuckles and secure them tightening the nuts (1b) to the recommended torque.

1. Connect the front suspension upper track control arms (1a) to the steering knuckles (1b) and secure them tightening the nuts (1c) to the recommended torque.

1. Position the front brake discs (1a) in their housings and secure them tightening the pins (1b) to the recommended torque.

1. Position the brake calipers (1a) in their housings and secure them tightening the bolts (1b) to the recommended torque.

2. Connect the electrical connection for the brake pad wear sensor.

1. Refit the hose retaining clip in its housing.

2. Connect the rigid pipe (2a), flexible pipe side and tighten the connector (2b) to the recommended torque.

- Connect the electrical connections to the glow plug control unit, then refit it in its seat and secure with the nut.

- Connect the rapid connector for the fuel return pipe, fuel return manifold side.

- Connect the fuel supply pipe rapid connector, pressure pump side.

- Connect the supply pipe from the pump to the power assisted steering box, power assisted steering pump side and tighten the connector to the recommended torque.

- Connect the supply pipe from the fluid reservoir to the power assisted steering pump, power assisted steering pump side, and tighten the band.

- Connect the vacuum pipe rapid connector to the vacuum pump.

- Place the throttle body rigid air inlet pipe complete with hose in position and secure it using the bolts.

- Connect the rapid connectors for the air conditioning system heater coolant inlet and outlet pipes.

- Fasten the gear selection and engagement cables to the mounting bracket securing them using the clips.

- Connect the gear selector and engagement cables.

- Connect the pipe between the damper and clutch operating cylinder, operating cylinder side and secure it using the retaining clip.

- Place the reversing light switch in position and tighten it to the recommended torque.

- Connect the electrical connection to the reversing light switch.

- Connect the earth lead to the gearbox and secure it using the nut.

- Connect the electrical connection.

- Place the junction unit in its housing and secure it using the clips.

- Close the junction unit cover.

Op. 7210A18 R.R FRONT CROSSMEMBER

1. Tighten the bolts fixing the power unit rear support flexible mounting, rigid support side, to the recommended torque.

1. Tighten the bolts fixing the power unit lower reaction rod, engine crankcase sump side, to the recommended torque.

Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R

- Place the engine cooling radiator in its housing complete with heat exchanger and air conditioning condenser using the hydraulic jack.

- Place the engine cooling radiator mounting brackets in their housings and secure them using the bolts.

- Remove the hydraulic jack from underneath the engine coolant radiator.

- Place the engine oil inlet and outlet pipes on the engine oil heat exchanger in their housings, connect them to the intermediate connectors and secure them with bolts.

- Place the power assisted steering fluid reservoir mounting bracket in its housing and secure it using the bolts.

- Place the power assisted steering fluid reservoir complete with pipes in its housing and secure it using the bolts.

- Connect the power steering systems pipes.

- Place the resonator back in its housing.

- Place the hose from the flow meter to the turbocharger back in its housing and secure it using the bands.

- Connect the engine oil supply and return pipes, engine oil heat exchanger side and secure them using the bolts.

- Disconnect the electrical connections for the radiator cooling fans.

- Place the radiator cooling fans heat shields in their housings.

- Secure the relay to the relative bracket on the radiator cooling fans.

- Connect the electrical connections to the radiator cooling fan resistors.

- Connect the power steering system pipe rapid connector to the power steering system heat exchanger.

- Connect the rapid connector for the radiator coolant outlet lower hose.

- Connect the air outlet hose to the air/ air turbocharger heat exchanger.

- Connect the air inlet hose to the air/ air turbocharger heat exchanger.

- Connect the coolant inlet and outlet pipes to the air conditioner compressor and secure by tightening the bolts to the specified torque.

Replace any O-Rings for the connectors using green coloured seals only which are resistant to the R134a refrigerant fluid. Lubricate the connector threads using anti-freeze.

- Connect the power steering system pipe rapid connector to the power steering system heat exchanger.

- Connect the rapid connector for the radiator upper water inlet hose.

- Tighten the coolant drain plug to the radiator.

Op. 7210A15 R.R. FRONT WING/HEADLAMP HOUSING CROSSMEMBER

Op. 5540B71 RIGHT FRONT LIGHT CLUSTER WITH DIRECTION INDICATOR - R.R.

Op. 5540B70 LEFT FRONT LIGHT CLUSTER WITH DIRECTION INDICATOR - 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. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 4450B12 FRONT WHEELS (TWO) - R+R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5530B10 BATTERY - R+R

Op. 0010T12 ENGINE OIL AND FILTER - REPLACE

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. 0010T71 POWER STEERING FLUID CHECK LEVEL AND TOP UP IF NECESSARY

Op. 0010T75 HYDRAULIC POWER STEERING SYSTEM BLEED AIR

Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

Op. 1016A10 SOUND-PROOFING COVER - R.R

- Remove the vehicle from the lift.