POWER UNIT WITH MANUAL GEARBOX - R.R

Operation 1004B10 · POWER UNIT ASSEMBLY

1.4 16v

Removing

Op. 5530B10 BATTERY - R+R

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

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R + R

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R

Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.

Op. 1072C16 EXHAUST MANIFOLD WITH CATALYTIC CONVERTER - R.R.

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.

Op. 1088D10 RADIATOR COOLANT OUTLET HOSE - R.R.

Op. 1088D14 UPPER RADIATOR COOLANT INLET HOSE - R.R.

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

Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.

Op. 4450B12 FRONT WHEELS (TWO) - 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.

1. Disconnect the rapid connectors for the heater water supply and return pipes.

1. Disconnect the electrical connection for the reversing switch.

2. Undo the bolts and move the clutch control actuator aside.

3. Undo the nut and disconnect the earth lead.

1. Disconnect the gear selector and engagement cables.

2. Undo the bolts and remove the bracket complete with gear selection and engagement cables.

1. Disconnect the single-acting valve from the brake servo and move it to one side.

1. Disconnect the fuel pipe rapid connector from the rail.

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

1. Remove the brake caliper fluid flexible pipe from the retaining bracket.

2. Remove the ABS wheel rpm sensor wiring from the retaining bracket.

3. Remove the wiring for the left front brake pad wear sensor from the retaining bracket.

4. Unscrew the nut (4a), fit the tool (4b) and disconnect the steering link (4c) from the wheel strut.

5. Undo the bolts securing the shock absorber to the wheel strut.

- Proceed in the same way for the right side.

1. Loosen the band (1a) and disconnect the left driveshaft (1b) from the differential internal driveshaft (1c).

1. Loosen the band (1a) and disconnect the right driveshaft (1b) from the differential internal driveshaft (1c).

1. Disconnect the rapid connector for the air conditioning coolant supply pipe.

1. Disconnect the rapid connector for the air conditioning coolant return pipe.

- Lower the lift and place a suitable support underneath the power unit.

1. Fit the element on the hydraulic hoist.

2. Attach the power unit at the points shown in the diagram (2a), (2b) and (2c).

- Gently raise the power unit and make sure that the chains have the same tension.

1. Undo the nuts fixing the flexible mounting to the timing side front support.

2. Undo the bolts (2a) and remove the timing front support flexible mounting (2b).

1. Undo the nut securing the flexible mounting to the gearbox side rigid power unit support.

- Lower the power unit until it rests on the board positioned previously.

- Release the power unit from the support tools.

Refitting

- Fit the support tools to the power unit.

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

- Tighten the nut fixing the flexible mounting to the gearbox side rigid power unit support to the recommended torque.

- Place the timing front support flexible mounting in position and tighten the bolts fixing it to the bodyshell to the recommended torque.

- Tighten the nuts fixing the flexible mounting to the timing side front support to the recommended torque.

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

- Connect the rapid connector for the air conditioning coolant pipes.

- Connect the right driveshaft to the differential internal driveshaft and fasten the boot using the band.

- Connect the left driveshaft to the differential internal driveshaft and fasten the boot using the band.

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

- Tighten the new bolts fixing the shock absorber to the steering knuckle to the recommended torque.

- Place the wiring for theleft front brake pad wear sensor in its housing and secure it to the retaining bracket.

- Position the wiring for the ABS rpm sensor in its housing and secure it to the retaining bracket.

- Place the brake caliper fluid flexible pipe in position and fasten it to the retaining bracket.

- Proceed in the same way for the right side.

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

- Connect the fuel pipe rapid connector to the rail.

- Connect the single-acting valve to the brake servo.

- Refit the bracket complete with gear selection and engagement cables in its seat and tighten the bolts.

- Connect the cables to the gear selector and engagement unit.

- Connect the battery earth lead and tighten the nut.

- Place the clutch control actuator in its housing and secure it tightening the bolts to the recommended torque.

- Connect the electrical connection for the reversing switch.

- Connect the rapid connectors for the heater water supply and return pipes.

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. 1008C32 GEARBOX LOWER REACTION ROD -R.R.

Op. 1088D14 UPPER RADIATOR COOLANT INLET HOSE - R.R.

Op. 1088D10 RADIATOR COOLANT OUTLET HOSE - R.R.

Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.

Op. 1072C16 EXHAUST MANIFOLD WITH CATALYTIC CONVERTER - R.R.

Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R

Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R + R

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

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

Op. 0010T20 ENGINE COOLANT - CHANGE

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

Op. 5530B10 BATTERY - R+R

1.9 JTD 8v

Removing

Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.

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

Op. 4450B12 FRONT WHEELS (TWO) - 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. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 0010T40 CHANGE MANUAL GEARBOX OIL

Op. 5530B10 BATTERY - R+R

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

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

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 1048B27 RIGID PIPE FOR AIR INLET TO THROTTLE BODY - R R

Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.

Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE

Op. 1076B20 REAR EXHAUST SILENCER - R + R

- For versions with DPF only:

Op. 1080B81 PARTICULATE FILTER (D.P.F.) - R.R.

- For versions without DPF only:

Op. 1080B62 CATALYTIC CONVERTER - R + R

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

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R

Op. 1048A41 HOSE FROM FLOW METER TO TURBOCHARGER - R.R.

Op. 1080C83 EXHAUST GAS INLET PIPING FROM EXHAUST MANIFOLD TO HEAT EXCHANGER EGR - R R

Op. 1048B19 TURBOCHARGER AIR OUTLET HOSE -R.R.

Op. 7210E10 R.R. FRONT BUMPER

Op. 1048B10 RIGID SUPPLY PIPE (ONE) BETWEEN TURBOCHARGER AND HEAT EXCHANGER -R.R.

Op. 1064A27 PIPE BETWEEN VACUUM RESERVOIR AND ACTUATOR CONTROL SOLENOID VALVE - R.R.

Op. 3310A60 FRONT BRAKE PADS - REPLACE

Op. 1008C30 POWER UNIT LOWER REACTION LINK - R.R.

Op. 1008C33 BRACKET ON ENGINE FOR LOWER REACTION ROD - R.R.

Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R

1. Remove the brake caliper fluid flexible pipe from the retaining bracket.

2. Remove the ABS wheel rpm sensor wiring from the retaining bracket.

3. Remove the wiring for the left front brake pad wear sensor from the retaining bracket.

4. Unscrew the nut (4a), fit the tool (4b) and disconnect the steering link (4c) from the wheel strut.

5. Undo the bolts securing the shock absorber to the wheel strut.

1. Loosen the band (1a) and disconnect the left driveshaft (1b) from the differential internal driveshaft (1c).

Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.

Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.

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

2. Disconnect the vacuum pipe to the turbocharger vane position actuator control solenoid valve.

1. Undo the bolts and disconnect the supply and return pipes from the air conditioning compressor.

2. Loosen the band and disconnect the coolant outlet hose from the radiator, water pump side.

1. Disconnect the quick connector for the fuel return pipe to the tank.

2. Disconnect the fuel supply pipe rapid connector to the pressure pump.

1. Undo nut (1a) securing the heater plugs control unit (1b) to the bracket and disconnect the electrical connection (1c).

1. Open the retaining clip (1a), disconnect the single-acting valve for the brake servo assembly (1b) and move it aside.

2. Disconnect the rapid connectors and disconnect the heater supply and return pipes.

1. Disconnect the gear selector and engagement cables.

2. Undo the nuts and remove the bracket complete with gear selection and engagement cables.

1. Lift up the clip and disconnect the flexible pipe from the clutch control actuator.

2. Undo the nut and disconnect the battery earth lead.

3. Loosen the band and disconnect the radiator water supply pipe, thermostat side.

- Postion a suitable footboard beneath the power unit.

- Remove the flexible mounting for the power unit support, timing side with reference to

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

1. Fit the element on the hydraulic hoist.

2. Attach the power unit at the points illustrated.

- Gently raise the power unit and make sure that the chains have the same tension.

1. Undo the nut securing the flexible mounting to the gearbox side rigid support.

2. Open the clutch control hydraulic system rigid pipe retaining clip.

- Raise the vehicle until the power unit is released from the engine compartment.

- Disconnect the hydraulic hoist arm from the balance and complete raising the vehicle.

- Reconnect the hydraulic hoist arm to the balance, raise the power unit and place it on one side on a suitable support.

- Release the power unit from the support tools.

Refitting

- Fit the support tools to the power unit.

- Raise the vehicle and place the power unit on a suitable support by the engine compartment.

- Remove the power unit support tools.

- Lower the vehicle until the power unit is in position.

- Tighten the nut fixing the flexible mounting to the gearbox side rigid support to the recommended torque.

- Close the clutch control hydraulic system rigid pipe retaining clip.

- Place the flexible mounting for the power unit support, timing side in position with reference to

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

- Raise the vehicle as necessary and remove the support underneath the power unit.

- Connect the battery earth lead and tighten the nut.

- Connect the flexible pipe to the clutch control actuator and close the clip.

- Connect the raidator coolant supply pipe, thermostat side and tighten the band.

- Refit the bracket with gear selection and engagement cables in its seat and tighten the nuts.

- Connect the gear selector and engagement cables to the levers.

- Connect the rapid connectors for the heater supply and return pipes.

- Connect the brake servo assembly single-acting valve and close the retaining clip.

- Connect the electrical connection for the heater plugs control unit and tighten the nut securing it to the bracket.

- Connect the fuel supply pipe rapid connector to the pressure pump.

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

- Connect the radiator coolant outlet hose, water pump side, and tighten the band.

- Connect the supply and return pipes from the air conditioning compressor and tighten the bolts.

- Connect the vacuum pipe to the turbocharger vane position actuator control solenoid valve.

- Connect the electrical connection from the turbocharger vane position actuator solenoid valve.

Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.

Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.

- Connect the left driveshaft to the differential internal driveshaft and fasten the boot using the band.

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

- Tighten the new bolts fixing the shock absorber to the steering knuckle to the recommended torque.

- Place the wiring for theleft front brake pad wear sensor in its housing and secure it to the retaining bracket.

- Position the wiring for the ABS rpm sensor in its housing and secure it to the retaining bracket.

- Place the brake caliper fluid flexible pipe in position and fasten it to the retaining bracket.

Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R

Op. 1008C33 BRACKET ON ENGINE FOR LOWER REACTION ROD - R.R.

Op. 1008C30 POWER UNIT LOWER REACTION LINK - R.R.

Op. 3310A60 FRONT BRAKE PADS - REPLACE

Op. 1064A27 PIPE BETWEEN VACUUM RESERVOIR AND ACTUATOR CONTROL SOLENOID VALVE - R.R.

Op. 1048B10 RIGID SUPPLY PIPE (ONE) BETWEEN TURBOCHARGER AND HEAT EXCHANGER -R.R.

Op. 7210E10 R.R. FRONT BUMPER

Op. 1048B19 TURBOCHARGER AIR OUTLET HOSE -R.R.

Op. 1080C83 EXHAUST GAS INLET PIPING FROM EXHAUST MANIFOLD TO HEAT EXCHANGER EGR - R R

Op. 1048A41 HOSE FROM FLOW METER TO TURBOCHARGER - R.R.

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R

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

- For versions with DPF only:

Op. 1080B81 PARTICULATE FILTER (D.P.F.) - R.R.

- For versions without DPF only:

Op. 1080B62 CATALYTIC CONVERTER - R + R

Op. 1076B20 REAR EXHAUST SILENCER - R + R

Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE

Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.

Op. 1048B27 RIGID PIPE FOR AIR INLET TO THROTTLE BODY - R R

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

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

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

Op. 5530B10 BATTERY - 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. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.

Op. 0010T40 CHANGE MANUAL GEARBOX OIL

Op. 0010T20 ENGINE COOLANT - CHANGE

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

1.9 JTD 16v

Removing

Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.

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

Op. 4450B12 FRONT WHEELS (TWO) - 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. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND REPRESSURIZE

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 0010T40 CHANGE MANUAL GEARBOX OIL

Op. 5530B10 BATTERY - R+R

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

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

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 1048B27 RIGID PIPE FOR AIR INLET TO THROTTLE BODY - R R

Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.

Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE

Op. 1076B20 REAR EXHAUST SILENCER - R + R

- For versions with DPF only:

Op. 1080B81 PARTICULATE FILTER (D.P.F.) - R.R.

- For versions without DPF only:

Op. 1080B62 CATALYTIC CONVERTER - R + R

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

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R

Op. 1048A41 HOSE FROM FLOW METER TO TURBOCHARGER - R.R.

Op. 1080C83 EXHAUST GAS INLET PIPING FROM EXHAUST MANIFOLD TO HEAT EXCHANGER EGR - R R

Op. 1048B19 TURBOCHARGER AIR OUTLET HOSE -R.R.

Op. 7210E10 R.R. FRONT BUMPER

Op. 1048B10 RIGID SUPPLY PIPE (ONE) BETWEEN TURBOCHARGER AND HEAT EXCHANGER -R.R.

Op. 1064A27 PIPE BETWEEN VACUUM RESERVOIR AND ACTUATOR CONTROL SOLENOID VALVE - R.R.

Op. 3310A60 FRONT BRAKE PADS - REPLACE

Op. 1008C30 POWER UNIT LOWER REACTION LINK - R.R.

Op. 1008C33 BRACKET ON ENGINE FOR LOWER REACTION ROD - R.R.

Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R

1. Remove the brake caliper fluid flexible pipe from the retaining bracket.

2. Remove the ABS wheel rpm sensor wiring from the retaining bracket.

3. Remove the wiring for the left front brake pad wear sensor from the retaining bracket.

4. Unscrew the nut (4a), fit the tool (4b) and disconnect the steering link (4c) from the wheel strut.

5. Undo the bolts securing the shock absorber to the wheel strut.

1. Loosen the band (1a) and disconnect the left driveshaft (1b) from the differential internal driveshaft (1c).

Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.

Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.

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

2. Disconnect the vacuum inlet pipe for the turbocharger vane position actuator control solenoid valve.

1. Undo the bolts and disconnect the supply and return pipes from the air conditioning compressor.

2. Loosen the band and disconnect the coolant outlet hose from the radiator, water pump side.

1. Disconnect the quick connector for the fuel return pipe to the tank.

1. Undo the nut (1a) securing the heater plugs control unit (1b) to the bracket and disconnect the electrical connection (1c).

1. Open the retaining clip (1a), disconnect the single-acting valve for the brake servo assembly (1b) and move it aside.

2. Disconnect the rapid connectors and disconnect the heater supply and return pipes.

1. Disconnect the gear selector and engagement cables.

2. Undo the nuts and remove the bracket complete with gear selection and engagement cables.

1. Lift up the clip and disconnect the flexible pipe from the clutch control actuator.

2. Undo the nut and disconnect the battery earth lead.

3. Loosen the band and disconnect the radiator water supply pipe, thermostat side.

- Postion a suitable footboard beneath the power unit.

- Remove the power unit support flexible mounting, timing side referring to

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

1. Fit the element on the hydraulic hoist.

2. Attach the power unit at the points illustrated.

- Gently raise the power unit and make sure that the chains have the same tension.

1. Undo the nut securing the rigid support flexible mounting, gearbox side.

2. Open the clutch hydraulic system rigid pipe retaining clip.

- Raise the vehicle until the power unit is released from the engine compartment.

- Disconnect the arm for the hydraulic hoist from the balance and complete the raising of the vehicle.

- Reconnect the hydraulic hoist arm to the balance, raise the power unit and position it on a suitable support.

- Release the power unit from the support tools.

Refitting

- Fit the support tools to the power unit.

- Raise the vehicle and place the power unit on a suitable support by the engine compartment.

- Remove the power unit support tools.

- Lower the vehicle until the power unit is back in place.

- Tighten the nut fixing the rigid support flexible mounting, gearbox side to the recommended torque.

- Close the clutch hydraulic system rigid pipe retaining clip.

- Place the power unit support flexible mounting, timing side back in position referring to

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

- Raise the vehicle as necessary and remove the support from underneath the power unit.

- Connect the battery earth lead and tighten the nut.

- Connect the flexible pipe to the clutch control actutator and secure it using the clip.

- Connect the raidator coolant supply pipe, thermostat side and tighten the band.

- Refit the bracket with gear selection and engagement cables in its seat and tighten the nuts.

- Connect the gear selector and engagement cables to the levers.

- Connect the rapid connectors for the heater supply and return pipes.

- Connect the brake servo assembly single-acting valve and close the retaining clip.

- Connect the electrical connection for the heater plugs control unit and tighten the nut to the bracket.

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

- Connect the radiator coolant outlet hose, water pump side, and tighten the band.

- Connect the supply and return pipes from the air conditioning compressor and tighten the bolts.

- Connect the vacuum inlet pipe for the turbocharger vane position actuator control solenoid valve.

- Connect the electrical connection from the turbocharger vane position actuator solenoid valve.

Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.

Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.

- Connect the left driveshaft to the differential internal driveshaft and fasten the boot using the band.

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

- Tighten the new bolts fixing the shock absorber to the steering knuckle to the recommended torque.

- Place the wiring for theleft front brake pad wear sensor in its housing and secure it to the retaining bracket.

- Position the wiring for the ABS rpm sensor in its housing and secure it to the retaining bracket.

- Place the brake caliper fluid flexible pipe in position and fasten it to the retaining bracket.

Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R

Op. 1008C33 BRACKET ON ENGINE FOR LOWER REACTION ROD - R.R.

Op. 1008C30 POWER UNIT LOWER REACTION LINK - R.R.

Op. 3310A60 FRONT BRAKE PADS - REPLACE

Op. 1064A27 PIPE BETWEEN VACUUM RESERVOIR AND ACTUATOR CONTROL SOLENOID VALVE - R.R.

Op. 1048B10 RIGID SUPPLY PIPE (ONE) BETWEEN TURBOCHARGER AND HEAT EXCHANGER -R.R.

Op. 7210E10 R.R. FRONT BUMPER

Op. 1048B19 TURBOCHARGER AIR OUTLET HOSE -R.R.

Op. 1080C83 EXHAUST GAS INLET PIPING FROM EXHAUST MANIFOLD TO HEAT EXCHANGER EGR - R R

Op. 1048A41 HOSE FROM FLOW METER TO TURBOCHARGER - R.R.

Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R

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

- For versions with DPF only:

Op. 1080B81 PARTICULATE FILTER (D.P.F.) - R.R.

- For versions without DPF only:

Op. 1080B62 CATALYTIC CONVERTER - R + R

Op. 1076B20 REAR EXHAUST SILENCER - R + R

Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE

Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.

Op. 1048B27 RIGID PIPE FOR AIR INLET TO THROTTLE BODY - R R

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

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

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

Op. 5530B10 BATTERY - 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. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.

Op. 0010T40 CHANGE MANUAL GEARBOX OIL

Op. 0010T20 ENGINE COOLANT - CHANGE

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

1.4 16v TJet

Removing

- Position the vehicle on a lift.

Op. 4450B12 FRONT WHEELS (TWO) - 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. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.

Op. 0010T40 CHANGE MANUAL GEARBOX OIL

Op. 0010T20 ENGINE COOLANT - CHANGE

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

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

Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.

Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.

Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R

1. Undo the two bolts securing the shock absorber to the steering knuckle.

1. Unscrew the nut (1a), fit the tool (1b) and disconnect the steering link (1c) from the strut.

- Prise up the left driveshaft from the differential and secure it appropriately.

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

Op. 5530B10 BATTERY - R+R

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

- Unscrew the brake-clutch fluid reservoir plug and fit the tool.

1. Undo the bolt and remove the earth lead.

2. Adjust the retaining clips and disconnect the oil input pipe to the clutch control actuator.

1. With the gear lever in neutral, insert the locking pin in the gear selection-engagement unit.

2. Disconnect the gear selector and engagement cables.

3. Adjust the clips and disconnect the gear selection-engagement cables from the reaction bracket.

Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.

Op. 1064B38 WASTE GATE SUPERCHARGING PRESSURE ADJUSTMENT SOLENOID VALVE - R.R.

Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R.

1. Loosen the band and disconnect the lower coolant outlet hose from the radiator, water pump side.

Op. 1048B19 TURBOCHARGER AIR OUTLET HOSE -R.R.

- Remove the air pressure pipes, refer to

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

1. Loosen the band and disconnect the upper coolant inlet hose to the radiator, thermostat side.

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

1. Disconnect the rapid connectors for the engine coolant supply and return pipes, heater side.

2. Undo the nut and disconnect the low pressure coolant pipe, expansion valve side.

1. Undo the bolt and disconnect the pressurised coolant pipe, compressor side.

- Open the retaining clip of the pipe disconnected earlier, compressor side.

1. Undo the bolt of the intermediate retainer bracket for the pressurised coolant pipe.

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

2. Disconnect the engine front coupling.

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

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

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

2. Disconnect the rapid connector for the fuel vapour recovery pipe, air chamber side.

1. Fit the power unit mounting bracket on the air conditioning compressor support as shown in the figure.

1. Fit the power unit mounting bracket, exhaust manifold side. as shown in the figure.

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

- Undo the nut securing the flexible mounting to the rigid power unit support, gearbox side, refer to

Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE

- Undo the nut securing the flexible mounting to the rigid power unit support, timing side, refer to

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

- Remove the power unit from the engine compartment and position it to a platform.

- Release the power unit from the support tools.

Refitting

- Fit the support tools to the power unit.

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

- Tighten the nuts fixing the flexible mounting to the timing side rigid power unit support to the recommended torque, refer to

Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE

- Tighten the nut fixing the flexible mounting to the gearbox side of the rigid power unit support to the recommended torque, refer to

Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE

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

- Connect the rapid connector for the fuel vapour recovery pipe, air chamber side.

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

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

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

- Connect the engine front coupling.

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

- Tighten the bolt of the intermediate retainer bracket for the pressurised coolant pipe.

- Connect the pressurised engine coolant pipe, compressor side, tighten the bolt and close the retaining clips.

- Connect the low pressure coolant pipe, expansion valve side and tighten the nut.

- Connect the rapid connectors for the engine coolant supply and return pipes, heater side.

- Disconnect the reversing light switch cable electrical connection..

- Connect the radiator upper coolant inlet hose, thermostat side, and tighten the band.

- Replace the air pressure pipes in their seats, refer to

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.

- Connect the radiator lower coolant outlet hose, water pump side, and tighten the band.

Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R.

Op. 1064B38 WASTE GATE SUPERCHARGING PRESSURE ADJUSTMENT SOLENOID VALVE - R.R.

Op. 1088B10 ENGINE COOLANT SUPPLY RESERVOIR - R.R.

- Place the gear selection and engagements cables in their seats and secure to the reaction bracket using the clips.

- Connect the cables to the gear selection and engagement unit and remove the locking pin.

- Use a three-way connector to connect the oil input pipe to the clutch control actuator and close the retaining clip.

- Connect the earth lead to the gearbox and tighten the bolt.

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

Op. 5530B10 BATTERY - R+R

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

- Connect the left driveshaft to the gearbox differential.

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

- Tighten the new bolts fixing the shock absorber to the steering knuckle to the recommended torque.

Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R

Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.

Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.

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

Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.

Op. 0010T40 CHANGE MANUAL GEARBOX OIL

- Check the clutch-brake fluid level and bleed if necessary, refer to

Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR

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

Op. 0010T20 ENGINE COOLANT - CHANGE

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - 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

- Remove the vehicle from the lift.