POWER UNIT WITH MANUAL GEARBOX - R.R

Operation 1004B10 · POWER UNIT ASSEMBLY

2.2

Removing

- Position the vehicle on a lift.

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

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. 1080B95 REAR LAMBDA SENSOR TO CATALYTIC CONVERTER - R.R

Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R

Op. 7055A43 CENTRE FRONT GRILLE - R.R.

Op. 4410D10 FRONT SUSPENSION FRAME - R+R

Op. 5530B10 BATTERY - R+R

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

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

1. Undo the bolts (1a) and remove the upper radiator crossmember guard (1b).

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

1. Undo the radiator coolant drain plug.

Collect the coolant in a suitable container.

1. Undo the water pump coolant drain plug.

Collect the coolant that comes out in a suitable container.

1. Disconnect the left driveshaft from the differential and move it to the side.

1. Disconnect the right driveshaft from the intermediate driveshaft and move it to the side.

1. Remove the electrical connection holder cover.

1. Rotate the electrical connections holder casing and disconnect the electrical connections.

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

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

1. Disconnect the electrical connection (1a) from the fans, then release the electrical wiring from the fastenings (1b) and move it aside.

1. Undo the nut (1a), loosen the bands and remove the engine coolant return pipe to the supply reservoir (1b).

1. Loosen the band and disconnect the engine oil vapour recovery pipe from the cylinder head cover.

2. Loosen the bands and remove the air supply hose from the air flow meter to the throttle casing.

1. Disconnect the electrical connection from the air flow meter.

2. Undo the bolts (2a) and remove the air filter cover (2b), complete with air flow meter (2c).

3. Remove the air cleaner filter element.

1. Release the fuel vapour pipe (1a) from the band (1b) on the air filter casing.

1. Disconnect the cold air intake from the air filter casing.

2. Remove the air filter casing fastened to the bodyshell by three pins.

1. Connect the tool to the bleed valve on the fuel supply pipe and discharge the fuel pressure.

Follow the safety instructions and specific recommendations.

1. Undo the connector (1a), disconnect the fuel supply pipe (1b), fuel manifold pipe side and move it to the side.

1. Disconnect the electrical connection from the air conditioning system multi-stage pressure switch.

2. Undo the nut fixing the air conditioning system pipe flange.

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

1. Disconnect the rapid connector for the air intake chamber fuel vapour inlet pipe, intermediate fuel vapour pipe side.

1. Loosen the bands and disconnect the engine coolant supply reservoir pipes.

1. Working underneath the vehicle, loosen the band and disconnect the radiator upper coolant inlet hose, radiator side.

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

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

1. Disconnect the quick-release fitting for the brake servo vacuum intake pipe, air chamber side.

1. Undo the bolt fixing the gear selector-engagement rods mounting bracket.

2. Disconnect the gear selection-engagement rods, then move them aside together with the mounting bracket.

- 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.

- Postion a suitable footboard beneath the power unit.

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

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

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

1. Lower the power unit with the hydraulic hoist until it rests on the board positioned previously.

- 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. Tighten the power unit gearbox side rigid support fixing bolts, manual gearbox side to the recommended torque.

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

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

- Remove the support used for supporting the power unit.

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

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

- Connect the gear selection-engagement rods.

- Tighten the bolt fixing the gear selection-engagement rods mounting bracket.

- Connect the quick-release fitting for the brake servo vacuum intake pipe, air chamber side.

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

- Place the radiator upper coolant inlet hose in position, connect it to the thermostat and tighten the band.

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

- Connect the pipes to the engine coolant supply reservoir and tighten the bands.

- Connect the rapid connector for the air intake chamber fuel vapour inlet pipe, intermediate fuel vapour pipe side.

- Connect the air conditioning system pipe flange and tighten the nut to the recommended torque.

- Connect the electrical connection to the air conditioning system multi-stage pressure switch.

1. Place the fuel supply pipe (1a) in its housing, connect it and tighten the connector (1b) to the recommended torque.

- Place the air filter casing in its housing and secure it to the bodyshell using the three pins.

- Connect the cold air intake to the air filter casing.

- Fasten the fuel vapour pipe to the air filter casing using the band.

- Fit the air filter filter element in place.

- Fit the cover for the air filter, complete with air flow meter, and secure it using the bolts.

- Connect the electrical connection to the air flow meter.

- Place the air supply hose from the air flow meter to the throttle casing back in its housing and secure it using the bands.

- Connect the engine oil vapour recovery pipe to the cylinder head cover and secure it using the band.

- Place the coolant return pipe to the engine coolant reservoir in position and tighten the bands and the nut.

- Place the electrical wiring back in its housing, then secure it and connect the electrical connection to the fans.

- Connect the earth leads to the bodyshell and secure them using the nuts.

- Connect the electrical connections, then place the electrical connections casing in its housing.

- Place the cover for the electrical connections casing in position.

- Connect the right driveshaft to the intermediate driveshaft.

- Connect the left driveshaft to the differential.

- Tighten the coolant drain plug to the water pump to the recommended torque.

- Tighten the radiator coolant drain plug.

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

- Place the upper radiator crossmember guard back in its housing and secure it using the bolts.

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

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

Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR

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

Op. 5530B10 BATTERY - R+R

Op. 4410D10 FRONT SUSPENSION FRAME - R+R

Op. 7055A43 CENTRE FRONT GRILLE - R.R.

Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R

Op. 1080B95 REAR LAMBDA SENSOR TO CATALYTIC CONVERTER - R.R

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. 0010T20 ENGINE COOLANT - CHANGE

- Connect the negative battery terminal.

- Remove the vehicle from the lift.

1.9 JTD 16v

Removing

- Position the vehicle on a lift.

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

Op. 5530B10 BATTERY - R+R

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

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

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

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.

1. Undo the radiator coolant drain plug.

Collect the coolant in a suitable container.

2. Loosen the bands (2a) and remove the intercooler air inlet sleeve (2b).

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

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

1. Disconnect the electrical connections from the diesel electronic injection system control unit.

1. Disconnect the electrical connection from the air flow meter.

2. Loosen the band and disconnect the corrugated sleeve from the tturbocharger air inlet hose.

3. Disconnect the cold air intake pipe from the air filter.

1. Release the air filter (1a) from the fastenings on the bodyshell and remove it complete with air flow meter (1b) and corrugated sleeve (1c).

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

1. Loosen the bands (1a) and remove the air outlet hose from the turbocharger (1b).

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

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

1. Loosen the bands and disconnect the engine coolant supply reservoir pipes.

1. Rotate the engine coolant supply reservoir as illustrated in the diagram, then remove it.

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

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

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

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

3. Undo the bolt (3a) and disconnect the earth lead (3b) from the gearbox.

1. Unscrew bolts (1a), loosen band (1b) and remove the sleeve (1c) and the rigid inlet pipe (1d) to the throttle body.

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

3. Loosen the band (3a) and disconnect the radiator upper coolant inlet hose to the radiator (3b), thermostat side.

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

2. Unscrew nuts (2a) and rmove aside the turbocharger vane position actuator control solenoid valve (2b).

- Disconnect the electrical connection from the water presence sensor on the fuel filter.

- Disconnect the electrical connection from the particle filter differential pressure sensor.

1. Undo the nut and move the glow plug control unit as far as necessary.

2. Disconnect the electrical connections from the heater plugs control unit.

3. Remove the glow plug control unit.

4. Disconnect the intermediate engine wiring coupling.

1. Disconnect the electrical connections from the power steering pump.

The version with ABS is shown in the diagram. The version with ESP comes with the two electrical connections indicated plus a third electrical connection with wiring for connection to the steering angle sensor.

1. Disconnect the electrical connection from the air conditioning system multi-stage pressure switch.

2. Undo the nut (2a) and disconnect the earth lead (2b).

- Secure the engine cooling radiator to the headlamp beam.

1. Undo the nut (1a) and disconnect the steering links (1b) from the steering knuckles using the tool (1c).

2. Undo the nuts (2a) and disconnect the left front anti-roll bar link (2b) from the antiroll bar.

1. Undo the fixing bolt (1a) and disconnect the steering column (1b) from the steering box.

The bolt is the pre-treated type and it therefore cannot be reused when refitting.

1. Remove right front hub cap (1a) using the tool (1b).

1. Undo the nut (1a) securing the right front driveshaft to the wheel hub using tool (1b) for counter-torque.

1. Undo the lower bolt securing the left front shock-absorber to the knuckle.

1. Undo the bolt (1a) and disconnect the lower track control arm for the front suspension (1b) from the steering knuckle pulling it downwards.

Do not use expansion tools for disconnecting the track control arm from the steering knuckle.

1. Use a suitable lever to disconnect the left driveshaft from the differential and move it to the side.

1. Undo the lower bolt securing the right front shock-absorber to the knuckle.

1. Undo the nuts (1a) and disconnect the right front anti-roll bar link (1b) from the antiroll bar.

1. Undo the bolt (1a) and disconnect the lower track control arm for the front suspension (1b) from the steering knuckle pulling it downwards.

Do not use expansion tools for disconnecting the track control arm from the steering knuckle.

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

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

2. Remove the right drive shaft (2a) complete with intermediate drive shaft (2b).

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

1. Undo the nuts (1a) and remove the engine coolant radiator mounts (1b).

- Position a hydraulic jack beneath the power unit.

1. Unscrew the left engine mount flexible block bolt, front suspension frame side.

1. Undo the bolt securing the lower gearbox reaction rod to the mounting bracket on the gearbox.

1. Position a hydraulic lift (1a) using tools (1b) and (1c) to support the front suspension frame.

Fit the guide pins (arrowed) into the front suspension frame body.

During disassembly, lower the two locating pins (1d) on the underbody.

- If the above hydraulic lift is not available, use a general hydraulic lift plus the adaptor shown in the drawing, which must be made up by the workshop to allow the use of the above frames.

(*): Ensure the shank diameter fits the hydraulic lift used.

1. Unscrew bolts (1a) and (1b) and remove the brackets securing the frame to the body (1c).

1. Undo the bolts fixing the front suspension frame to the bodyshell.

1. Lower the hydraulic jack and remove the front suspension frame assembly.

- Postion a suitable footboard beneath the power unit.

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

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

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

- Slowly lower the power unit with the hydraulic hoist until it rests on the board positioned previously.

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

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

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

- Remove the support used for supporting the power unit.

1. Refit the front suspension frame assembly using the mounting tools and hydraulic jack.

During refitting, remove both locating pins (1a), which must fit into the holes in the underbody during assembly.

1. Tighten the new side bolts fixing the front suspension crossmember to the bodyshell to the recommended torque.

1. Place the underbody reinforcement (1a) in its housing and secure it tightening the new bolts (1b), (1c) and (1d) to the recommended torque.

- Remove the tools and the hydraulic jack used to support the front suspension frame.

1. Undo the bolt securing the lower gearbox reaction rod to the mounting bracket on the gearbox to the specified torque.

1. Tighten the left engine mount flexible block bolt, front suspension frame side, to the specified torque.

- Remove the hydraulic jack from beneath the power unit

1. Position the engine cooling radiator mount (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

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

1. Refit the right drive shaft (1a) complete with intermediate drive shaft (1b).

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

1. Connect the front suspension lower track control arm (1a) to the steering knuckle and secure it tightening a new bolt (1b) to the recommended torque.

1. Connect the right front antiroll bar link (1a), antiroll bar side, and tighten nut (1b) to the specified torque.

1. Tighten the new lower bolt fixing the right front shock absorber to the steering knuckle to the recommended torque.

- Connect the left driveshaft to the differential.

1. Connect the left lower suspension lower track control arm (1a) to the steering knuckle and secure it tightening a new bolt (1b) to the recommended torque.

1. Tighten the new lower bolt fixing the left front shock absorber to the steering knuckle to the recommended torque.

1. Tighten nut (1a) securing the right front drive shaft to the wheel hub using tool (1b) for countertorque.

- Refit a new front hub cap in its seat using the appropriate tool.

1. Connect the steering column (1a) to the power steering box pinion and secure by tightening a new bolt (1b) to the specified torque.

1. Connect the left front antiroll bar link (1a) to the antiroll bar and tighten nut (1b) to the specified torque.

2. Connect the left steering link (2a) to the front steering knuckles and tighten the nut (2b) to the specified torque.

- Release the engine cooling radiator from the headlamp beam.

- Connect the earth lead and tighten the nut.

- Connect the electrical connection to the air conditioning system multi-stage pressure switch.

- Connect the electrical connections to the power steering pump.

- Connect the intermediate engine wiring coupling.

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

- Place the heater plugs control unit in position and secure it using the nut.

- Connect the electrical connection to the particle filter differential pressure sensor.

- Connect the electrical connection to the water presence sensor on the fuel filter.

- Refit the turbocharger vane position actuator control solenoid valve and secure with nuts.

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

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

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

- Place the throttle body rigid air inlet pipe in its housing complete with hose and tighten the bolts and the band.

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

- Connect the electrical connection to the reversing light switch.

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

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

- Connect the gear engagement cable.

- Connect the gear selector cable.

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

- Place the engine coolant supply reservoir in its housing.

- Connect the pipes to the engine coolant supply reservoir and tighten the bands.

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

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

- Place the air outllet hose from the turbocharger back in its housing and secure it using the bands.

- Connect the lower coolant inlet hose from the radiator, water pump rigid coolant inlet pipe side and tighten the band.

- Refit the air filter with air flow meter and corrugated hose in its seat.

- Connect the cold air intake pipe to the air filter.

- Connect the corrugated hose to the turbocharger air inlet pipe and tighten the band.

- Connect the electrical connection to the air flow meter.

- Connect the electrical connections to the diesel electronic injection system control unit.

1. Connect the flange for the air conditioning compressor coolant inlet and outlet pipes (1a) and tighten the bolt (1b) to the recommended torque.

- Place the intercooler air intake sleeve back in its housing and secure it using the bands.

- Tighten the radiator coolant drain plug.

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

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

Op. 5530B10 BATTERY - R+R

Op. 0010T20 ENGINE COOLANT - CHANGE

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

Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR

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

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

- Remove the vehicle from the lift.

1.9 JTD 8v

Removing

- Position the vehicle on a lift.

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

Op. 5530B10 BATTERY - R+R

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

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

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

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.

1. Undo the radiator coolant drain plug.

Collect the coolant in a suitable container.

2. Loosen the bands (2a) and remove the heat exchanger air inlet hose (2b).

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

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

1. Disconnect the electrical connections from the diesel electronic injection system control unit.

1. Disconnect the electrical connection from the air flow meter.

2. Loosen the band and disconnect the corrugated sleeve from the turbocharger air inlet hose.

3. Disconnect the cold air intake pipe from the air filter.

1. Release the air filter (1a) from the fastenings on the bodyshell and remove it complete with air flow meter (1b) and corrugated sleeve (1c).

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

1. Loosen the bands (1a) and remove the air outlet hose from the turbocharger (1b).

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

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

1. Loosen the bands and disconnect the engine coolant supply reservoir pipes.

1. Rotate the engine coolant supply reservoir as illustrated in the diagram, then remove it.

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

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

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

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

3. Undo the bolt (3a) and disconnect the earth lead (3b) from the gearbox.

1. Unscrew bolts (1a), loosen collar (1b) and remove the sleeve (1c) and rigid air intake pipe (1d) to the throttle body.

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

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

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

2. Unscrew nuts (2a) and move aside the turbocharger vane position actuator control solenoid valve (3b).

- Disconnect the electrical connection from the water presence sensor on the fuel filter.

- Disconnect the electrical connection from the particulate filter differential pressure sensor.

1. Unscrew the nut and move the glow plug control unit as necessary.

2. Disconnect the electrical connections from the heater plugs control unit.

3. Remove the control unit for glow plugs.

4. Disconnect the intermediate engine wiring coupling.

1. Disconnect the electrical connections from the power steering pump.

1. Disconnect the electrical connection from the air conditioning system multi-stage pressure switch.

2. Undo the nut (2a) and disconnect the earth lead (2b).

- Secure the engine cooling radiator to the headlamp beam.

1. Undo the nut (1a) and disconnect the steering links (1b) from the steering knuckles using the tool (1c).

2. Undo the nuts (2a) and disconnect the rear suspension anti-roll bar joints (2b), anti-roll bar side.

1. Undo the fixing bolt (1a) and disconnect the steering column (1b) from the steering box.

The bolt is the pre-treated type and it therefore cannot be reused when refitting.

1. Remove right front hub cap (1a) using the tool (1b).

1. Undo the nut (1a) securing the right front driveshaft to the wheel hub using tool (1b) for counter-torque.

1. Undo the lower bolt securing the left front shock absorber to the knuckle.

1. Undo the bolt (1a) and disconnect the left lower track control arm for the front suspension (1b) from the steering knuckle pulling it downwards.

Do not use expansion tools for disconnecting the track control arm from the steering knuckle.

1. Disconnect the left driveshaft from the differential using a suitable lever and move it to the side.

1. Undo the lower bolt securing the right front shock absorber to the knuckle.

1. Undo the nuts (1a) and disconnect the rear front suspension anti-roll bar link (1b) from the anti-roll bar.

1. Undo the bolt (1a) and disconnect the right lower track control arm for the front suspension (1b) from the steering knuckle pulling it downwards.

Do not use expansion tools for disconnecting the track control arm from the steering knuckle.

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

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

2. Remove the right drive shaft (2a) with intermediate drive shaft (2b).

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

1. Undo the nuts (1a) and remove the engine coolant radiator mounts (1b).

- Position a hydraulic jack beneath the power unit.

1. Unscrew the left engine mount flexible block bolt, front suspension frame side.

1. Undo the bolt securing the lower gearbox reaction rod to the bracket on the gearbox.

1. Position a hydraulic lift (1a) using tools (1b) and (1c) to support the front suspension frame.

Fit the guide pins (arrowed) into the front suspension frame body.

During disassembly, lower the two locating pins (1d) on the body.

- If the above hydraulic lift is not available, use a general hydraulic lift plus the adaptor shown in the drawing, which must be made up by the workshop to allow the use of the above frames

(*): Ensure the shank diameter fits the hydraulic lift used.

1. Unscrew bolts (1a) and (1b) and remove the brackets securing the frame to the body (1c).

1. Undo the bolts fixing the front suspension frame to the bodyshell.

1. Lower the hydraulic jack and remove the front suspension frame assembly.

- Postion a suitable footboard beneath the power unit.

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

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

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

- Slowly lower the power unit with the hydraulic hoist until it rests on the board positioned previously.

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

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

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

- Remove the support used for supporting the power unit.

1. Refit the front suspension frame assembly using the mounting tools and hydraulic jack.

During refitting, remove both locating pins (1a), which must fit into the holes in the underbody during assembly.

1. Tighten the bolts fixing the front suspension crossmember to the bodyshell to the recommended torque.

1. Place the underbody reinforcement (1a) in its housing and secure it tightening the new bolts (1b), (1c) and (1d) to the recommended torque.

- Remove the tools and the hydraulic jack used to support the front suspension frame.

1. Undo the bolt securing the lower gearbox reaction rod to the mounting bracket on the gearbox to the specified torque.

1. Tighten the left engine mount flexible block bolt, front suspension frame side, to the specified torque.

- Remove the hydraulic jack from beneath the power unit

1. Position the engine cooling radiator mount (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

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

1. Refit the right drive shaft (1a) complete with intermediate drive shaft (1b).

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

1. Connect the front suspension lower track control arm (1a) to the steering knuckle and secure it tightening a new bolt (1b) to the recommended torque.

1. Connect the right front antiroll bar link (1a), antiroll bar side, and tighten nut (1b) to the specified torque.

1. Tighten the new lower bolt fixing the right front shock absorber to the steering knuckle to the recommended torque.

- Connect the left driveshaft to the differential.

1. Connect the left lower suspension lower track control arm (1a) to the steering knuckle and secure it tightening a new bolt (1b) to the recommended torque.

1. Tighten the new lower bolt fixing the right front shock absorber to the steering knuckle to the recommended torque.

1. Tighten nut (1a) securing the right front drive shaft to the wheel hub using tool (1b) for countertorque.

- Refit a new front hub cap in its seat using the appropriate tool.

1. Connect the steering column (1a) to the power steering box pinion and secure by tightening a new bolt (1b) to the specified torque.

1. Connect the left front antiroll bar link (1a) to the antiroll bar and tighten nut (1b) to the specified torque.

2. Connect the left steering link (2a) to the front steering knuckles and tighten the nut (2b) to the specified torque.

- Release the engine cooling radiator from the headlamp beam.

- Connect the earth lead and tighten the nut.

- Connect the electrical connection to the air conditioning system multi-stage pressure switch.

- Connect the electrical connections to the power steering pump.

- Connect the intermediate engine wiring coupling.

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

- Place the heater plugs control unit in position and secure it using the nut.

- Connect the electrical connection to the particle filter differential pressure sensor.

- Connect the electrical connection to the water presence sensor on the fuel filter.

- Refit the turbocharger vane position actuator control solenoid valve and secure with nuts.

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

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

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

- Place the throttle body rigid air inlet pipe in its housing complete with hose and tighten the bolts and the band.

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

- Connect the electrical connection to the reversing light switch.

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

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

- Place the engine coolant supply reservoir in its housing.

- Connect the pipes to the engine coolant supply reservoir and tighten the bands.

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

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

- Place the air outllet hose from the turbocharger back in its housing and secure it using the bands.

- Connect the lower coolant inlet hose from the radiator, water pump rigid coolant inlet pipe side and tighten the band.

- Refit the air filter with air flow meter and corrugated hose in its seat.

- Connect the cold air intake pipe to the air filter.

- Connect the corrugated hose to the turbocharger air inlet pipe and tighten the band.

- Connect the electrical connection to the air flow meter.

- Connect the electrical connections to the diesel electronic injection system control unit.

1. Connect the coolant inlet and outlet pipe flange (1a)

to the air conditioner compressor and secure by tightening bolt (1b) to the specified torque.

- Place the intercooler air intake sleeve back in its housing and secure it using the bands.

- Tighten the coolant drain plug to the radiator.

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

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

Op. 5530B10 BATTERY - R+R

Op. 0010T20 ENGINE COOLANT - CHANGE

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

Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR

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

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

- Remove the vehicle from the lift.

1.8

Removing

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

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

Op. 1080B95 REAR LAMBDA SENSOR TO CATALYTIC CONVERTER - R.R

Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R

Op. 4410D10 FRONT SUSPENSION FRAME - R+R

Op. 5530B10 BATTERY - R+R

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

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

Op. 0010T20 ENGINE COOLANT - CHANGE

1. Disconnect the right driveshaft from the differential, move it to one side and secure it appropriately.

2. Disconnect the left driveshaft from the differential, move it to one side and secure it appropriately.

1. Undo the nuts and remove the wiring for the alternator.

2. Undo the nuts and remove the wiring for the starter motor.

1. Disconnect the electrical connection for the coolant temperature sensor on the radiator.

1. Undo the bolt fixing the flange for the air conditioning compressor inlet and supply pipes.

1. Disconnect the (rear) electrical connection for the injection control unit.

2. Disconnect the engine coupling.

3. Undo the injection control unit fixing nut and remove the earth lead.

1. Disconnect the electrical connection for the reversing sensor.

2. Undo the bolt and remove the battery earth lead from the gearbox.

- Move the cable loom to one side.

1. Remove the brake/clutch fluid reservoir cap and tighten the tool.

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

1. Disconnect the electrical connection for the air flow meter.

1. Disconnect the electrical connection for the multilevel sensor.

1. Loosen the bands and disconnect the two heater water supply and return pipes from the thermostat.

1. Loosen the band and disconnect the flexible water return pipe from the throttle body, intermediate connector side.

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

1. Loosen the band and disconnect the lower radiator, water pump side.

- Disconnect the brake servo vacuum pipe, intake chamber side.

1. Loosen the bands and remove the air hose between the flow meter and throttle body.

1. Loosen the band and remove the fuel vapour pipe from the solenoid valve.

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

1. Disconnect the gear selector and engagement cables.

2. Adjust the retaining clips (2a) manually and remove the gear selection-engagement cables (2b) from the reaction bracket.

- Postion a suitable footboard beneath the power unit.

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

1. Undo the bolts (1a) fixing the flexible mounting (1b) to the timing side rigid power unit support.

1. Undo the bolts (1a) fixing the flexible mounting (1b) to the gearbox side rigid power unit support.

- Slowly lower the power unit with the hydraulic hoist until it rests on the board positioned previously.

Refitting

- Connect the power unit to the support tools and, using a hydraulic hoist, place it in position in the engine compartment.

- Place the gearbox side support 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 timing side rigid power unit support tightening the bolts to the recommended torque.

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

Make sure that the gear lever is in neutral.

- Introduce the gear selection and engagement cables in the openings in the reaction bracket and secure them exerting manual pressure until they are properly attached.

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

- Connect the fuel supply pipe rapid connector to the rail.

- Connect the fuel vapour pipe to the solenoid valve and secure it using the band.

- Place the air hose from the flow meter to the throttle body in its housing and tighten the bands.

- Connect the brake servo vacuum pipe to the modular intake chamber.

- Connect the lower radiator hose to the water pump and secure it using the band.

- Connect the upper radiator hose to the thermostat and secure it using the band.

- Connect the water return pipe from the throttle body to the intermediate connector and secure it using the band.

- Connect the two passenger compartment heater supply and return pipes to the thermostat and secure them using the bands.

- Connect the electrical connection to the multilevel sensor.

- Connect the electrical connection for the air flow meter.

- Connect the clutch fluid pipe to the three-way connector and secure it using the retaining clip.

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

- Connect the electrical connection for the reversing light sensor.

- Connect the earth lead to the injection control unit and secure it using the nut.

- Connect the engine coupling.

- Connect the (rear) electrical connection for the injection control unit.

- Connect the flanges for the air conditioning compressor inlet and supply pipes and secure them using the bolt.

- Connect the electrical connection for the coolant temperature sensor on the radiator.

- Connect the starter motor wiring and secure it using the nuts.

- Connect the alternator wiring and secure it using the nuts.

- Connect the left and right driveshafts to the differential.

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

Op. 5530B10 BATTERY - R+R

Op. 4410D10 FRONT SUSPENSION FRAME - R+R

Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R

Op. 1080B95 REAR LAMBDA SENSOR TO CATALYTIC CONVERTER - R.R

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT 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. 0010T64 BRAKE AND/OR CLUTCH FLUID CHECK LEVEL AND TOP UP AS NECESSARY

Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR