GEAR BOX LEFT RIGID MOUNT - R R

Operation 1008A42 · POWER UNIT FASTENINGS

2.0 JTD 8V

Removing

- Position the vehicle on a lift.

1. Disconnect the intake hose from the air filter casing and from the cold intake on the crossmember.

2. Remove the cold intake and intake hose assembly from the engine compartment.

See in Op. 1048A10

1. Release the two ends (1a), move the two gear selector and engagement flexible cables (1b) out of the slot in the bracket (1c) and place them outside of the work area.

- Raise the vehicle.

Op. 7055B54 UNDER-ENGINE GUARD - R R

1. Remove the cover (1a), undo the nut (1b) and remove the selector unit idler connecting rod (1c).

1. Undo the nuts fixing the gearbox side flexible mounting to the rigid support.

2. Undo the bolts and the nut fixing the rigid support to the gearbox.

- Gently lower the engine until the studs on the rigid support comes out of the housing in the flexible mounting.

3. Undo the bolts fixing the rigid engine coolant pipe between the radiator and thermostat flexible hoses.

4. Remove the gearbox side rigid power unit support.

Refitting

- Fit the gearbox side rigid engine support.

- Tighten the nuts fixing the gearbox side flexible mounting to the rigid support.

- Tighten the bolts and the nuts fixing the rigid support to the gearbox to torque.

- Tighten the bolts fixing the rigid engine coolant pipe between the radiator and thermostat flexible hoses.

- Remove the hydraulic arm positioned previously to support the gearbox.

- Fit the idler connecting rod on the gear selector and enagement assembly, tighten the nut and fit the plug.

Op. 7055B54 UNDER-ENGINE GUARD - R R

- Lock the ends of the gear selector and engagement flexible cables.

- Secure the cables to the mounting bracket.

- Fit the air supply hose to the turbocharger and secure it to the air filter casing.

See in Op. 1048A10

- Fit the cold intake and intake hose assembly in the engine compartment.

- Connect the intake hose to the air filter casing and to the cold intake on the crossmember.

- Remove the vehicle from the lift.

2.8 JTD 8V

Removing

See in Op. 1048A10

Op. 1048A12 AIR CLEANER SUPPORT - R R WITH AIR CLEANER ASSEMBLY REMOVED

Op. 7055B54 UNDER-ENGINE GUARD - R R

See in Op. 1008B30

1. Release the two ends (1a), move the two gear selector and engagement flexible cables (1b) out of the slot in the bracket (1c) and place them outside of the work area.

1. Remove the cover.

2. Undo the fixing nut.

3. Remove the idler connecting rod for the selector unit.

1. Undo the fixing nuts and bolts (1a) and remove the support (1b).

Refitting

- Place the rigid support in position.

- Tighten the fixing nuts and bolts and check the torque.

- Fit the idler connecting rod on the gear selector and enagement assembly, tighten the nut and fit the plug.

- Lock the ends of the gear selector and engagement flexible cables.

- Secure the cables to the mounting bracket.

See in Op. 1008B30

Op. 7055B54 UNDER-ENGINE GUARD - R R

Op. 1048A12 AIR CLEANER SUPPORT - R R WITH AIR CLEANER ASSEMBLY REMOVED

See in Op. 1048A10

2.0 16V

Removing

1. Disconnect the intake hose from the air filter casing and from the cold intake on the crossmember.

2. Remove the intake hose from the engine compartment.

See in Op. 1048A10

1. Release the two ends (1a), move the two gear selector and engagement flexible cables (1b) out of the slot in the bracket (1c) and place them outside of the work area.

Op. 7055B54 UNDER-ENGINE GUARD - R R

- Lower the vehicle and position a hydraulic arm support beneath the gearbox to support the engine.

1. Remove the cover.

2. Undo the nut

3. Remove the idler connecting rod for the selector unit.

1. Undo the nuts fixing the gearbox side flexible mounting to the rigid support.

2. Undo the bolts and the nut fixing the rigid support to the gearbox.

- Gently lower the engine until the studs on the rigid support comes out of the housing in the flexible mounting.

3. Remove the gearbox side rigid power unit support.

Refitting

- Fit the gearbox side rigid engine support.

- Tighten the nuts fixing the gearbox side flexible mounting to the rigid support.

- Tighten the bolts and the nuts fixing the rigid support to the gearbox to torque.

- Remove the hydraulic arm positioned previously to support the gearbox.

- Fit the idler connecting rod on the gear selector and enagement assembly, tighten the nut and fit the plug.

Op. 7055B54 UNDER-ENGINE GUARD - R R

- Lock the ends of the gear selector and engagement flexible cables.

- Secure the cables to the mounting bracket.

- Fit the air supply hose to the turbocharger and secure it to the air filter casing.

See in Op. 1048A10

- Fit the intake hose.

- Connect the intake hose to the air filter casing and to the cold intake on the crossmember.

- Remove the vehicle from the lift.

2.3 JTD 16V

Removing

- Position the vehicle on a lift.

1. Unscrew the bolts securing the cold air intake to the upper crossmember.

2. Disconnect the intake sleeve from the air cleaner case.

3. Remove the intake and cold air input sleeve assembly from the engine bay.

1. Disconnect the collar securing the air delivery sleeve to the turbocharger.

2. Disconnect the vapour recovery pipe from the air delivery sleeve to the turbocharger.

3. Disconnect the collar from air cleaner case (3a) and remove the air delivery sleeve to turbocharger (3b).

1. Prise up both heads (1a), move both gear selection and engagement cables (1b) out of the slot on bracket (1c) and place outside the working area.

1. Unscrew the air cleaner case bracket bolts.

2. Undo the bolts securing the air cleaner case to the bracket joining it to the screen washer reservoir.

3. Remove the air cleaner case from the engine bay.

- Raise the vehicle.

Op. 7055B54 UNDER-ENGINE GUARD - R R

1. Remove cover (1a), unscrew nut (1b) and remove selection unit idler rod (1c).

1. Undo the bolts securing the flexible gearbox side block to its rigid support.

2. Undo the bolts and nut securing the rigid support to the gearbox.

- Slightly lower the engine until the stud on the rigid mount emerges from its seat on the flexible block.

3. Remove the gearbox side rigid engine mount.

Refitting

- Fit the gearbox side rigid engine mount.

- Tighten the bolts securing the flexible gearbox side block to its rigid support to torque.

- Tighten the bolts and nut securing the rigid support to the gearbox to torque.

- Remove the hdyraulic arm positioned previously to support the gearbox.

- Fit the idler rod to the gear selection and engagement unit, tighten the nut and apply the relevant plug.

Op. 7055B54 UNDER-ENGINE GUARD - R R

- Fit the air cleaner case.

- Screw in the bolt securing the air cleaner case to the bracket joining it to the screen washer reservoir.

- Screw in the air cleaner case bracket bolts.

- Press home the gear selection and engagement cable heads.

- Secure the cables to the bracket.

- Fit the air delivery sleeve to the turbocharger and secure to the air cleaner case.

- Connect the vapour recovery pipe to the air delivery sleeve.

- Fit the intake and cold air input sleeve assembly in the engine bay.

- Connect the intake sleeve to the air cleaner case.

- Screw in the bolts securing the cold air intake to the upper crossmember.

- Remove the vehicle from the lift.