- Position the vehicle on a lift.1. Disconnect the windscreen washer jet pipe.2. Undo the bolts fixing the bonnet lid hinges to the bodyshell.3. Remove the bonnet lid, with the help of a second mechanic, and place it on a surface taking care over the paintwork.
Engines: 2.3 JTD 16V
1. Undo the bolts fixing the cold air intake to the upper crossmember.2. Disconnect the intake hose from the air filter casing.3. Remove the cold intake and intake hose assembly from the engine compartment.
Engines: 2.3 JTD 16V
1. Remove the air delivery sleeve to the air-air heat exchanger (intercooler).
Engines: 2.3 JTD 16V
- Raise the vehicle.1. Disconnect the oil pipe from the power steering pump and drain the power steering system into a suitable container.- Reconnect the power steering fluid pipe.
Engines: 2.3 JTD 16V
1. Undo the bolts securing the power steering fluid reservoir bracket.2. Disconnect the fluid pipes from the reservoir.3. Remove the power assisted steering fluid reservoir complete with bracket.
Engines: 2.3 JTD 16V
1. Remove the second section of the air delivery sleeve to the air-air heat exchanger (intercooler).
Engines: 2.3 JTD 16V
1. Disconnect the right front light cluster electrical connection.
Description
Connector
1
Right headlamp
F011
2. Disconnect the collars at both ends and remove the air hose from intercooler to intake manifold.
Engines: 2.3 JTD 16V
- Arrange a container beneath the engine to recover the engine coolant.1. Disconnect lower pipe (1a) and upper pipe (1b) from the radiator.2. Disconnect the pipes from the rigid pipes.3. Remove the lower and upper radiator pipes.
Engines: 2.3 JTD 16V
1. Undo the fixing bolts.2. Remove the front grille.
Engines: 2.3 JTD 16V
1. Undo the retaining nuts.2. Disconnect the bonnet lid opening cable.3. Remove the bonnet lid catch.- Release the cable from the retaining collars in the engine bay.
1. Disconnect the fan electrical connections and release the wiring from the retaining collars.
Description
Connector
1
Fan motor
N011
Description
Connector
1
Engine fan motor 2
N012
2. Unscrew the upper radiator/fan unit and intercooler retaining bolts.- Raise the vehicle and release the lower radiator support beam from the attached wiring.- Arrange an appropriate hydraulic safety lift beneath the beam.3. Unscrew the bolts securing the lower beam to the struts.4. With the aid of a second operator, remove the assembly from the lower part of the engine bay.
Engines: 2.3 JTD 16V
- Disconnect the left front light cluster electrical connection.
Description
Connector
.
Left headlamp
F010
1. Unscrew the upper light cluster retaining bolt.2. Use a suitable tool (2a) to prise light cluster (2b) from its seat, while releasing the pin from the wing.- Repeat the same operation on the right front light cluster.
Description
Code
Function
2a
Knife
1.078.077.000
Prise light cluster out of beam
Engines: 2.3 JTD 16V
1. Unscrew the nuts and bolts securing the upper beam located inside the light cluster seats.2. Remove the upper beam from the engine bay complete with front light clusters.
Engines: 2.3 JTD 16V
1. Undo the fixing bolts.2. Remove the crossmember.
Engines: 2.3 JTD 16V
1. Disconnect the band retaining the coolant pipe on the reservoir to the cylinder head.2. Remove the electrical connection from its seat on the reservoir.3. Undo the nuts fixing the expansion tank.4. Disconnect the water pump coolant supply pipe (4a) and remove the expansion tank (4b).
Engines: 2.3 JTD 16V
1. Undo the fixing bolts (1a) and remove the protective cover (1b) for the heater plugs control unit.2. Disconnect the electrical connections for the heater plugs control unit (2a) and (2b) and the control unit positive electrical connection (2c).
Description
Connector
2a
Heater plugs control unit
M015A
Description
Connector
2b
Heater plugs control unit
M015B
Description
Connector
2c
Heater plugs control unit
M015C
3. Undo the fixing nuts (3a) and remove the mounting bracket (3b) complete with heater plugs control unit.
Engines: 2.3 JTD 16V
1. Disconnect coolant delivery line (1a) and return line (1b) from the heater.
Engines: 2.3 JTD 16V
1. Disconnect the band fastening the air supply hose to the turbocharger.2. Disconnect the vapour recovery pipe from the air supply hose to the turbocharger.3. Disconnect the band from the air filter casing (3a) and remove the air supply hose to the turbocharger (3b).
Engines: 2.3 JTD 16V
1. Undo bolts (1a) and remove the clutch release cylinder (1b) from its housing.
Engines: 2.3 JTD 16V
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.
Engines: 2.3 JTD 16V
1. Disconnect the engine management unit electrical connections.
Description
Connector
1
Engine management control unit
M010A
Description
Connector
1
Engine management control unit
M010B
Engines: 2.3 JTD 16V
1. Disconnect the wiring from the starter motor.
Description
Connector
1
Starter motor
A020A
Description
Connector
1
Starter motor
A020B
Engines: 2.3 JTD 16V
1. Disconnect the electrical connection for the reversing light switch.
Description
Connector
1
Reversing lights switch
I020
Engines: 2.3 JTD 16V
1. Disconnect the electrical connection for the voltage regulator on the alternator.
Description
Connector
1
Alternator
A010A
- Disconnect the remaining electrical wiring from the alternator.
Description
Connector
.
Alternator
A010B
Engines: 2.3 JTD 16V
1. Undo the bolts fixing the air filter casing mounting bracket.2. Undo the bolt fixing the air filter casing to the bracket joined to the windscreen washer fluid reservoir.3. Remove the air filter casing from the engine compartment.
Engines: 2.3 JTD 16V
1. Disconnect the electrical connection for the speedometer sensor.
Description
Connector
1
Speedometer sensor
K084
Engines: 2.3 JTD 16V
1. Undo the retaining bolt.2. Remove the engine bay junction unit protective cover.
Engines: 2.3 JTD 16V
1. Release the junction unit from its seat in the mount and disconnect electrical connections (1a) and (1b).
Description
Connector
1a
Engine compartment junction unit
B001C
Description
Connector
1b
Front/facia coupling
D001A
Engines: 2.3 JTD 16V
1. Disconnect the brake servo vacuum pipe from the vacuum unit
Engines: 2.3 JTD 16V
1. Disconnect the two rapid connectors for the fuel supply and return pipes.
Engines: 2.3 JTD 16V
- Have a suitable container for collecting the transmission fluid ready.1. Undo the plug, using a suitable spanner, and drain the transmission fluid.
Description
Code
Function
.
Spanner
1.850.182.000
Wrench for slackening/tightening differential fluid plug
Engines: 2.3 JTD 16V
- Position a hydraulic column lift under the track control arm to work safely.1. Undo the nut fixing the track rod end to the steering knuckle.2. Extract the track rod end (2b) from the housing in the steering knuckle using the tool (2a).
Description
Code
Function
2a
Head extractor
1.847.038.000
Ball joint removal
Engines: 2.3 JTD 16V
1. Undo the fixing bolts (1a) and remove the brake caliper-bracket assembly (1b) from the brake disc without disconnect the fluid pipes.
Engines: 2.3 JTD 16V
1. Remove the staking and undo the right hub nut.2. Undo the bolts fixing the steering knuckle to the shock absorber.3. Undo the nuts (3a) and remove the right driveshaft (3b) complete with intermediate shaft (3c).
Engines: 2.3 JTD 16V
1. Undo the fixing bolts (1a) and remove the left brake caliper-bracket assembly (1b) from the brake disc without disconnect the fluid pipes.
Engines: 2.3 JTD 16V
1. Undo the nut fixing the track rod end to the steering knuckle.2. Extract the track rod end (2b) from the housing in the steering knuckle using the tool (2a).
Description
Code
Function
2a
Head extractor
1.847.038.000
Ball joint removal
3. Undo the bolts fixing the steering knuckle to the shock absorber.
Engines: 2.3 JTD 16V
1. Release the inner driveshaft (1a) from the differential and move the right driveshaft (1b) away from the work area.
Engines: 2.3 JTD 16V
1. Undo the fixing nuts (1a) and separate the ridid middle section of the exhaust pipe from the turbocharger hose flange (1b).2. Undo the bolts fixing the rear flange (2a) and remove the rigid middle section (2b) of the exhaust pipe.
Engines: 2.3 JTD 16V
1. Undo the bolt securing the lower reaction rod to the suspension crossmember.2. Undo the bolt securing the lower reaction rod to the mounting bracket on the gearbox.3. Remove the lower reaction link.
Engines: 2.3 JTD 16V
1. Disconnect the return pipe from the power steering pump.2. Open collar (2a) and disconnect power steering pump delivery pipe (2b) to the steering box.
Engines: 2.3 JTD 16V
- Lower the vehicle.1. Undo retaining bolts (1a) and remove the wiring channel (1b).
Engines: 2.3 JTD 16V
1. Loosen the bolt fixing the collar joining the rigid section of the intake pipe to the turbocharger.2. Undo the nut (2a) fixing the pipe to the bracket on the cylinder head and the bolt (2b) fixing the connector for the engine oil vapour pipe.3. Remove the rigid section of the air pipe from the turbocharger.
Engines: 2.3 JTD 16V
1. Undo the fixing bolts.2. Remove the engine oil vapour separator.
Engines: 2.3 JTD 16V
1. Fit the two brackets secured to the cylinder head.2. Position the tool and secure to the brackets positioned previously.3. Secure the tool to a hydraulic lift for supporting and removing the power unit.
Description
Code
Function
2
Crossmember
1.860.851.003
Power unit anchorage beam
Engines: 2.3 JTD 16V
1. Undo the nut and both bolts securing the flexible mount to the timing side rigid power unit mount.
Engines: 2.3 JTD 16V
1. Undo the bolts fixing the gearbox side flexible mounting to the rigid support.
Engines: 2.3 JTD 16V
1. Manoeuvre the power unit by tilting and turning. Then adjust the hydraulic lift to move the power unit onto the platform.
- Support the power unit by means of a hydraulic lift with chains and position the power unit in its compartment on the vehicle.- Tighten the bolts fixing the gearbox side flexible mounting to the rigid support.
Value - daNm
Fastening
Component
Ø
.
(Rigid mount) 5
Bolt
GEARBOX SIDE RUBBER MOUNT
M10
- Tighten the nut and the two bolts fixing the flexible mounting to the timing side rigid power unit support to torque.
Value - daNm
Fastening
Component
Ø
.
(Rigid mount on engine) 5
Bolt
FRONT FLEXIBLE MOUNTING BLOCKS, POWER UNIT
M10
Value - daNm
Fastening
Component
Ø
.
(Rigid mount on engine) 8
Nut
FRONT FLEXIBLE MOUNTING BLOCKS, POWER UNIT
M12
- Remove the tool and hydraulic lift for supporting and removing the power unit.
Description
Code
Function
.
Crossmember
1.860.851.003
Power unit anchorage beam
- Remove the two brackets secured to the cylinder head.- Fit the engine oil vapour separator and tighten the retaining bolts.- Fit the rigid section of the air pipe from the turbocharger.- Tighten the retaining bolt for the turbocharger union collar to torque.- Tighten the bolt securing the engine oil vapour recovery pipe connection and nut securing the piping to the cylinder head.- Positin the wiring channel and secure to the engine bulkhead using retaining bolts.- Raise the vehicle.- Connect the delivery and return pipes to the power steering pump.- Fit the lower reaction rod in the housing and tighten the bolt fixing the suspension crossmember to torque.- Tighten the nut fixing the reaction rod to the gearbox to torque.- Fit the rigid middle section of the exhaust pipe and tighten the bolts securing it to the rear section to torque.
Value - daNm
Fastening
Component
Ø
.
(Front section flange) 2.6
Bolts
REAR SILENCER EXHAUST
M8
- Tighten the nuts securing the front section of the exhaust pipe to the turbocharger to torque.
Value - daNm
Fastening
Component
Ø
.
(Flange on turbocharger) 2.6
Nut
REAR SILENCER EXHAUST
M8
- Fit the inner driveshaft in the housing on the differential for the right driveshaft.- Tighten the bolts fixing the steering knuckle to the shock absorber to torque.
Value - daNm
Fastening
Component
Ø
.
(damper strut) 19
Bolt
FRONT HUB STRUT
M16
- Tighten the nut fixing the ball joint to the steering rod to torque.
Value - daNm
Fastening
Component
Ø
.
6.9
Nut
ADJUSTABLE LINK BALL JOINTS
M16
- Fit the brake caliper - bracket assembly and tighten the bolts fixing the bracket to the left disc to torque.
Value - daNm
Fastening
Component
Ø
.
21
Bolt
FRONT BRAKE CALIPER BRACKET
M16
- Fit the right driveshaft - intermediate driveshaft assembly.- Tighten the nuts fixing the intermediate driveshaft to the support to torque.- Tighten the bolts fixing the steering knuckle to the shock absorber to torque.
Value - daNm
Fastening
Component
Ø
.
(damper strut) 19
Bolts
FRONT HUB STRUT
-
- Tighten the nut fixing the ball joint to the steering rod to torque.
Value - daNm
Fastening
Component
Ø
.
6.9
Nut
ADJUSTABLE LINK BALL JOINTS
M16
- Fit the brake caliper - bracket assembly and tighten the bolts fixing the bracket to the disc to torque.
Value - daNm
Fastening
Component
Ø
.
21
Bolt
FRONT BRAKE CALIPER BRACKET
M16
1. Use a hammer and chisel to stake the wheel hub drive shaft retaining nut as shown in the figure.- The figure below refers to the 15 quintal version.
Value - daNm
Fastening
Component
Ø
.
37
Nut
FRONT HUBS COMPLETE WITH BEARING
M28
- The figure below refers to the 1800 kg version.
Value - daNm
Fastening
Component
Ø
.
42
Nut
FRONT HUBS COMPLETE WITH BEARING
M33
Engines: 2.3 JTD 16V
- Connect the fuel delivery line to the pressure pump and the fuel return line to the tank to the quick-release fittings on the return manifold.- Connect the brake servo vacuum pipe to the vacuum unit- Connect the electrical connections to the junction unit.
Description
Connector
.
Engine compartment junction unit
B001C
Description
Connector
.
Front/facia coupling
D001A
- Position the junction unit in its seat on the mount and fit the protective cover.- Disconnect the electrical connection from the speedometer sensor.
Description
Connector
.
Speedometer sensor
K084
- Fit the air filter casing in the engine compartment.- Tighten the bolt fixing the air filter casing to the bracket joined to the windscreen washer fluid reservoir.- Tighten the bolts fixing the air filter casing mounting bracket.- Connect the voltage regulator electrical connection and the remaining alterantor wiring.
Description
Connector
.
Alternator
A010A
Description
Connector
.
Alternator
A010B
- Disconnect the electrical connection for the reversing lights switch.
Description
Connector
.
Reversing lights switch
I020
- Connect the wiring to the starter motor.
Description
Connector
.
Starter motor
A020A
Description
Connector
.
Starter motor
A020B
- Connect the electrical connections for the engine management control unit.
Description
Connector
.
Engine management control unit
M010A
Description
Connector
.
Engine management control unit
M010B
- Fit both heads of the gear selection and engagement cables and secure them to the bracket.- Fit the clutch release cylinder and tighten the retaining bolts to the bracket.- Fit the air supply hose to the turbocharger and connect the two ends to the filter casing and to the actual turbocharger.- Connect the vapour recovery pipe to the air supply hose to the turbocharger.- Connect coolant delivery line and return line to the heater.- Fit the mounting bracket complete with heater plugs control unit.- Tighten the nuts fixing the control unit to the bodyshell.- Connect the electrical connections for the heater plugs control unit.
Description
Connector
.
Heater plugs control unit
M015A
Description
Connector
.
Heater plugs control unit
M015B
Description
Connector
.
Heater plugs control unit
M015C
- Fit the protective cover for the heater plugs control unit and tighten the bolts fixing it to the mounting bracket underneath.- Fit the engine coolant reservoir and tighten the nuts fixing it to the bodyshell.- Connect the coolant delivery pipe to the pump.- Fasten the electrical connection in the housing on the tank.- Connect the band retaining the coolant pipe to the cylinder head.- Fit the crossmember and tighten the crossmember to torque.- Fit the upper crossmember in the engine bay complete with front light clusters.- Tighten the retaining bolts and nuts to torque.
Value - daNm
Fastening
Component
Ø
.
2.9
Nuts
FRONT WING - HEADLAMP SEAT BEAM
M8
- Secure the front light clusters to the crossmember.- Tighten the upper light cluster retaining bolts to the crossmember.- Connect the left front light cluster electrical connection.
Description
Connector
.
Left headlamp
F010
- With the aid of a second operator, fit the lower crossmember and radiator assembly from underneath the engine bay.- Tighten the bolts securing the radiator mounting beam to torque.
Value - daNm
Fastening
Component
Ø
.
8.5
Bolt
COOLANT RADIATOR SUPPORT BEAM
M12
- Secure the wiring to the lower radiator beam and fasten with collars.- Tighten the upper bolts securing the radiator brackets and fans to the crossmember.
Value - daNm
Fastening
Component
Ø
.
2
Bolt
ENGINE RADIATOR
M8
Value - daNm
Fastening
Component
Ø
.
2
Bolt
ENGINE RADIATOR FAN/S
M8
- Connect the fan electrical connections and release the wiring from the retaining collars.
- Fit the second section of the air delivery sleeve to the air-air heat exchanger (intercooler).- Fit the power steering fluid reservoir complete with bracket.- Connect the oil hoses to the reservoir and tighten the power steering fluid reservoir bracket bolts to the beam.- Fit the air delivery sleeve to the air-air heat exchanger (intercooler).- Fit the cold intake and intake hose assembly in the engine compartment and tighten the bolts fixing the cold air intake to the upper headlamp holder crossmember.- Connect the intake hose to the air filter casing.- Fit the bonnet lid with the help of a second mechanic, taking care not to damage the paintwork.- Screw in the bolts securing the bonnet lid to the bodyshell without tightening them.- Connect the windscreen washer jet pipe.- Adjust the bonnet lid Op. 0010T10 ENGINE OIL CHECK LEVEL AND TOP UP Op. 0010T20 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY Op. 0010T21 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY Op. 0010T70 POWER ASSISTED STEERING FLUID - REPLACE Op. 7055B54 UNDER-ENGINE GUARD - R R
- Position the vehicle on a lift.1. Disconnect the windscreen washer jet pipe.2. Undo the bolts fixing the bonnet lid hinges to the bodyshell.3. Remove the bonnet lid, with the help of a second mechanic, and place it on a surface taking care over the paintwork.
- Using a syringe, draw off the power assisted steering fluid from the reservoir.1. Undo the bolts securing the power steering fluid reservoir to the mounting bracket.2. Disconnect the fluid pipes from the reservoir.3. Remove the power steering fluid reservoir.
Engines: 2.0 JTD 8V
1. Disconnect cold air intake hose from the air filter casing and from the cold air intake.2. Remove the intake sleeve assembly from the engine bay.
Engines: 2.0 JTD 8V
1. Undo the retaining nuts.2. Disconnect the bonnet lid opening cable.3. Remove the bonnet lid catch.- Release the cable from the retaining collars in the engine bay.
Engines: 2.0 JTD 8V
- Disconnect the left and right front light cluster electrical connection.
Description
Connector
.
Left headlamp
F010
Description
Connector
.
Right headlamp
F011
1. Unscrew the upper light cluster retaining bolt.2. Use a suitable tool (2a) to prise light cluster from its seat, while releasing the pin from the opening in the wing.3. Undo the nuts fixing the hinges for the left light cluster (3a) and remove the left front light cluster (3b).- Repeat the same operation on the right front light cluster.
Description
Code
Function
2
Knife
1.078.077.000
Prise light cluster out of beam
Engines: 2.0 JTD 8V
1. Undo the upper retaining bolts for the radiator/fan assembly.2. Unscrew the nuts and bolts securing the upper beam located inside the light cluster seats.3. Remove the upper beam from the engine bay complete with front light clusters.
Engines: 2.0 JTD 8V
- Arrange a container beneath the engine to recover the engine coolant.1. Disconnect bands (1a) and disconnect the lower radiator pipe from rigid section (1b).
Engines: 2.0 JTD 8V
1. Disconnect the uppper radiator pipe.2. Disconnect the pipes from the thermotat.3. Remove the upper radiator pipe.
Engines: 2.0 JTD 8V
1. Undo the bolt securing the plastic side guard.2. Disconnect the recirculation pipe to the tank from the radiator.3. Disconnect the fan electrical connections.
Description
Connector
3
Fan motor
N011
Description
Connector
3
Engine fan motor 2
N012
4. Remove the radiator unit with fans.
Engines: 2.0 JTD 8V
1. Disconnect the right front wheel ABS sensor electrical connection.
Description
Connector
1
Right front wheel sensor for ABS
K071
2. Undo bolt (2a) and disconnect earth lead (2b) from the body.
Engines: 2.0 JTD 8V
1. Remove the protective caps, unscrew retaining nuts (1a) and disconnect alternator electrical wiring (1b).
Description
Connector
1b
Alternator
A010A
Description
Connector
1b
Alternator
A010B
Engines: 2.0 JTD 8V
1. Remove the protective boot, undo the fixing nuts (1a) and disconnect the electrical wiring for the starter mtor (1b).
Description
Connector
1b
Starter motor
A020A
Description
Connector
1b
Starter motor
A020B
- Release the electrical wiring from the bands on the radiator beam and place to one side outside the working area.
Engines: 2.0 JTD 8V
- Partly raise the lift.1. Undo the fixing bolts.2. Remove the radiator supporting crossmember.
Engines: 2.0 JTD 8V
1. Disconnect the band retaining the coolant pipe to the cylinder head.2. Undo the nuts securing the reservoir to the bodyshell.3. Disconnect sleeve (3a) from the rigid pipe and remove expansion tank (3b).
Engines: 2.0 JTD 8V
1. Undo the fixing bolts (1a) and remove the protective cover (1b) for the heater plugs control unit.
Engines: 2.0 JTD 8V
1. Undo the bolts securing both EGR and turbocharging control solenoids to the support beam.
Engines: 2.0 JTD 8V
1. Disconnect the electrical connection for the heater plugs control unit.
Description
Connector
1
Heater plugs control unit
M015C
2. Undo the nut securing the glow plug control unit to the bracket.- Release the wiring from the bands and replace the control unit on the engine.3. Undo the retaining nuts.4. Remove the bracket from the engine compartment.
Engines: 2.0 JTD 8V
1. Disconnect the single-acting valve from the brake servo.
Engines: 2.0 JTD 8V
1. Remove the turbocharger intake manifold rigid delivery hose.
Engines: 2.0 JTD 8V
1. Open retaining clips (1a) and remove protective cover (1b) from the filter element.2. Remove the filter element from the filter casing.
Engines: 2.0 JTD 8V
1. Disconnect the electrical connection for the air flow meter.
Description
Connector
1
Air flow meter
K041
2. Undo the nuts securing the filter casing to the bracket.3. Disconnect the band securing the air flow meter to the air delivery pipe to the turbo.4. Remove the air filter casing.
Engines: 2.0 JTD 8V
1. Disconnect the lower radiator sleeve from the thermostat.2. Undo the bolts securing the rigid section of the pipe to the gearbox.3. Remove the lower radiator pipe.
Engines: 2.0 JTD 8V
1. Undo bolts (1a) and remove the clutch release cylinder (1b) from its housing.
Engines: 2.0 JTD 8V
1. Disconnect the engine management unit electrical connections.
Description
Connector
1
Engine management control unit
M010A
Description
Connector
1
Engine management control unit
M010B
Engines: 2.0 JTD 8V
1. Disconnect the electrical connection for the reversing light switch.
Description
Connector
1
Reversing lights switch
I020
Engines: 2.0 JTD 8V
1. Disconnect the electrical connection for the speedometer sensor.
Description
Connector
1
Speedometer sensor
K084
Engines: 2.0 JTD 8V
1. Undo the retaining bolt.2. Remove the engine bay junction unit protective cover.
Engines: 2.0 JTD 8V
1. Release the junction unit from its seat in the mount and disconnect electrical connections (1a) and (1b).
Description
Connector
1a
Engine compartment junction unit
B001C
Description
Connector
1b
Front/facia coupling
D001A
Engines: 2.0 JTD 8V
1. Undo bolt (1a) and remove gearbox earth lead (1b) from the body.
Engines: 2.0 JTD 8V
1. Disconnect the fuel pipe from the return manifold by releasing from the retaining bands.
Engines: 2.0 JTD 8V
1. Undo connector (1a) and disconnect oil delivery pipe (1b) to the power assisted steering box.
Engines: 2.0 JTD 8V
1. Disconnect the engine coolant return pipe from the heater.2. Disconnect the engine coolant delivery pipe to the supplementary radiator from the rigid exhaust gas recirculation pipe.
Engines: 2.0 JTD 8V
- Have a suitable container for collecting the transmission fluid ready.1. Undo the plug, using a suitable spanner, and drain the transmission fluid.
Description
Code
Function
.
Spanner
1.850.182.000
Wrench for slackening/tightening differential fluid plug
Engines: 2.0 JTD 8V
1. Disconnect the electrical connection for the left front brake pad wear sensor.
Description
Connector
1
Left brake pad wear sensor (switch)
K020
2. Undo the bolts fixing the brake caliper to the bracket and move it aside without disconnecting the oil pipe.
Engines: 2.0 JTD 8V
- Position a hydraulic column lift under the track control arm to work safely.1. Undo the nut fixing the track rod end to the steering knuckle.2. Extract the track rod end (2b) from the housing in the steering knuckle using the tool (2a).
Description
Code
Function
2a
Head extractor
1.847.038.000
Ball joint removal
Engines: 2.0 JTD 8V
1. Undo the bolts fixing the steering knuckle to the shock absorber.2. Undo the retaining bolt.3. Remove the left ABS sensor from the housing and place it outside the work area.
Engines: 2.0 JTD 8V
1. Undo the bolts fixing the stub axle to the steering knuckle.
Engines: 2.0 JTD 8V
1. Prise up the internal drive shaft (1a) from its seat on the differential, then remove the drive shaft - strut - brake disc assembly (1b).
Engines: 2.0 JTD 8V
- Position a hydraulic column lift under the track control arm to work safely.1. Undo the nut fixing the track rod end to the steering knuckle.2. Extract the track rod end (2b) from the housing in the steering knuckle using the tool (2a).
Description
Code
Function
1a
Head extractor
1.847.038.000
Ball joint removal
Engines: 2.0 JTD 8V
1. Undo the bolts fixing the brake caliper to the bracket and move it aside without disconnecting the oil pipe.
Engines: 2.0 JTD 8V
1. Undo the bolts fixing the steering knuckle to the shock absorber.2. Undo the retaining bolt.3. Remove the right ABS sensor from the housing and place it outside the work area.
Engines: 2.0 JTD 8V
1. Undo the bolts fixing the stub axle to the steering knuckle.
Engines: 2.0 JTD 8V
1. Undo the bolts securing the intermediate driveshaft to the mount.2. Remove the intermediate drive shaft - right drive shaft assembly with strut and brake disc.
Engines: 2.0 JTD 8V
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.
Engines: 2.0 JTD 8V
1. Undo nuts (1a) and separate the exhaust pipe from the flange (1b) for the turbocharger hose.2. Undo the bolts securing the rear flange (2a) and remove the exhaust pipe attachment to the engine (2b).
Engines: 2.0 JTD 8V
1. Undo the clip and disconnect the oil vapour recovery pipe from the cam cover.2. Undo the retaining nuts.3. Remove the throttle body from the intake manifold.
Engines: 2.0 JTD 8V
1. Undo the bolt securing the lower reaction rod to the suspension crossmember.2. Undo the bolt securing the lower reaction rod to the mounting bracket on the gearbox.3. Remove the lower reaction link.
Engines: 2.0 JTD 8V
1. Position the tool and secure with hooks to the brackets on the engine.2. Secure the tool to a hydraulic lift for supporting and removing the power unit.
Description
Code
Function
1
Crossmember
1.860.851.003
Power unit anchorage beam
Engines: 2.0 JTD 8V
- Place a support under the power unit to rest the power unit on later on.1. Undo the bolts fixing the flexible mounting to the timing side rigid power unit support.
Engines: 2.0 JTD 8V
1. Undo the nuts fixing the gearbox side flexible mounting to the rigid support.
Engines: 2.0 JTD 8V
1. Manoeuvre the power unit acting on the hydraulic lift and lower it slowly until it is resting on the support.- Raise the vehicle and extract the support placing it away from the actual vehicle.
- Support the power unit by means of a hydraulic lift with chains and position the power unit in its compartment on the vehicle.- Tighten the nuts fixing the gearbox side flexible mounting to the rigid support.
Value - daNm
Fastening
Component
Ø
.
(Rigid mount) 5
Nuts
GEARBOX SIDE RUBBER MOUNT
M10
- Tighten the nut and the two bolts fixing the flexible mounting to the timing side rigid power unit support to torque.
Value - daNm
Fastening
Component
Ø
.
(Rigid mount on engine) 5
Bolt
FRONT FLEXIBLE MOUNTING BLOCKS, POWER UNIT
M10
Value - daNm
Fastening
Component
Ø
.
(Rigid mount on engine) 8
Nut
FRONT FLEXIBLE MOUNTING BLOCKS, POWER UNIT
M12
- Remove the tool and hydraulic lift for supporting and removing the power unit.
Description
Code
Function
.
Crossmember
1.860.851.000
Power unit anchorage beam
- Fit the throttle body with built-in pneumatic valve and tighten the retaining nuts.- Fit the lower reaction rod in the housing and tighten the bolt fixing the suspension crossmember to torque.- Tighten the nut fixing the reaction rod to the gearbox to torque.- Fit the rigid middle section of the exhaust pipe and tighten the bolts securing it to the rear section to torque.
Value - daNm
Fastening
Component
Ø
.
(Front section flange) 2.6
Bolts
REAR SILENCER EXHAUST
M8
- Tighten the nuts securing the front section of the exhaust pipe to the turbocharger to torque.
Value - daNm
Fastening
Component
Ø
.
(Flange on turbocharger) 2.6
Nut
REAR SILENCER EXHAUST
M8
- Connect the oil vapour recovery pipe to the cam cover.- Connect both ends of the gear selection and engagement cables and secure them to the mounting bracket.- Fit the intermediate drive shaft - right drive shaft assembly with strut and brake disc.- Tighten the nuts fixing the intermediate driveshaft to the support to torque.- Tighten the bolts securing the stub axle to the hub to torque.- Fit the right ABS sensor in its housing and tighten the retaining bolt.- Tighten the bolts fixing the steering knuckle to the shock absorber to torque.
Value - daNm
Fastening
Component
Ø
.
(damper strut) 19
Bolts
FRONT HUB STRUT
-
- Fit the brake caliper - bracket assembly and tighten the bolts fixing the bracket to the left disc to torque.
Value - daNm
Fastening
Component
Ø
.
21
Bolt
FRONT BRAKE CALIPER BRACKET
M16
- Tighten the nut fixing the ball joint to the steering rod to torque.
Value - daNm
Fastening
Component
Ø
.
6.9
Nut
ADJUSTABLE LINK BALL JOINTS
M16
- Fit the left driveshaft assembly and press fit the inner driveshaft in the housing on the left differential.- Tighten the bolts fixing the stub axle to the left hub to torque.- Fit the right ABS sensor in its housing and tighten the retaining bolt.- Tighten the bolts fixing the steering knuckle to the shock absorber to torque.
Value - daNm
Fastening
Component
Ø
.
(damper strut) 19
Bolt
FRONT HUB STRUT
M16
- Tighten the nut fixing the ball joint to the steering rod to torque.
Value - daNm
Fastening
Component
Ø
.
6.9
Nut
ADJUSTABLE LINK BALL JOINTS
M16
- Fit the brake caliper - bracket assembly and tighten the bolts fixing the bracket to the left disc to torque.
Value - daNm
Fastening
Component
Ø
.
21
Bolt
FRONT BRAKE CALIPER BRACKET
M16
- Connect the engine coolant return pipe to the heater.- Connect the engine coolant delivery pipe to the supplementary radiator to the rigid exhaust gas recirculation pipe.- Connect the fluid supply pipe to the power assisted steering box and tighten the connector.- Connect the fuel pipes to the return manifold, securing them to the retaining bands.- Connect the gearbox earth lead to the bodyshell.- Connect the electrical connections and reposition the junction unit in the casing.
Description
Connector
.
Engine compartment junction unit
B001C
Description
Connector
.
Front/facia coupling
D001A
- Fit the engine compartment junction unit protective cover and tighten the fixing bolt.- Connect the electrical connection for the speedometer sensor.
Description
Connector
.
Speedometer sensor
K084
- Connect the electrical connection for the reversing light switch.
Description
Connector
.
Reversing lights switch
I020
- Connect the electrical connections for the engine management control unit.
Description
Connector
.
Engine management control unit
M010A
Description
Connector
.
Engine management control unit
M010B
- Place the clutch release cylinder in the housing and tighten the fixing bolts.- Fit the lower radiator pipe, tighten the bolts fixing it to the bellhousing and connect the hose to the thermostat.- Fit the air filter casing.- Connect the band securing the air flow meter to the air delivery pipe to the turbo.- Tighten the nuts fixing the filter casing to the mounting bracket.- Connect the electrical connection for the air flow meter.
Description
Connector
.
Air flow meter
K041
- Fit the filter element in the filter casing and fit the protective cover securing it using the fastenings.- Fit the turbocharger intake manifold rigid delivery hose.- Connect the single-acting valve to the brake servo.- Fit the junctiton unit and solenoid valve mounting bracket and tighten the fixing nuts.- Fit the glow plug control unit to the bracket and tighten the retaining nut.- Connect the electrical connection for the heater plugs control unit.
Description
Connector
.
Heater plugs control unit
M015C
- Fit both EGR and turbo control solenoids to the bracket and tighten the retaining bolts.- Fit the glow plug and solenoid unit control unit protective cover.- Fit the engine coolant reservoir and connect the coolant hoses.- Tighten the nuts securing the reservoir to the bodyshell.- Fit the radiator supporting crossmember and tighten the fixing bolts to torque.
Value - daNm
Fastening
Component
Ø
.
8.5
Bolt
COOLANT RADIATOR SUPPORT BEAM
M12
- Connect the electrical wiring for the starter motor.
Description
Connector
.
Starter motor
A020A
Description
Connector
.
Starter motor
A020B
- Connect the alternator electrical wiring.
Description
Connector
.
Alternator
A010A
Description
Connector
.
Alternator
A010B
- Connect the electrical connection for the right front wheel A.B.S. sensor.
Description
Connector
.
Right front wheel sensor for ABS
K071
- Tighten the fixing bolt and connect the earth lead to the bodyshell.- Fit the radiator assembly complete with fans.- Connect the electrical connections for the fans.
Description
Connector
.
Fan motor
N011
Description
Connector
.
Engine fan motor 2
N012
- Tighten the bolt fixing the side plastic shield.- Fit the upper radiator pipe and connect it to the thermostat and to the radiator.- Connect the lower radiator hose to the rigid section of the pipe.- Fit the upper crossmember in the engine bay complete with front light clusters.- Tighten the retaining bolts and nuts to torque.
Value - daNm
Fastening
Component
Ø
.
2.9
Nuts
FRONT WING - HEADLAMP SEAT BEAM
M8
- Tighten the nuts fixing the light clusters to the headlamp carrier crossmember.- Connect the left and right front light cluster electrical connection.
