- 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: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
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: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Remove the air delivery sleeve to the air-air heat exchanger (intercooler).
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Undo the fixing bolts (1a) and remove the protective cover 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
Engine management control unit
M010B
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: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
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: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Undo bolts (1a) and remove the clutch release cylinder (1b) from its housing.
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 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, 2.3 JTD 16V, 2.8 JTD 8V
1. Undo the retaining bolt.2. Disconnect the earth lead from the gearbox.
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Disconnect the electrical connection for the reversing light switch.
Description
Connector
1
Reversing lights switch
I020
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Disconnect the electrical connection for the voltage regulator on the alternator.
Description
Connector
1
Alternator
A010A
2. Disconnect the remaining alternator electrical wiring.
Description
Connector
Alternator
A010B
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
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: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Disconnect the electrical connection for the speedometer sensor.
Description
Connector
1
Speedometer sensor
K084
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Disconnect the brake servo vacuum pipe from the vacuum unit
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Disconnect the two rapid connectors for the fuel supply and return pipes.
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
- Raise the vehicle. Op. 7055B54 UNDER-ENGINE GUARD - R R- 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, 2.3 JTD 16V, 2.8 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, 2.3 JTD 16V, 2.8 JTD 8V
1. Undo the fixing bolts (1a) and remove the brake caliper-bracket assembly (1b) from the brake disc without disconnect the fluid pipes.
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
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: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
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: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
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: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Release the inner driveshaft (1a) from the differential and move the right driveshaft (1b) away from the work area.
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
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: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Undo the nut (1a), remove the protective cover (1b) and disconnect the starter motor supply leads (1c).2. Undo the retaining bolts (2a) and remove the starter motor (2b), complete with spacer (2c).
Description
Connector
1c
Starter motor
A020A
Description
Connector
1c
Starter motor
A020B
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Undo the retaining nuts.2. Remove the operating cylinder mounting bracket on the bellhousing.
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Remove the cover (1a), undo the nut (1b) and remove the selector unit idler connecting rod (1c).
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Undo the bolts 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 stud on the rigid support comes out of the housing in the flexible mounting.3. Remove the gearbox side rigid power unit support.
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Take a hydraulic lift fitted with a plate and adjustment screws (1a) and fit the two brackets (1b) for securing the gearbox and differential unit on it.
Description
Code
Function
1a
Adjustable support
1.870.856.000
Removing - refitting gearbox
Description
Code
Function
1b
Brackets
1.870.847.000
Removing - refitting gearbox
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Raise the hydraulic lift, tilt the base and position the bracket in contact with the gearbox-differential unit.
Description
Code
Function
1
Brackets
1.870.847.000
Removing - refitting gearbox
2. Fasten the second bracket to the gearbox unit at the back.
Description
Code
Function
2
Brackets
1.870.847.000
Removing - refitting gearbox
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 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.
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
1. Undo the fixing bolts.2. Remove the gearbox-differential unit.
1. Undo the bolts (1a) and remove the pressure plate and the clutch disc (1b).
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
- Fit the gearbox-differential unit and tighten the nuts and bolts to torque.
Value - daNm
Fastening
Component
Ø
.
7
Bolt
MANUAL GEARBOX/DIFFERENTIAL
M12
Value - daNm
Fastening
Component
Ø
.
6
Nut
MANUAL GEARBOX/DIFFERENTIAL
M10
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
- 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 gearbox side rigid engine support.- 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 bolts and the nut fixing the rigid support to the gearbox to torque.
Value - daNm
Fastening
Component
Ø
.
(Gearbox) 9
Nut
GEARBOX SIDE RUBBER MOUNT
M14
Value - daNm
Fastening
Component
Ø
.
(Gearbox) 9
Bolt
GEARBOX SIDE RUBBER MOUNT
M14
- Remove the tool complete with brackets positioned previously for supporting the gearbox.
Description
Code
Function
.
Adjustable support
1.870.856.000
Removing - refitting gearbox
Description
Code
Function
.
Brackets
1.870.847.000
Removing - refitting gearbox
Description
Code
Function
.
Brackets
1.870.847.000
Removing - refitting gearbox
- Fit the idler connecting rod on the gear selector and enagement assembly, tighten the nut and fit the plug.- Fit the operating cylinder mounting bracket on the bellhousing.- Tighten the fixing nuts.
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
- Fit the starter motor and tighten the retaining bolts to torque.
Value - daNm
Fastening
Component
Ø
.
2
Bolt
STARTER MOTOR
M8
- Connect the starter motor electrical wiring
Description
Connector
.
Starter motor
A020A
Description
Connector
.
Starter motor
A020B
- 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
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 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
.
-
Nut
FRONT HUBS COMPLETE WITH BEARING
M28
- The figure below refers to the 18 quintal version.
Value - daNm
Fastening
Component
Ø
.
-
Nut
FRONT HUBS COMPLETE WITH BEARING
M33
Engines: 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V
- Lower the vehicle.- Connect the two rapid connectors for the fuel supply and return pipes.- Connect the brake servo vacuum pipe to the vacuum unit- Connect the electrical connection for the speedometer sensor.
Description
Connector
.
Speedometer sensor
K084
- Fit the air filter casing.- 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 electrical connection for the voltage regulator on the alternator.
Description
Connector
.
Alternator
A010A
- Connect the remaining alternator electrical wiring.
Description
Connector
.
Alternator
A010B
- Disconnect the electrical connection for the reversing lights switch.
Description
Connector
.
Reversing lights switch
I020
- Connect the earth lead to the gearbox and tighten the fixing nut.- Lock the ends of the gear selector and engagement flexible cables.- Secure the cables to the mounting bracket.- Fit the clutch release operating cylinder in the housing on the gearbox and tighten the fixing bolts.- Fit the air supply hose to the turbocharger and secure it to the air filter casing.- Connect the vapour recovery pipe to the turbocharger air supply hose.- Fit the mounting bracket complete with heater plugs control unit.- 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 fixing bolts.- Fit the air delivery sleeve to the air-air heat exchanger (intercooler).- Fit the cold intake and intake hose assembly in the engine compartment.- Connect the intake hose to the air filter casing.- Tighten the bolts fixing the cold air intake to the upper crossmember.- 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. Op. 0010T40 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY Op. 7055B54 UNDER-ENGINE GUARD - R R
Engines: 2.3 JTD 16V
- Completely lower the vehicle.1. Position the crossmember (1), complete with side supports (1b) for supporting the engine whilst removing the gearbox and differential unit.
Description
Code
Function
1a
Crossmember
1.870.595.000
Power unit supporting crossmember
Description
Code
Function
1b
Support mountings
1.870.650.000
Side support for crossmember
2. Secure the reinforcement illustrated to the tool and to the front crossmember.
Description
Code
Function
2
Support
1.870.595.020
Support for front reinforcement crossmember
3. Fit the brackets (3a) to the power unit and secure them to the crossmember using the chain (3b).
Engines: 2.0 JTD 8V, 2.8 JTD 8V
1. Place the tool for supporting the power unit, fastened to the suspension crossmember and to the lower crossmember, under the engine oil sump in a central position.2. In order to be able to position the crossmember correctly and safely, the corners of the actual crossmember at the two ends have to be smoothed making sure that they match correctly with the front crossmember and the suspension crossmember.
Description
Code
Function
1
Crossmember
1.870.735.000
Lower engine mounting beam
Engines: 2.3 JTD 16V, 2.8 JTD 8V
1. In order to extract the for lever pin, a tool has to be made cutting a length of around 25 mm from a 26 mm diameter pipe.2. Fit a suitable washer (2a) on the tool and tighten an M6x1 bolt (2b) at least 55 mm long in the pin housing.- Tighten the tool produced on the pin and extract the shaft fixing the fork lever.
Engines: 2.3 JTD 16V
1. Undo the bolts fixing it to the gearbox and to the cylinder block/crankcase.2. Remove the front support joining the engine to the gearbox.
Engines: 2.3 JTD 16V
1. Undo the fixing bolts.2. Remove the rear bracket joining the gearbox to the engine.
Engines: 2.3 JTD 16V, 2.8 JTD 8V
1. Remove the thrust bearing (1b) from the clutch using the tool (1a).
Description
Code
Function
1a
Extractor
1.870.840.000
Thrust bearing removal
Engines: 2.3 JTD 16V, 2.8 JTD 8V
1. Fit the driven disc and the pressure plate and align them using the clutch centering tool.
Description
Code
Function
1
Clutch locating tool
1.875.029.000
Driven plate locating
Engines: 2.3 JTD 16V, 2.8 JTD 8V
- Tighten the bolts fixing the clutch to the flywheel to torque.
Value - daNm
Fastening
Component
Ø
.
3.2
Bolt
CLUTCH ASSEMBLY
M8
Engines: 2.3 JTD 16V, 2.8 JTD 8V
1. Position the thrust bearing (1a) on the main gearbox shaft hose and fit it on the clutch release lever (1b), then fit the release lever fixing shaft (1c).
Engines: 2.3 JTD 16V
- Fit the rear bracket joining the gearbox to the engine.- Tighten the fixing bolts to torque.- Fit the front bracket joining the gearbox to the engine.- Tighten the fixing bolts to torque.
Engines: 2.3 JTD 16V
- Remove the support tool used for supporting the engine and remove the brackets fastened to the engine.
Description
Code
Function
.
Support
1.870.595.020
Support for front reinforcement crossmember
Description
Code
Function
.
Crossmember
1.870.595.000
Power unit supporting crossmember
Description
Code
Function
.
Support mountings
1.870.650.000
Side support for crossmember
Engines: 2.0 JTD 8V, 2.8 JTD 8V
- Remove the tool for supporting the power unit, fastened to the suspension crossmember and to the lower crossmember, from under the engine oil sump.
