2429109 - 2110A10 manual gearbox and differential - r + r

Removing ( Refitting ) Position the vehicle on the ramp. Proceed with removal  - 4450B12  front or rear wheels (two) - r+r . Proceed with removal . Proceed with removal  - 7055B66  Engine compartment DUST SHIELD protection in right front wheel arch - R.R. . Proceed with removal  - 7055B90  Left front WHEEL ARCH LINER - R.R. . Proceed with removal  - 7055B91  Right front WHEEL ARCH LINER - R.R. . Proceed with removal  - 5530B10  battery - r+r . Proceed with removal  - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. . 1. Disconnect the electrical connection from the air flow meter.

NameConnector
1Air flow meter  K41 
2. Loosen the band and disconnect the the turbocharger air inlet sleeve from the rigid pipe, air flow meter side.
1. Remove the air filter (1a) complete with air flow meter (1b) by releasing it first from the lower pins and then from the rear fastening.
1. Undo the bolts (1a) and move the clutch operating cylinder (1b) aside without disconnecting the pipe.
1. Disconnect the gear engagement/selector cables.2. Remove the stops and release the gear engagement/selector cables from the mounting bracket.
1. Loosen the band and disconnect the air supply duct from heat exchanger to inlet manifold, heat exchanger side.
1. Undo the nut securing the air supply pipe from the heat exchanger to the inlet manifold.2. Release the electrical wiring and cooling system pipe from the bands on the air supply pipe from the heat exchanger to the inlet manifold. 3. Loosen the band and disconnect the air supply pipe from the heat exchanger to the inlet manifold, inlet manifold side, and remove it.
1. Undo the plug and drain the gearbox-differential oil.
Collect the gearbox-differential oil in a suitable container.
1. Disconnect the electrical connection from the reversing lights switch.

NameConnector
1Reversing lights switch  I20 
2. Undo the bolt (2a) and disconnect the battery earth lead (2b) from the gearbox.

NameConnector
2bBattery earth  C1 
1. Undo the bolts fixing the left driveshaft to the differential internal driveshaft.2. Undo the top bolt (2a) and loosen the bottom bolt (2b) securing the front left damper to the steering knuckle.Move the left drive shaft away from the differential internal drive shaft and secure it as appropriate.
1. Unscrew the bolts securing the right drive shaft to the intermediate drive shaft.Recover the safety plates.2. Undo the top bolt (2a) and loosen the bottom boltt (2b) securing the front right damper to the steering knuckle.Move the right drive shaft away from the intermediate drive shaft and secure it as appropriate.
1. Undo the bolts (1a) and remove the intermediate drive shaft (1b).2. Remove the dust excluder.
1. Tighten the nuts fastening the rigid section of the exhaust pipe between the catalytic converter and the silencer, silencer side.Release the rigid pipe for the exhaust pipe between the catalytic converter and silencer from the silencer.2. Loosen the collar (2a) and remove the rigid pipe for the exhaust pipe between the catalytic converter and the silencer (2b). 3. Undo the bolts fixing the catalytic converter mounting bracket to the manual gearbox/engine connecting bracket.
1. Undo the bolts securing the bracket between the manual gearbox/engine to the gearbox.2. Undo the bolts securing the bracket between the manual gearbox/engine to the gearbox.3. Remove the bracket between the manual gearbox/engine.
1. Fit the tool (1a), complete with support mountings (1b).

NameCountry
1aCrossmember1.870.595.000

NameCountry
1bSupport mountings1.870.650.000
2. Fit the tools (2a) and (2b), then connect them using links (2c) to the brackets fitted previously.

NameCountry
2aCrossmember1.860.851.000

NameCountry
2bVertical support1.871.001.300
1. Undo the nut fixing the power unit gearbox side rigid support to the flexible mounting.2. Undo the bolts (2a) and remove the flexible mounting of the power unit gearbox side rigid engine mount (2b).
1. Undo the bolts (1a) and remove the damping mass (1b) from the gear selector/engagement device.
The bolts are pre-treated with sealant and so new ones should be fitted whenever they are replaced.
1. Undo the top bolts securing the manual gearbox with differential to the crankcase.
1. Working from the front left wheelarch, undo the bolts (1a) and remove the gearbox side rigid power unit support (1b).
Position a hydraulic jack under the gearbox.1. Undo the bolt (1a), bolt (1b) and remove the power unit reaction rod (1c).
To remove the screwbolt securing the lower reaction link to the gearbox, turn it by hand while pushing the power unit forward gently without affecting the flexible mounts.
Remove the hydraulic jack from under the gearbox.
1. Fit the tool (1a) supporting the manual gearbox with differential using the bolt (1b) securing the gearbox casing.

NameCountry
1aGearbox mount1.860.873.000
2. Position a hydraulic jack under the tool supporting the manual gearbox with differential.3. Undo the remaining bolt (3a) and nut (3b) securing the manual gearbox with differential to the engine block.4. Remove the manual gearbox with differential, first moving it away from the engine and then lowering it with the hydraulic jack.
Refitting ( Removing ) Place the manual gearbox and differential back in its housing using the hydrauilc jack and support tool.1. Tighten the bolts (1a) and nut (1b) securing the manual gearbox with differential to the specified torque.

FasteningComponentØValue(daNm)
1aBoltMANUAL GEARBOXM12(Crankcase side) 7.2 ÷ 8.8

FasteningComponentØValue(daNm)
1bNutMANUAL GEARBOXM12(Crankcase side) 7.2 ÷ 8.8
2. Remove the manual gearbox and differential support tool (2a) and the hydraulic jack (2b).

NameCountry
2aGearbox mount1.860.873.000
Tighten the bolt securing the gearbox casing used for fittign the tool to the specified torque.

FasteningComponentØValue(daNm)
-BoltGEARBOX GEAR CASINGM8(Bellhousing support side) 2.3 ÷ 2.8
Position a hydraulic jack under the gearbox.1. Refit the power unit reaction rod (1a) back in its seating, then secure it with the bolt (1b) and bolt (1c) to the specified torque.
To fit the screwbolt securing the lower reaction link to the gearbox, turn it by hand while pushing the power unit forward gently without affecting the flexible mounts.

FasteningComponentØValue(daNm)
1bBoltREACTION RODM12(Gearbox side) 7.2 ÷ 8.8

FasteningComponentØValue(daNm)
1cBoltREACTION RODM12(Front suspension crossmember side) 11.4 ÷ 12.6
Remove the hydraulic jack from under the gearbox.
1. Refit the gearbox side power unit rigid support (1a) in its seating and tighten the bolts (1b) to the specified torque.

FasteningComponentØValue(daNm)
1bBoltPOWER UNIT GEAR BOX END RIGID MOUNTM10(Gearbox side) 4.5 ÷ 5.5
1. Refit the damping mass (1a) of the gear selector-engagement device into its seating and secure it with new bolts (1b) to the specified torque.

FasteningComponentØValue(daNm)
1b----
1. Refit the flexible mounting of the gearbox side power unit rigid support (1a) in its seating and tighten the bolts (1b) to the specified torque.

FasteningComponentØValue(daNm)
1bBoltGEARBOX SIDE RUBBER MOUNTM8(Bodyshell side) 2.3 ÷ 2.8
2. Undo the nut fixing the gearbox side rigid power unit support to the flexbile mounting to the specified torque.

FasteningComponentØValue(daNm)
2NutPOWER UNIT GEAR BOX END RIGID MOUNTM12(Flexible mounting side) 8.1 ÷ 9.9
Remove the safety tools used for supporting the power unit.

NameCountry
-Crossmember1.860.851.000

NameCountry
-Vertical support1.871.001.300

NameCountry
-Crossmember1.870.595.000

NameCountry
-Support mountings1.870.650.000
1. Refit the bracket between the manual gearbox/engine (1a) in its seating, then secure it with the bolts (1b) and (1c) to the specified torque.

FasteningComponentØValue(daNm)
1bBoltGEARBOX/ENGINE COUPLING BRACKETM8(Gearbox side) 2.3 ÷ 2.8

FasteningComponentØValue(daNm)
1cBoltGEARBOX/ENGINE COUPLING BRACKETM8(Engine crankcase side) 2.7 ÷ 3.3
Tighten the bolts fixing the catalytic converter mounting bracket to the manual gearbox/engine connecting bracket.Refit the rigid exhaust pipe section between the catalytic converter and the silencer and secure it using the collar.Tighten the nuts fastening the rigid section of the exhaust pipe between the catalytic converter and the silencer, silencer side.1. Place back in its housing the intermediate drive shaft (1a) complete with dust cover (1b) and secure it with its bolts (1c) to the specified torque.

FasteningComponentØValue(daNm)
1c----
Connect the right drive shaft to the intermediate drive shaft.1. Tighten the bolts securing the front right damper to the steering knuckle to the specified torque.

FasteningComponentØValue(daNm)
1BoltFRONT DAMPERM10(ore) 7.1 ÷ 7.9
2. Tighten the bolts securing the right drive shaft to the intermediate drive shaft to the specified torque.

FasteningComponentØValue(daNm)
2BoltFRONT DRIVE SHAFT COMPLETE WITH JOINTSM8(Intermediate driveshaft side) 3.6 ÷ 4.4
Connect the left drive shaft to the differential inner drive shaft.1. Tighten the bolts securing the front left shock absorber to the steering knuckle to the specified torque.

FasteningComponentØValue(daNm)
1BoltFRONT DAMPERM10(ore) 7.1 ÷ 7.9
2. Tighten the bolts fixing the left driveshaft to the left differential internal driveshaft to the recommended torque.

FasteningComponentØValue(daNm)
2BoltFRONT DRIVE SHAFT COMPLETE WITH JOINTSM8(Differential internal driveshaft side) 3.6 ÷ 4.4
Connect the battery earth lead to the gearbox and fix it using the bolt.Connect the electrical connection to the reversing lights switch.1. Tighten the gearbox-differential drain plug to the specified torque.

FasteningComponentØValue(daNm)
1Drain plugGEAR CASING PADSM22(Differential side) 4.6
Refit the air supply pipe from heat exchanger to inlet manifold, connect it to the heat exchanger and tighten the relevant bands.Tighten the nut securing the air supply pipe from the heat exhanger to the inlet manifold.Secure the electrical wiringg and cooling pipe with the bands present on the air supply pipe from the heat exchanger to the inlet manifold.Secure the gear engagement/selector cables to the mounting bracket with the stops.Connect the gear engagement/selector cables.Replace the clutch operating cylinder, then fix it using the bolts.Replace the air filter, complete with air flow meter, in its housing.Connect the air intake sleeve to the turbocharger, air flow meter side, and tighten the band.Connect the electrical connection to the air flow meter. Proceed with refitting  - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. . Proceed with refitting  - 5530B10  battery - r+r . Proceed with refitting  - 7055B91  Right front WHEEL ARCH LINER - R.R. . Proceed with refitting  - 7055B90  Left front WHEEL ARCH LINER - R.R. . Proceed with refitting  - 7055B66  Engine compartment DUST SHIELD protection in right front wheel arch - R.R. . Proceed with refitting . Proceed with refitting  - 4450B12  front or rear wheels (two) - r+r . Refill the manual gearbox and differential  - 0010T40  change manual gearbox oil . Remove the car from the ramps.