3237924 - 2110A10 manual gearbox and differential - r + r

Removing ( Refitting ) Position the vehicle on the ramp. Proceed with removal  - 1016A10  sound-proofing cover - r + r . Proceed with removal  - 7055B54  under-engine guard - r r . Proceed with removal  - 1048A50  air inlet pipe to turbo charger - r + r . Proceed with removal  - 1088D24  rigid pipe for coolant inlet to water pump - r + r . Proceed with removal  - 5530B10  battery - r+r . Proceed with removal  - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. . Proceed with removal  - 1048A10  air cleaner filtering element - replace . 1. Loosen the bands (1a) and remove the air supply hose between the turbocharger and the heat exchanger (1b).2. Undo the nut (2a) and disconnect the earth lead (2b) from the gearbox.

	Name	Connector
2b	Battery earth	C1

1. Undo the bolts (1a) and remove the exhaust manifold heat shield (1b). 1. Undo the nuts (1a) and remove the upper exhaust manifold heat shield (1b). 1. Disconnect the quick-release connector for the front fuel supply pipe, fuel filter side.2. Disconnect the rapid attachment on the fuel return pipe to the fuel return manifold pipe, fuel filter side.3. Disconnect the quick-release connector for the fuel supply pipe to the pressure pump, fuel filter side.

Recover the fuel which comes out in a suitable container.

4. Disconnect the electrical connection from the fuel temperature sensor.

	Name	Connector
4	Fuel temperature sensor	K81

5. Disconnect the electrical connection from the fuel pre-heating device.

	Name	Connector
5	Fuel temperature sensor	K81

1. Undo the nuts (1a), raise the fuel filter sufficiently to disconnect the electrical connection from the water presence sensor in the fuel filter (1b).

	Name	Connector
1b	Water in diesel filter sensor	K31

2. Remove the fuel filter. Proceed with removal  - 1076B70  exhaust pipe between pre-catalytic converter and catalytic converter - r r . Proceed with removal  - 5520B10  starter motor - r+r . Remove the protective cap on the master cylinder bleed valve.Connect the collection system (pipe and reservoir) to the bleed valve on the master cylinder.Operate the clutch pedal until the brake-clutch fluid reservoir is empty.1. Undo the connector (1a) and disconnect the pipe from the vibration damper to the operating cylinder (1b), operating cylinder side.2. Remove the circlip (2a) and remove the master cylinder (2b) from the support.3. Disconnect the electrical connection from the reversing lights switch.

	Name	Connector
3	Reversing lights switch	I20

1. Disconnect the gear selector and engagement cables.2. Undo the nuts (2a) and move the mounting brackets (2b) complete with gear selector and engagement cables aside. Proceed with removal  - 4450B12  front or rear wheels (two) - r+r . Proceed with removal - 7055B90 Left front WHEEL ARCH LINER - R.R. . Proceed with removal  - 7055A43  central front grille - r r . Proceed with removal  - 7055A41  RIGHT FRONT GRILLE - R.R. . Proceed with removal  - 7210E10  R.R. FRONT BUMPER . 1. Fit the bracket (1a) on the exhaust manifold and secure it using the nut (1b).2. Fit the bracket (2a) on the crankcase sump and fasten it using the bolt (2b).3. Fit the tool (3a) complete with support mountings (3b).

	Name	Country
3a	Crossmember	1.820.581.000

	Name	Country
3b	Support mountings	1.870.650.000

4. Fit the tools (4a) and (4b), then connect them using the rods (4c) to the brackets fitted previously.

	Name	Country
4a	Crossmember	1.860.851.003

	Name	Country
4b	Vertical support	1.870.748.000

1. Undo the upper bolts securing the manual gearbox and differential to the engine. 1. Undo the bolts fixing the driveshafts to the differential internal driveshaft/intermediate driveshaft. 1. Undo the nut for the bolts securing the fronts suspension lower wishbones to the knuckles.2. Loosen the bolts fixing the front shock absorber forks to the lower track control arms.3. Disconnect the lower track control arms for the front suspension from the steering knuckles using the tool.

	Name	Country
3	Extractor	1.821.169.000

1. Undo the nuts (1a) and disconnect the front anti-roll bar joints (1b) from the front damper forks. 1. Undo the bolt (1a), nut (1b) and remove the power unit rigid rear support (1c).2. Undo the nut fixing the rear power unit rigid support to the flexible mounting.3. Undo the bolts (3a) and remove the rear support for the power unit (3b). 1. Undo the bolts securing the catalytic converter to the rigid exhaust pipe section.2. Remove the catalytic converter (2a) after having released it from the flexible mountings (2b).Remove the gasket. 1. Undo bolts (1a) and nuts (1b) fixing the manual gear lever mounting.2. Recover the plates.3. Slacken the rear bolts fixing the manual gear lever mounting.4. Lower the manual gear lever mounting as much as necessary. 1. Support the front suspension crossmember using a hydraulic jack (1a) fitted with a suitable flange (1b).2. Undo the bolts securing the power steering box to the front suspension crossmember.3. Undo the rear bolts fixing the front suspension crossmember to the bodyshell.4. Undo the side bolts fixing the front suspension crossmember to the bodyshell. 1. Undo the bolt (1a) and release the power assisted steering pipes mounting bracket (1b) from the front suspension crossmember. 1. Slowly lower the hydraulic jack and remove the front suspension crossmember (1a) complete with lower track control arms (1b) and anti-roll bar (1c). 1. Undo the drain plugs and drain the manual gearbox-differential oil.

Collect the gearbox-differential oil in a suitable container.

1. Undo the bolts (1a) and remove the intermediate drive shaft (1b).2. Remove the dust excluder. 1. Undo the bolts (1a) and remove the engine flywheel protection (1b).2. Undo the bolts fixing the manual gearbox and differential to the crankcase sump.3. Loosen the nut fixing the manual gearbox and differential to the crankcase. 1. Undo the bolts fixing the power unit gearbox side rigid support to the flexible mounting.2. Undo the bolt (2a) and remove the power unit gearbox side rigid engine mount (2b). 1. Fit the tool (1a) for supporting the gearbox and secure it with the bolts (1b) to the holes present on the gearbox and by means of bolt (1c) to the gearbox bracket (1d).

	Name	Country
1a	Mount	1.870.826.000

2. Position a hydraulic jack under the gearbox support tool. 1. Undo the remaining bolts fixing the manual gearbox and differential to the engine.2. Retract the hydraulic jack and remove the manual gearbox and differential.

Check that the gearbox is balanced on the hydraulic jack.

Proceed with removal  - 1810A24  clutch - r + r with gearbox removed . Refitting ( Removing ) Proceed with refitting  - 1810A24  clutch - r + r with gearbox removed . 1. Lift up the tapered seal (1a) for the clutch release bearing until the spring (1b) is covered.2. Fit the clutch release bearing (2a) on the main shaft and match it with the clutch release fork (2b). Place the manual gearbox and differential back in its housing using the hydraulic jack and the support tool and secure it using the lower bolt to the crankcase without tightening it. Remove the manual gearbox and differential support tool and the hydraulic jack.

	Name	Country
-	Mount	1.870.826.000

1. Refit the gearbox side power unit rigid support (1a) in its seating and tighten the bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10	(Manual gearbox/differential side) 4.5 ÷ 5.5

2. Undo the bolt fixing the gearbox side rigid power unit support to the flexbile block to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2	-	-	-	-

Tighten the bolts and the nut securing the manual gearbox with differential to the crankcase to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MANUAL GEARBOX	M12	(Crankcase side) 7.2 ÷ 8.8

Tighten the bolts fixing the manual gearbox and differential to the crankcase sump to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MANUAL GEARBOX	M10	(Crankcase sump side) 5.0 ÷ 6.1

Act on the gear control lever to engage the clutch release bearing in the clutch.Place the engine flywheel protection back in its housing and secure it using the bolts.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.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	INTERMEDIATE DRIVE SHAFT	M8	(Support side) 2.5 ÷ 2.8

1. Clean the transmission fluid drain plugs (1a) and (1b) and tighten to the specified torque. engine) 3.0 4.8, daNm

	Fastening	Component	Ø	Value(daNm)
1a	Plug	GEAR CASING PADS	M18	Differential side 1.6 - 2.6

	Fastening	Component	Ø	Value(daNm)
1b	Side bolt	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 ÷ 13.2

Place the front suspension crossmember, complete with lower track control arms and anti-roll bar, back in its housing using a hydraulic jack fitted with the special support tool.1. Tighten the side bolts securing the front suspension crossmember to the bodyshell to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Rear bolt	ENGINE OR ROD ANCHORAGE BEAM	M12	(Bodyshell side) 10.8 ÷ 13.2

2. Tighten the rear bolts securing the front suspension crossmember to the bodyshell to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Rear bolt	ENGINE OR ROD ANCHORAGE BEAM	M10	(Bodyshell side) 8.1 ÷ 9.9

	Fastening	Component	Ø	Value(daNm)
2	Bolt	POWER STEERING BOX	M14	(Front suspension crossmember side) 11.7 ÷ 14.3

3. Tighten the bolts securing the power steering box to the front suspension crossmember to the specified torque.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	CATALYTIC CONVERTER (ONE)	M8	(Rigid pipe side) 2.3 ÷ 2.8

Remove the hydraulic jack with mounting tool from the front suspension beam. Fasten the power assisted steering system pipes mounting bracket to the front suspension crossmember and tighten the bolt.Refit the handbrake control mount and secure with bolts and nuts.1. Place the catalytic converter (1a) complete with gasket in its housing and secure it to the flexible mountings (1b).2. Tighten the bolts securing the catalytic converter to the exhaust pipe rigid section to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	POWER UNIT RIGID REAR MOUNT	M16	(Manual gearbox/differential side) 10.8 ÷ 13.2

1. Refit the gearbox side power unit rear rigid support (1a) in its seating and tighten the bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	-	-	-	-

2. Tighten the nut securing the rear power unit rigid support to the flexible mounting to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	-	-	-	-

3. Refit the gearbox side power unit rear rigid support reinforcement (3a) in its seating and secure by tightening the bolt (3b) and nut (3c) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
3b	-	-	-	-

	Fastening	Component	Ø	Value(daNm)
3c	Nut	FRONT ANTI-ROLL BAR JOINTS	M10	(Front shock absorber fork side) 4.1 ÷ 5.0

1. Connect the front suspension anti-roll bar joints (1a) to the front shock absorber forks and secure them tightening the nuts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	FRONT SUSPENSION LOWER LEVER	M14	(Steering knuckle side) 8.1 ÷ 9.9

1. Connect the front suspension lower wishbones to the knuckles and secure by tightening the nuts to the required torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	FRONT DAMPER FORK ON WISHBONE	M12	(Lower track control arm side) 10.8 ÷ 13.2

2. Tighten the bolts fixing the front shock absorber forks to the lower track control arms.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	DRIVESHAFT	M10	(Intermediate driveshaft side) 5.8 ÷ 7.0

1. Tighten the bolts securing the drive shafts to the intermediate differential/drive shaft internal drive shaft to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	DRIVESHAFT	M8	(Differential internal driveshaft side) 3.6 ÷ 4.4

	Fastening	Component	Ø	Value(daNm)
1	Connector	HOSE FROM VIBRATION DAMPER	M12	(Operating cylinder side) 1.4 ÷ 2.2

Remove the safety tools used for supporting the power unit.

	Name	Country
-	Crossmember	1.820.581.000

	Name	Country
-	Support mountings	1.870.650.000

	Name	Country
-	Crossmember	1.860.851.003

	Name	Country
-	Vertical support	1.870.748.000

Proceed with refitting  - 7210E10  R.R. FRONT BUMPER . Proceed with refitting  - 7055A41  RIGHT FRONT GRILLE - R.R. . Proceed with refitting  - 7055A43  central front grille - r r . Proceed with refitting - 7055B90 Left front WHEEL ARCH LINER - R.R. . Proceed with refitting  - 4450B12  front or rear wheels (two) - r+r . Place the mounting bracket, complete with gear selector and engagement cables, back in its housing.Connect the gear selector and engagement cables.1. Connect the electrical connection to the reversing lights switch.2. Place the clutch operating cylinder (2a) back in its housing and secure it using the circlip (2b).3. Connect the pipe from the vibration damper to the operating cylinder (3a), operating cylinder side and tighten the connector (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	Connector	HOSE FROM VIBRATION DAMPER	M12	(Operating cylinder side) 1.4 ÷ 2.2

Proceed with refitting  - 5520B10  starter motor - r+r . Proceed with refitting  - 1076B70  exhaust pipe between pre-catalytic converter and catalytic converter - r r . Connect the electrical connection to the water-in-fuel filter sensor, then refit the complete fuel filter in its seating and secure with its nuts.Connect the electrical connection to the fuel pre-heating device.Connect the electrical connection to the fuel temperature sensor.Connect the quick-release connector for the fuel supply pipe to the pressure pump, fuel filter side.Connect the rapid attachment of the front fuel return pipe to the fuel return manifold pipe, fuel filter side.Connect the quick-release connector for the front fuel supply pipe, fuel filter side.Place the upper exhaust manifold heat shield back in its housing and fix it using the nuts.Place the lower exhaust manifold heat shield back in its housing and fix it using the bolts.Connect the earth lead to the gearbox and tighten the nut.Refit in its seating the air supply duct between turbocharger and heat exchanger and tighten the bands. Proceed with refitting  - 1048A10  air cleaner filtering element - replace . Proceed with refitting  - 0010T67  hydraulic clutch system bleed air . Proceed with refitting  - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. . Proceed with refitting  - 5530B10  battery - r+r . Proceed with refitting  - 1088D24  rigid pipe for coolant inlet to water pump - r + r . Proceed with refitting  - 1048A50  air inlet pipe to turbo charger - r + r . Refill the engine cooling system with coolant  - 0010T20  coolant change . Refill the manual gearbox and differential  - 0010T40  change manual gearbox oil . Proceed with refitting  - 7055B54  under-engine guard - r r . Proceed with refitting  - 1016A10  sound-proofing cover - r + r . Remove the car from the ramps.