2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R - Fiat - IDEA - eLearn

2400295 - 2110A10 manual gearbox and differential - r + r

) 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.

	Name	Connector
1	Air 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 rigid air supply pipe from the heat exchanger to the inlet manifold, hose 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.

	Name	Connector
1	Reversing lights switch	I20

2. Undo the bolt (2a) and disconnect the battery earth lead (2b) from the gearbox.

	Name	Connector
2b	Battery 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.

Proceed with removal - 7055A43 central front grille - r r1. Using the bolt (1a) shown fastening the camshaft housing, fit a suitable bracket (1b).

This bracket is used exclusively for balancing the power unit.

2. Fit the tool (2a), complete with support mountings (2b).

	Name	Country
2a	Crossmember	1.870.595.000

	Name	Country
2b	Support mountings	1.870.650.000

3. Fit the tools (3a) and (3b), then connect them via the links (3c) to the bracket previously fitted and to the exhaust manifold.

	Name	Country
3a	Crossmember	1.860.851.000

	Name	Country
3a	Vertical support	1.871.001.300

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 fixing the power unit lower reaction rod to the front suspension crossmember.Remove the hydraulic jack from under the gearbox.2. Undo the bolt fixing the lower reaction rod for the gearbox side power unit assembly.

To extract the above mentioned bolt, manually rotate the power unit pushing it slightly forwards without affecting the flexible mountings.

3. Remove the lower reaction rod for the power unit.

1. Move the two rods for the power unit support equipment forwards as much as necessary to move the gearbox away from the front suspension crossmember.

1. Fit the tool (1a) supporting the manual gearbox with differential using the bolt (1b) securing the gearbox casing.

	Name	Country
1a	Gearbox mount	1.860.873.000

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.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	MANUAL GEARBOX	M12	(Crankcase side) 7.2 ÷ 8.8

	Fastening	Component	Ø	Value(daNm)
1b	Nut	MANUAL GEARBOX	M12	(Crankcase side) 7.2 ÷ 8.8

2. Remove the manual gearbox and differential support tool (2a) and the hydraulic jack (2b).

	Name	Country
2a	Gearbox mount	1.860.873.000

Tighten the bolt securing the gearbox casing used for fittign the tool to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX GEAR CASING	M8	(Bellhousing support side) 2.3 ÷ 2.8

Move the power unit support equipment rods back to their original position. Place the power unit lower reaction rod back in its housing and fix it to the gearbox using the bolt without tightening it.

To fi the above bolt the power unit must be rotated manually, pushing it slightly forwards, without affecting the flexible mountings.

Position a hydraulic jack under the gearbox.Faste the power unit lower reaction rod to the front suspension crossmember without tightenint the bolt.Tighten the bolt securing the power unit lower reaction rod to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	LOWER ROD ON ENGINE	M12	(Gearbox side) 7.2 ÷ 8.8

	Fastening	Component	Ø	Value(daNm)
-	Bolt	LOWER ROD ON ENGINE	M12	(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.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10	(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.

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.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	GEARBOX SIDE RUBBER MOUNT	M8	(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.

	Fastening	Component	Ø	Value(daNm)
2	Nut	POWER UNIT GEAR BOX END RIGID MOUNT	M12	(Flexible mounting side) 8.1 ÷ 9.9

Remove the safety tools used for supporting the power unit.

	Name	Country
-	Crossmember	1.870.595.000

	Name	Country
-	Support mountings	1.870.650.000

	Name	Country
-	Crossmember	1.860.851.000

	Name	Country
-	Vertical support	1.871.001.300

Remove the bracket and tighten the bolt fixing the camshaft housing to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CYLINDER HEAD EXTENSION	M7	(Lower cylinder head side) 1.8

Proceed with refitting - 7055A43 central front grille - r r . 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.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	GEARBOX/ENGINE COUPLING BRACKET	M8	(Gearbox side) 2.3 ÷ 2.8

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	GEARBOX/ENGINE COUPLING BRACKET	M8	(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.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	INTERMEDIATE DRIVE SHAFT	-	Support side -

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.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	FRONT DAMPER	M10	(Front steering knuckle side) 6.2 ÷ 6.8

2. Tighten the bolts securing the right drive shaft to the intermediate drive shaft to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M8	(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.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	FRONT DAMPER	M10	(Front steering knuckle side) 6.2 ÷ 6.8

2. Tighten the bolts fixing the left driveshaft to the left differential internal driveshaft to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M8	(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.

	Fastening	Component	Ø	Value(daNm)
1	Drain plug	GEAR CASING PADS	M22	(Differential side) 4.6

Refit the rigid 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.