3314479 - 2110A10 manual gearbox and differential - r + r

Removing ( Refitting ) Position the vehicle on the ramp. Make sure that the ignition is OFF (STOP position), then disconnect the negative battery terminal (refer to op.   5530B10  battery - r+r ).

	Name	Connector
-	Battery	A1B

 - 7040D12  engine front side cover (one) lh or rh - r r (left and right).  - 7040D30  engine bay front beam cover - r r .  - 7040D14  engine bay rear side cover (one) lh or rh - r r (left and right).  - 4450B12  front or rear wheels (two) - r+r .  - 7055B54  under-engine guard - r r . 1. Disconnect the lower engine radiator hose from the water pump rigid inlet pipe

Recover the coolant using a suitable container.

 - 1016A40  ignition coil cover on cylinder head- r+r .  - 1048A48  throttle heater sleeve - r r .  - 1048A10  air cleaner filtering element - replace . 1. Undo the bolts for the A.B.S. hydraulic/electronic control units mounting bracket2. Move the support complete with A.B.S. hydraulic/electronic control units and pipes, then fix it to the bodyshell, as appropriate.3. Undo the bolts (3a) and move the operating cylinder (3b), complete with pipe and bracket, aside. 1. Disconnect the electrical connection from the reversing lights switch.

	Name	Connector
1	Reversing light control	I20

1. Disconnect the gear engagement/selector cables.2. Undo the bolts (2a) and move the two mounting brackets (2b), complete with gear selector/engagement cables. 1. Fit the bracket for lifting the engine. 1. Disconnect the electrical connection for the Lambda sensor.

	Name	Connector
1	Lambda sensor	K40

1. Remove the cover from the junction unit.2. Disconnect the starter motor supply cable from the junction unit.

	Name	Connector
2	Data not available yet	-

 - 1008C10  power unit upper reaction link r r . 1. Open the fixings for the air conditioning system pipes.  - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R. (left). 1. Disconnect the battery earth lead from the power unit rigid mounting, gearbox side.

	Name	Connector
1	Battery earth	C1

Disconnect the left front brake caliper flexible pipe from the retaining bracket.Disconnect the left brake pad wear sensor cable from the retaining bracket.1. Undo the bolts (1a) and move the left front disc brake caliper (1b).

Suitably fix the left front disc brake caliper so that it does not hinder future operations.

1. Undo the bolts (1a) and disconnect the left front driveshaft (1b) from the differential.

The above bolts are treated with eslok anti-slackening material and must therefore be replaced whenever they are removed.

2. Undo the nut (2a) and disconnect the left power steering box rod (2b) from the front steering knuckle using the tool (2c).

	Name	Country
2c	Extractor	1.821.169.000

3. Undo the bolt (3a) and disconnect the A.B.S. front wheel rpm sensor (3b) from the left front steering knuckle. 1. Undo the nut (1a) and disconnect the left front anti-roll bar joint (1b) from the anti-roll bar.2. Undo the bolts (2a), (2b), (2c), (2d) and (2e), then remove the left front lower track control arm.Position a ramp under the left front steering knuckle. 1. Undo the nuts fixing the left front upper track control arm support to the bodyshell.2. Raise the vehicle, as necessary, to remove the left front suspension from the bodyshell. 1. Undo the upper two bolts fixing the manual gearbox/differential to the engine.  - 1076B50  exhaust pipe attachment to engine - r + r . Undo the manual gearbox/differential fluid drain plug.

Recover the manual gearbox/differential fluid in a suitable container.

1. Undo the bolts (1a) and remove the lower engine flywheel protection (1b). 1. Undo the bolts (1a) and disconnect the right front driveshaft (1b) from the intermediate shaft.

The above bolts are treated with eslok anti-slackening material and must therefore be replaced whenever they are removed.

2. Undo the nut (2a) and disconnect the right power steering box rod (2b) from the front steering knuckle using the tool (2c).

	Name	Country
2c	Extractor	1.821.169.000

1. Undo the nut (1a) and disconnect the right front upper track control arm (1b) from the front steering knuckle using the tool (1c).

	Name	Country
1c	Extractor	1.821.169.000

1. Undo the bolts (1a) and remove the intermediate driveshaft (1b) from the differential and fix it as appropriate.2. Disconnect the supply cable from the alternator.

	Name	Connector
2	Alternator	A10

3. Disconnect the supply cable from the starter motor.

	Name	Connector
3	Starter motor	A20

1. Undo the bolts (1a) and remove the starter motor (1b), complete with wiring. 1. Loosen one of the bolts fixing the manual gearbox and differential to the engine and completely undo the remaining bolts. 1. Fit the tool (1a), complete with support mountings (1b).

	Name	Country
1a	Crossmember	1.820.581.000

	Name	Country
1b	Support mountings	1.870.650.000

2. Undo the bolts fixing the gearbox side flexible mounting to the front suspension frame.3. Adjust the adjustment nut and raise the power unit by about 10 cm. 1. Fit the tool (1a) on a hydraulic jack and fix it to the manual gearbox and differential (1b) with the bolts (1c).

	Name	Country
1a	Support	1.870.681.000

Completely undo the bolt, previously loosened, fixing the manual gearbox and differential to the power unit.Separate the manual gearbox and differential from the power unit.  - 1810A24  clutch - r + r with gearbox removed . Refitting ( Removing )  - 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).

The matching surface between the main shaft cover/thrust bearing and the two fork levers should be lubricated with Molycote PG 21 type grease.

Replace the manual gearbox and differential in its housing using the hydraulic jack and tool, then fix it tightening the nuts and bolts to the recommended torque.

	Name	Country
-	Support	1.870.681.000

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MANUAL GEARBOX	M12	Engine side 6.8 - 8.4

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MANUAL GEARBOX	M10	Engine side 3.7 - 4.5

	Fastening	Component	Ø	Value(daNm)
-	Nut	MANUAL GEARBOX	M12	Engine side 4.7 - 5.8

Undo the bolts and separate the supporting tool from the gearbox, then replace it after having removed it from the hydraulic jack.1. Adjust the nut and restore the power unit to its correct position.2. Fix the gearbox side power unit rigid mounting to the front suspension frame tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	GEARBOX SIDE RUBBER MOUNT	M8	(Front suspension frame side) 2.4 - 2.9

Act on the gear control lever to engage the clutch release bearing in the clutch.3. Remove the tools (3a) and (3b), fitted previously.

	Name	Country
3a	Crossmember	1.820.581.000

	Name	Country
3b	Support mountings	1.870.650.000

1. Fit the starter motor (1a), complete with wiring, and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	STARTER MOTOR	M8	Gearbox side 2.3 - 2.8

1. Connect the supply cable to the starter motor.2. Connect the supply cable to the alternator.

Take particular care to position the alternator leads correctly in their seats and ensure the leads are routed correctly.

3. Replace the front intermediate driveshaft (3a) in its housing, then fix it tightening the bolts (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	INTERMEDIATE DRIVE SHAFT	M8	(Support side) 2.6 - 3.2

1. Connect the right front upper track control arm (1a) to the front seering knuckle and fix it tightening the nut (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	FRONT SUSPENSION TOP LEVER	M10	Front hub steering knuckle side 4.3 - 4.7

1. Connect the right power steering box rod (1a) to the front steering knuckle and fix it tightening the nut (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	ADJUSTABLE STEERING LINKS	M10	(Front wheel hub steering knuckle side) 4.3 ÷ 4.7

2. Connect the right front driveshaft (2a) to the intermediate shaft and tighten the bolts (2b) to the recommended torque.

The above bolts are treated with eslok anti-slackening material and must therefore be replaced whenever they are removed.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M8	(Intermediate drive shaft side) 4.0 ÷ 4.4

Fit the engine flywheel lower protection.Tighten the manual gearbox and differential fluid drain plug to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Plug	GEAR CASING PADS	M18	1.6 - 2.6

 - 1076B50  exhaust pipe attachment to engine - r + r . 1. Replace the left front suspension in its housing and support it using a hydraulic jack.2. Tighten the nuts fixing the left front upper track control arm support to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Nut	FRONT UPPER SWINGING ARM MOUNT	M8	Bodyshell side 1.8 - 2.0

1. Replace the left front lower track control arm (1a) in its housing and fix it with the centring bolts (1b).2. Tighten the bolts (2a), (2b), (2c) and the nut (2d) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	FRONT SUSPENSION LOWER LEVER	M10	Front suspension. frame side 3.8 - 4.2

	Fastening	Component	Ø	Value(daNm)
2b	Rear bolts	FRONT SUSPENSION SUBFRAME	M12	(Bodyshell side) 12.4 - 13.7

	Fastening	Component	Ø	Value(daNm)
2c	Bolt	FRONT SUSPENSION LOWER LEVER	M12	Shock absorber fork side 8.6 - 9.5

	Fastening	Component	Ø	Value(daNm)
2d	Nut	FRONT SUSPENSION LOWER LEVER	M14	Front wheel hub steering knuckle side 8.6 - 9.5

3. Connect the left front anti-roll bar joint (3a) to the anti-roll bar and fix it tightening the nut (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	Nut	FRONT ANTI-ROLL BAR JOINTS	M10	Front anti-roll bar side. 3.8 - 4.7

1. Connect the A.B.S. front wheel rpm sensor to the left front steering knuckle and fix it with the bolt.2. Connect the left power steering box rod (2a) to the front steering knuckle and fix it tightening the nut (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Nut	ADJUSTABLE STEERING LINKS	M10	(Front wheel hub steering knuckle side) 4.3 ÷ 4.7

3. Connect the left front driveshaft (3a) to the differential and tighten the bolts (3b) to the recommended torque.

The above bolts are treated with eslok anti-slackening material and must therefore be replaced whenever they are removed.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	FRONT DRIVE SHAFT COMPLETE WITH JOINTS	M8	Differential side 4.0 - 4.4

1. Replace the left front disc brake caliper (1a) in its housing and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FRONT BRAKE CALIPER BRACKET	M14	(Steering knuckle side) 15.2 - 16.8

Connect the left brake pad wear sensor cable to the mounting bracket.Connect the left front brake caliper flexible pipe to the mounting bracket.Connect the power unit earth cable to the gearbox side power unit rigid mounting. - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R. (left).  - 1008C10  power unit upper reaction link r r . Connect the starter motor supply cable to the junction unit.Fit the junction unit cover.Connect the electrical connection for the Lambda sensor.Remove the engine lifting bracket.Replace the two mounting brackets, complete with gear selector/engagement cables and fix them using the bolts.Connect the gear selector/engagement cables.Connect the electrical connection for the reversing lights switch.Fit the operating cylinder, complete with pipe and bracket, then fix it using the bolts.Replace the A.B.S. hydraulic/electronic control units, complete with bracket and pipes, in their housing, then fix them using the bolts to the bodyshell. - 1048A10  air cleaner filtering element - replace .  - 1048A48  throttle heater sleeve - r r .  - 1016A40  ignition coil cover on cylinder head- r+r . Connect the lower engine radiator hose to the water pump rigid inlet pipe. - 7055B54  under-engine guard - r r .  - 4450B12  front or rear wheels (two) - r+r .  - 7040D14  engine bay rear side cover (one) lh or rh - r r (left and right).  - 7040D30  engine bay front beam cover - r r .  - 7040D12  engine front side cover (one) lh or rh - r r (left and right). Connect the battery terminal (-).Supply the engine cooling system with the recommended fluid.

	Type	Component	Name	Qty.
-	Fluid [l]	ENGINE COOLING CIRCUIT	Alfa Romeo Climafluid Super Permanent -40	7.9

Supply the gearbox and differential with the recommended fluid.

	Type	Component	Name	Qty.
-	Oli [l]	MANUAL GEARBOX	Tutela ZC 75 SYNTH	1.6

Remove the car from the ramp.