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 .  - 1048A48  throttle heater sleeve - r r . 1. Disconnect the electrical connection for the detonation sensor.

	Name	Connector
1	Detonation sensor	K50

2. Disconnect the electrical connection for the cam angle sensor.

	Name	Connector
2	Cam angle sensor	K47

3. Disconnect the electrical connection for the engine rpm and timing sensor.

	Name	Connector
3	Rpm sensor	K46

4. Disconnect the electrical connections.

	Name	Connector
4	Engine-i.e coupling.	D24

5. Disconnect the electrical connection from the throttle casing integrated with the D.V.L.

	Name	Connector
5	Integrated throttle body actuator	N75

6. Remove the protection (6a) and disconnect the electrical connection (6b).

	Name	Connector
6	Engine front connection	D4

1. Disconnect the electrical connection from the engine coolant temperature sensor.

	Name	Connector
1	Data not available yet	K45

1. Disconnect the electrical connection from the reversing lights switch.

	Name	Connector
1	Reversing light control	I20

Release the engine wiring from the retaining bands and move it.2. Disconnect the gear engagement/selector cables. 1. Undo the nuts (1a) and move the two mounting brackets (1b), complete with gear selector/engagement cables. 1. Undo the bolts for the A.B.S. hydraulic/electronic control units bracket.2. Undo the bolts for the A.B.S. pipe bracket. 1. Undo the bolt for the strut securing the A.B.S. hydraulic/electronic control units to the bodyshell.2. Undo the bolt securing the A.B.S. hydraulic/electronic control unit bracket to the air filter.3. Move the A.B.S. hydraulic/electronic control unit assembly, complete with bracket and pipes, aside, then fix it to the bodyshell, as appropriate. 1. Disconnect the electrical connection from the air flow meter.

	Name	Connector
1	Air flow meter	K41

Disconnect the cold air intake from the air filter casing.2. Remove the air filter complete with air flow meter.  - 1088E10  radiator cooling fan - r + r .  - 1008C10  power unit upper reaction link r r . 1. Undo the nuts (1a) and remove the exhaust manifold heat shield (1b). 1. Undo the upper four bolts securing the manual gearbox and differential to the engine.  - 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

1. Undo the bolts (1a) and move the clutch operating cylinder (1b), complete with bracket and pipe, aside.

Suitably fix the clutch operating cylinder to the bodyshell so that it does not hinder future operations.

1. Disconnect the left front brake caliper flexible pipe from the mounting bracket.2. Undo the bolts (2a) and move the left front disc brake caliper (2b).

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

Disconnect the A.B.S. front wheel rpm sensor cable from the mounting bracket.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 front anti-roll bar.2. Undo the bolts (2a), the securing screws (2b) and the centering bolts (2c) from the left front lower track control arm.3. Recover the bracket (3a) and the spacers (3b) and (3c).Position a hydraulic jack under the left front steering knuckle. 1. Undo the bolt (1a) and lift up the services chamber (1b) left side protection.2. Undo the nuts fixing the left front upper track control arm support to the bodyshell. 1. Raise the vehicle, as necessary, and remove the left front suspension from the bodyshell.  - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R. (right) 1. Undo the nut (1a) and disconnect the right power steering box rod (1b) from the front vertical link using the tool (1c).

	Name	Country
1c	Extractor	1.821.169.000

Disconnect the A.B.S. right front wheel rpm sensor cable from the retaining bracket.Undo the bolt and disconnect the A.B.S. front wheel rpm sensor from the right front steering knuckle.  - 1092G10  single engine belt r r . 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 front upper track control arm (2b) from the front steering knuckle using the tool (2c).

	Name	Country
2c	Extractor	1.821.169.000

1. Undo the bolt (1a) and remove the single drive belt fixed tensioner (1b). Position a hydraulic jack under the front suspension frame.1. Loosen the bolts securing the front suspension frame to the bodyshell, right hand side. 1. Loosen the bolts securing the front suspension frame to the bodyshell, right hand side. Lower the front suspension frame, as necessary, to gain access to the upper alternator bolt.1. Undo the bolts (1a) and remove the alternator (1b), after having disconnected the two electrical connections (1c).

	Name	Connector
1c	Alternator	A10

Undo the manual gearbox-differential fluid drain plug.

Recover the manual gearbox-differential fluid using a suitable container.

 - 1076B52  exhaust pipe (one) leaving l/h or r/h exhaust manifold - r + r (right and left)  - 1072C34  r/h exhaust manifold - r + r and replace seal . 1. Undo the bolts (1a) and move the starter motor (1b) aside, as necessary, in order to disconnect the electrical connections (1c), then remove it.

	Name	Connector
1c	Starter motor	A20

1. Undo the bolts (1a) and remove the front intermediate driveshaft (1b) from the differential and fix it appropriately. 1. Undo the bolts (1a) and remove the lower engine flywheel protection (1b). 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

1. Undo the bolts fixing the gearbox side flexible mounting to the front suspension frame. Adjust the tool nut and place the power unit under tension.1. Undo the bolts (1a) and remove the gearbox side rigid support (1b), complete with flexible mounting (1c). 1. Remove the bolt fixing the manual gearbox and differential to the power unit. 1. Fit the tool (1a) on a hydraulic jack and fix it to the manual gearbox and differential using the bolts (1b).

	Name	Country
1a	Support	1.870.681.000

2. Undo the bolts (2a) and remove the manual gearbox and differential (2b).  - 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). Replace the gearbox and differential in its housing using the hydraulic jack and special tool.

	Name	Country
-	Support	1.870.681.000

Tighten the bolts fixing the gearbox and differential to the engine to the recommended torque.

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

Act on the gear control lever to engage the clutch release bearing in the clutch.Undo the bolts and remove the tool from the gearbox.

	Name	Country
-	Support	1.870.681.000

1. Fit the gearbox side rigid support (1a), complete with flexible mounting (1b), and fix it to the gearbox using the bolts (1c).

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10	(Gearbox side) 4.3 - 5.3

Lower the vehicle, as necessary, to position the power unit in its housing.1. Tighten the bolts fixing the gearbox side flexible mounting to the front suspension frame.

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

Remove the tools supporting the power unit.

	Name	Country
-	Crossmember	1.820.581.000

	Name	Country
-	Support mountings	1.870.650.000

Fit the lower engine flywheel protection and fix it using the bolts.1. Replace the front intermediate driveshaft in its housing on the differential.2. Tighten the bolts fixing the front intermediate driveshaft to the front driveshaft bearing support to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	INTERMEDIATE DRIVE SHAFT	M6	(Support side) 0.5 - 0.8

1. Connect the electrical connections (1a) to the starter motor (1b), then fit it and fix it tightening the fixing bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	STARTER MOTOR	M8	Gearbox side 1.8 - 2.2

 - 1072C34  r/h exhaust manifold - r + r and replace seal .  - 1076B52  exhaust pipe (one) leaving l/h or r/h exhaust manifold - r + r (right and left) 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

1. Fit the alternator (1a) and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	ALTERNATOR ASSEMBLY	M8	(Mounting bracket side) 1.9 ÷ 2.3

1. Check electrical connections (1a) and (1b). Ensure there is no contact between the terminal of lead B+ (1c) and the pini of lead D+ (1d).

	Name	Connector
1a	Alternator	A10A

	Name	Connector
1b	Alternator	A10B

2. Secure the leads with bolts.

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

Raise the suspension frame, as necessary, to return it to its correct position.1. Tighten the bolts securing the front suspension frame to the bodyshell to the recommended torque.

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

1. Tighten the bolts fixing the front suspension frame to the bodyshell to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Front bolts	FRONT SUSPENSION SUBFRAME	M12	(Bodyshell side) 10.5 -11.6

Remove the hydraulic jack from the front suspension frame. 1. Fit the single belt fixed tensioner (1a) and fix it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FIXED SINGLE SERVICE BELT TENSIONER	M8	1.7 ÷ 2.1

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

2. Connect the right front driveshaft (2a) to the intermediate driveshaft and fix it tightening 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	M10	(Intermediate driveshaft side) 5.2 ÷ 5.8

 - 1092G10  single engine belt r r . Connect the rpm sensor cable to the mounting bracket.Connect the A.B.S. front wheel rpm sensor to the right front steering knuckle and fix it using the bolt.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

 - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R. (right) Replace the left front suspension in its housing.1. Tighten the nuts fixing the left front upper track control arm support to the recommended torque.

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

2. Fit the bulkhead side guard (2a) using the bolt (2b). 1. Replace the left front lower track control arm (1a) in its housing fitting the spacers (1b).2. Tighten the centring bolts.3. Fit the bracket (3a) and the spacers (3b), then tighten the bolts (3c) and (3d) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3c	Bolt	FRONT SUSPENSION LOWER LEVER	M10	Front suspension. frame side 3.8 - 4.2

	Fastening	Component	Ø	Value(daNm)
3d	Bolt	FRONT SUSPENSION SUBFRAME	M12	(Bodyshell side) 12.4 - 13.7

4. Connect the left front anti-roll bar joint (4a) to the front anti-roll bar and tighten the nut (4b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
4b	Nut	FRONT ANTI-ROLL BAR JOINTS	M10	Front anti-roll bar side. 3.8 - 4.7

Connect the A.B.S. front wheel rpm sensor to the left front steering knuckle and fix it using the bolt.1. Connect the left 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 left front driveshaft (2a) to the differential 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	M10	Differential side 5.2 - 5.8

1. Fit the left front disc brake caliper (1a) and tighten the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FRONT BRAKE CALIPER ASSEMBLY	M14	15.2 - 16.8

2. Connect the left front brake caliper flexible pipe to the retaining bracket. Fit the clutch operating cylinder, complete with pipe and bracket, then fix it using the bolts.Connect the battery earth lead to the gearbox side power unit rigid support. - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R. (left).  - 1008C10  power unit upper reaction link r r . Fit the exhaust manifold heat shield and fix it using the nuts. - 1088E10  radiator cooling fan - r + r . Replace the air filter, complete with air flow meter, in its housing.Connect the cold air intake to the air filter casing.Connect the electrical connection to the air flow meter.Replace the A.B.S. hydraulic/electronic control units in their housing.Tighten the bolt securing the A.B.S. hydraulic/electronic control units bracket to the complete air filter.Tighten the bolt fixing the A.B.S. hydraulic/electronic control units strut to the bodyshell.Tighten the bolt fixing the A.B.S. pipes bracket.Tighten the bolts fixing the A.B.S. hydraulic/electronic control units bracket to the bodyshell.Replace the two mounting brackets, complete with gear selector/engagement cables, in their housing and fix them using the nuts.Connect the gear selector/engagement cables.Fix the engine wiring to the securing bands.Connect the electrical connection to the reversing lights switch.Connect the electrical connection to the engine temperature sensor.Connect the electrical connection and fit the protection.Connect the electrical connection to the throttle body integrated with the D.V.L.Connect the electrical connectionConnect the electrical connection for the engine rpm and timing sensor.Connect the electrical connection for the cam angle sensor.Connect the electrical connection for the detonation sensor. - 1048A48  throttle heater sleeve - r r .  - 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 (-).Refill the gearbox and differential with the recommended fluid.

	Type	Component	Name	Qty.
-	Oil	MANUAL GEARBOX	TUTELA ZC 75 FF SEMI SYNTH	-

Remove the car from the ramp.