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

3362746 - 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

) Position the vehicle on a lift. Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R Op. 1048A10 AIR FILTER ASSEMBLY - R.R.1. Undo the fixing bolts (1a) and move the control unit complete with bracket (1b) aside.

1. Prise up the gear selection and engagement cable (1b) swivel heads (1a).Place the gear selection and engagement cables at the side.

1. Unscrew the fixing bolts (1a) and remove the mounting bracket for the gear selection and engagement cables (1b).

1. Undo the fixing bolts (1a) and place the clutch operating cylinder (1b) at the side.

1. Undo the fixing nut (1a) and disconnect the engine earth lead (1b).

	Description	Connector
1b	Earth on engine	C40

2. Disconnect the reversing sensor switch electrical connection.

	Description	Connector
2	Reversing lights switch	I20

1. Undo the bolts (1a) fixing the flywheel guard (1b).

1. Undo the nut fixing the steering box track rod end to the front steering knuckle.2. Separate the end (2a) from the front steering knuckle using the tool (2b).

	Description	Code
2b	Head extractor	1.847.035.000

3. Undo the bolts fixing the shock absorber to the front steering knuckle.Carry out the same operations on both front steering knuckles.

1. Remove the bands (1a) securing the sliding joint boots (1b), then move the driveshafts away from the differential.

1. Undo the fixing bolts (1a) and move the left brake caliper (1b) aside.2. Undo the bolt (2a) fixing the end of the left track control arm (2b).Remove the driveshaft complete with left hub and brake disc.

1. Undo the engine side and gearbox side fixing bolts (1a) and place the starter motor (1b) at the side.

1. Position an ordinary bracket at the front (1a) and the rear (1b) for supporting the engine.2. Position the tools (2a), (2b), (2c) and secure the hooks (2d) to the brackets.

	Description	Code
2a	Crossmember	1.870.595.000

	Description	Code
2b	Vertical support	1.870.748.000

	Description	Code
2c	Crossmember	1.860.851.000

1. Undo the bolts (1a) fixing the engine support (1b), gearbox side.

1008C30 TIRANTE INFERIORE DI REAZIONE del gruppo motopropulsore - S.R. 1008C34 STAFFA SU CAMBIO PER TIRANTE INFERIORE DI REAZIONE - S.R.1. Undo the centre nut fixing the gearbox side engine support flexible mounting.2. Undo the bolts fixing the mounting to the bodyshell.3. Remove the gearbox side flexible mounting from the engine compartment.Remove the engine mounting bracket complete with flexible mounting.

1. Undo the upper gearbox fixing bolts after having released the heater pipes and the connection for the Lambda sensor upstream of the catalyzer from the mounting brackets.2. Use a hydraulic jack (2a) and position the tool (2b).

	Description	Code
2b	Gearbox support	1.860.873.000

3. Undo the bolt (3a) and fasten the arm of the tool (3b) to the front of the gearbox.4. Use the nut and the bolt fixing the reaction rod (4a) and secure the arm of the tool (4b) to the rear of the gearbox.5. Unscrew the lower gearbox fixing bolts.Move the gearbox back slightly and keep the engine flywheel protective cover.

Manoeuvre the hydraulic jack so that the gearbox is released without damaging the surrounding components and extract it from the engine compartment lowering the hydraulic jack slowly.

Refitting ( Removing

) Fasten the gearbox assembly to the tool used for the removal and raise the hydraulic jack slowly taking care over the surrounding components.

	Description	Code
-	Gearbox support	1.860.873.000

Position the engine flywheel protective cover and tighten the lower nuts and bolts fixing the gearbox to the engine.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MANUAL GEARBOX/DIFFERENTIAL	M12 X 1.25	(lower gearbox) 5.5

	Fastening	Component	Ø	Value(daNm)
-	Nut	MANUAL GEARBOX/DIFFERENTIAL	M10 X 1.25	(lower gearbox) 4

Remove the tool for supporting the gearbox.

	Description	Code
-	Gearbox support	1.860.873.000

Tighten the upper bolts fixing the gearbox to the engine; secure the heater pipes and the connection for the Lambda sensor upstream of the catalyzer to the mounting brackets.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MANUAL GEARBOX/DIFFERENTIAL	M10 X 1.25	(upper gearbox) 8

Refit the engine mounting bracket complete with mounting and tighten the bolts fixing the flexible mounting to the bodyshell to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX SIDE RUBBER MOUNT	M10	(to the bodyshell vertical wall) 6

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX SIDE RUBBER MOUNT	M12 X 1.25	(to the bodyshell horizontal wall) 8.5

1008C34 STAFFA SU CAMBIO PER TIRANTE INFERIORE DI REAZIONE - S.R. 1008C30 TIRANTE INFERIORE DI REAZIONE del gruppo motopropulsore - S.R.Tighten the bolts fixing the engine support to the gearbox.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10 X 1.25	(gearbox) 3.5

Remove the tools and the brackets used for supporting the engine.

	Description	Code
-	Crossmember	1.870.595.000

	Description	Code
-	Vertical support	1.870.748.000

	Description	Code
-	Crossmember	1.860.851.000

Position the starter motor and tighten the gearbox side fixing bolt to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	STARTER MOTOR	M8	(Gearbox) 2.7

Lower the lift and complete the fastening of the starter motor.Fit the driveshaft complete with hub and brake disc and tighten the bolt fixing the track control end to the front steering knuckle to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	FRONT LOWER WISHBONE ARTICULATED HEAD	M8	3.2

Refit the brake caliper and tighten the fixing bolts on the steering knuckle to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT DISC BRAKE CALIPERS COMPLETE	M10 X 1.25	5.7

Fit the driveshafts on the differential and fasten the sliding joint boots using the retaining bands.Tighten the bolts fixing the shock absorber to the front steering knuckle to torque and carry out the same operation on the remaining shock absorber.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	FRONT HUB STRUT	M10	7

Fit the steering box track rod end to the front steering knuckle.Repeat the operation on the remaining steering box rod.Tighten the nut fixing the steering rod to the steering knuckle to the torque given below; carry out the same operation on the remaining steering rod.

	Fastening	Component	Ø	Value(daNm)
-	Nut	ADJUSTABLE STEERINGI LINK JOINTS (C-S)	M10 X 1.25	(to the steering knuckle) 4

Secure the engine flywheel guard to the gearbox using the bolts.Connect the reversing lights switch electrical connection.

	Description	Connector
-	Reversing lights switch	I20

Connect the earth lead and tighten the fixing nut.

	Description	Connector
-	Earth on engine	C40

Fit the operating cylinder and tighten the fixing bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CLUTCH CONTROL HYDRAULIC ACTIVATOR	M8	1.8

Fit the mounting bracket for the gear selection and engagement cables and secure it using the bolts.Fit the ends of the flexible cables.Refit the injection control unit compl

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