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

194000442 - 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

) - Position the vehicle on a lift.- Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).

	Description	Connector
-	Battery	See A001 BATTERY

Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R. Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R. Op. 1080B95 REAR LAMBDA SENSOR TO CATALYTIC CONVERTER - R.R Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R Op. 7055A43 CENTRE FRONT GRILLE - R.R. Op. 4410D10 FRONT SUSPENSION FRAME - R+R Op. 5520B10 STARTER MOTOR - R+R1. Disconnect the gear selector cable.2. Disconnect the gear engagement cable.

1. Open the clips (1a) and release the gear selector and engagement cables (1b) from the mounting bracket.

1. Release the retaining clip (1a) and disconnect the pipe (1b) between the damper and the clutch operating cylinder (1b), operating cylinder side.

Collect the bake/clutch fluid that comes out in a suitable container.

2. Disconnect the electrical connection from the reversing light switch.

	Description	Connector
2	Reversing lights switch	See I020 REVERSING LIGHTS SWITCH

3. Undo the bolt (3a) and disconnect the earth lead (3b) from the gearbox.

1. Disconnect the electrical connection from the fuel pressure sensor on the fuel manifold.

	Description	Connector
1	Fuel pressure sensor	See K083 FUEL PRESSURE SENSOR

2. Fit a suitable bracket used for supporting the engine.

1. Fit the tool (1a) complete with support mountings (1b).

Tool	Description	Function	Validity
1820581000	Crossmember	Power unit support

Tool	Description	Function	Validity
1870650000	Support blocks	Power unit support

2. Fit the tools (2a) and (2b), then connect them using the rods (2c) to the brackets fitted previously and to the one on the engine.

Tool	Description	Function	Validity
1860851003	Crossmember	Power unit support

Tool	Description	Function	Validity
1870748000	Vertical support	Power unit support

1. Undo the bolts fixing the gearbox side power unit flexible mounting to the rigid support.2. Undo the bolts (2a) and remove the power unit gearbox side rigid support (2b).

1. Undo the upper bolts fixing the manual gearbox to the engine block.

1. Undo the bolts (1a) and remove the left side engine support flexible mounting (1b).

1. Undo the bolts (1a) and remove the bracket on the gearbox for the lower reaction rod (1b).

- Using the two engine supporting rods, lower the power unit so that the gearbox is in a position that it can be removed from the engine.1. Fit the tool complete with hydraulic jack for removing the manual gearbox.

Tool	Description	Function	Validity
1870847000	Support	Removing-refitting manual gearbox

1. Undo the remaining bolts and the nut securing the manual gearbox.2. Detach the manual gearbox and differential from the engine, then carefully lower the hydraulic jack.

Refitting ( Removing

) - Carefully raise the manual gearbox and differential using the hydraulic jack.- Align the manual gearbox and tighten it evenly to the engine.

Before fitting the manual gearbox to the engine, apply a thin layer of lubricating grease to the shaft teeth.

1. Tighten the bolts (1a), (1b) and the nut (1c) securing the manual gearbox to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox	Bolt	M12	(engine crankcase side) 4.8 - 7.2	1.9 JTD 16v1.9 JTD 8v

Component	Fastening	dia	Value (daNm)	Validity
Engine oil sump	Bolt	M10	(gearbox side) 3.2 - 4.8	1.9 JTD 16v 1.9 JTD 8v

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox	Nut	M12	(engine crankcase side) 4.8 - 7.2	1.9 JTD 16v1.9 JTD 8v

- Remove the tool complete with hydraulic jack used for removing the manual gearbox.

Tool	Description	Function	Validity
1870847000	Support	Removing-refitting manual gearbox

- Adjust the rods for the tools for supporting the engine to place the power unit in the correct position.1. Refit the lower reaction rod bracket (1a) in its seat on the gearbox and secure it by tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Bracket on gearbox for lower reaction rod	Bolt	M12	(gearbox side) 7.5 - 8.5

1. Place the left side engine support flexible mounting (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Flexible mounting for left side engine support	Bolt	M12	(gearbox side) 7.5 - 8.5

1. Place the power unit gearbox side rigid support (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side power unit rigid support	Bolt	M10/12	(gearbox side) 5.0 - 6.0

2. Tighten the bolts fixing the gearbox side power unit flexible mounting to the rigid support to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side support flexible mounting	Bolt	M10	(support side) 5.0 - 6.0

- Remove the tools used for supporting the engine.

Tool	Description	Function	Validity
1820581000	Crossmember	Power unit support

Tool	Description	Function	Validity
1870650000	Support blocks	Power unit support

Tool	Description	Function	Validity
1860851003	Crossmember	Power unit support

Tool	Description	Function	Validity
1870748000	Vertical support	Power unit support

- Remove the bracket used for supporting the engine.- Connect the electrical connection to the fuel pressure sensor on the fuel manifold.- Connect the earth lead to the gearbox and secure it using the bolt.- Connect the electrical connection to the reversing light switch.- Connect the pipe between the damper and clutch operating cylinder, operating cylinder side and secure it using the retaining clip.- Fasten the gear selection and engagement cables to the mounting bracket securing them using the clips.- Connect the gear engagement cable.- Connect the gear selector cable. Op. 5520B10 STARTER MOTOR - R+R Op. 4410D10 FRONT SUSPENSION FRAME - R+R Op. 7055A43 CENTRE FRONT GRILLE - R.R. Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R Op. 1080B95 REAR LAMBDA SENSOR TO CATALYTIC CONVERTER - R.R Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R. Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R. Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 0010T64 BRAKE AND/OR CLUTCH FLUID CHECK LEVEL AND TOP UP AS NECESSARY Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR Op. 0010T41 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY- Connect the negative battery terminal.- Remove the vehicle from the lift.