198000190 - 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

Removing ( Refitting )     Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.    Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.     Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 7055B65 ENGINE COMPARTMENT DUST COVER IN LEFT FRONT WHEEL ARCH - R.R.     Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.     Op. 0010T40 CHANGE MANUAL GEARBOX OIL     Op. 5530B10 BATTERY - R+R     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 1016A10 SOUND-PROOFING COVER - R.R     Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 1048B27 RIGID PIPE FOR AIR INLET TO THROTTLE BODY - R R    Op. 1076B20 REAR EXHAUST SILENCER - R + R     Op. 1080B81 PARTICULATE FILTER (D.P.F.) - R.R.    Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R     Op. 1048A41 HOSE FROM FLOW METER TO TURBOCHARGER - R.R.    Op. 3310A60 FRONT BRAKE PADS - REPLACE     Op. 1008C30 POWER UNIT LOWER REACTION LINK - R.R.    Op. 1008C33 BRACKET ON ENGINE FOR LOWER REACTION ROD - R.R.    Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R - Unscrew the brake-clutch fluid reservoir plug and fit the tool.

Tool	Description	Function	Validity
2000001400	Plug	Brake/ clutch system vacuum

1. Remove the brake caliper fluid flexible pipe from the retaining bracket.2. Remove the ABS wheel rpm sensor wiring from the retaining bracket.3. Remove the wiring for the left front brake pad wear sensor from the retaining bracket.4. Unscrew the nut (4a), fit the tool (4b) and disconnect the steering link (4c) from the wheel strut.

Tool	Description	Function	Validity
1871000700	Extractor	Extracting steering rod from strut

5. Undo the bolts securing the shock absorber to the wheel strut. 1. Loosen the band (1a) and disconnect the left driveshaft (1b) from the differential internal driveshaft (1c).     Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.- Remove the starter motor referring to    Op. 5520B10 STARTER MOTOR - R+R 1. Disconnect the gear selector and engagement cables.2. Undo the nuts and remove the bracket complete with gear selection and engagement cables.3. Disconnect the electrical connection for the reversing light switch.

	Description	Connector
3	Reversing light switch	See I020 REVERSING LIGHTS SWITCH

1. Lift up the clip and disconnect the flexible pipe from the clutch control actuator.2. Undo the nut and disconnect the battery earth lead.

	Description	Connector
2	Battery earth on engine	See C002 BATTERY EARTH ON ENGINE

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

Tool	Description	Function	Validity
1870595000	Crossmember	Power unit mount

Tool	Description	Function	Validity
1870650000	Support blocks	Power unit mount

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

Tool	Description	Function	Validity
1860851000	Crossmember	Power unit mount

Tool	Description	Function	Validity
1871001300	Vertical mount	Power unit mount

- Remove the flexible mounting and the rigid support for the power unit, gearbox side with reference to    Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE     Op. 1008A42 POWER UNIT RIGID SUPPORT - GEARBOX SIDE - R.R. - Undo the upper bolts securing the gearbox to the engine block.1 Support the gearbox as illustrated using the brackets and the hydraulic jack.

Tool	Description	Function	Validity
1870847000	Brackets	Gearbox support

Tool	Description	Function	Validity
1870835001	Hydraulic lift	Gearbox support

2. Undo the rear nut fixing the gearbox to the engine block.3. Undo the rear bolt fixing the gearbox to the engine oil sump. 1. Undo the bolts and remove the flywheel guard.2. Undo the front bolt fixing the gearbox to the engine oil sump.3. Undo the front nut fixing the gearbox to the engine block.4. Remove the gearbox. Refitting ( Removing ) - Place the gearbox in position using the support tools.- Tighten the bolts and the nuts securing the gearbox to the engine to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox-differential ring gear	Bolt	M10 x 1.25	6.0 + 90°	1.4 16v TJet

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox to engine - crankcase side	Nut	M12	4.8 ÷ 7.2	1.9 JTD

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox to oil sump	Bolt	M10	3.6 ÷ 4.4

- Place the rear flywheel guard in its housing and tighten the bolts.- Place the rigid support for the power unit, gearbox side and the flexible mounting in their housings with reference to    Op. 1008A42 POWER UNIT RIGID SUPPORT - GEARBOX SIDE - R.R.     Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE - Remove the tools fitted previously for supporting the engine.- Connect the battery earth lead and tighten the nut.- Connect the flexible pipe to the clutch control actuator and close the clip.- Connect the electrical connection for the reversing light switch.- Refit the bracket with gear selection and engagement cables in its seat and tighten the nuts.- Connect the gear selector and engagement cables to the levers.- Place the starter motor in position with reference to    Op. 5520B10 STARTER MOTOR - R+R     Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.    Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R. - Connect the left driveshaft to the differential internal driveshaft and fasten the boot using the band.- Connect the left steering links to the knuckle and tighten the new nut to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Steering rod to pillar	Nut	M10	3.6 ÷ 4.4

- Tighten the new bolts fixing the shock absorber to the steering knuckle to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Front shock absorber to wheel strut	Bolt (to be replaced)	M12	9.5 ÷ 10.5	1.9 JTD 16v

- Place the wiring for theleft front brake pad wear sensor in its housing and secure it to the retaining bracket.- Position the wiring for the ABS rpm sensor in its housing and secure it to the retaining bracket.- Place the brake caliper fluid flexible pipe in position and fasten it to the retaining bracket.     Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R     Op. 1008C33 BRACKET ON ENGINE FOR LOWER REACTION ROD - R.R.    Op. 1008C30 POWER UNIT LOWER REACTION LINK - R.R.    Op. 3310A60 FRONT BRAKE PADS - REPLACE     Op. 1048A41 HOSE FROM FLOW METER TO TURBOCHARGER - R.R.    Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R     Op. 1080B81 PARTICULATE FILTER (D.P.F.) - R.R.    Op. 1076B20 REAR EXHAUST SILENCER - R + R     Op. 1048B27 RIGID PIPE FOR AIR INLET TO THROTTLE BODY - R R    Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 1016A10 SOUND-PROOFING COVER - R.R     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 5530B10 BATTERY - R+R     Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.     Op. 7055B65 ENGINE COMPARTMENT DUST COVER IN LEFT FRONT WHEEL ARCH - R.R.     Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.     Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.    Op. 0010T40 CHANGE MANUAL GEARBOX OIL     Op. 0010T64 BRAKE AND/OR CLUTCH FLUID CHECK LEVEL AND TOP UP AS NECESSARY - Check the brake-clutch fluid level and, if necessary, bleed the system, with reference to    Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR