199000943 - 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

Removing ( Refitting )     Op. 5530B10 BATTERY - R+R     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R     Op. 0010T40 CHANGE MANUAL GEARBOX OIL     Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.    Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.    Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 2110A60 MANUAL GEARBOX/ENGINE COUPLING BRACKET - R+R - Disconnect the exhaust pipe from the flexible mountings, move it aside and secure it appropriately.1. Disconnect the electrical connection for the reversing switch.

	Description	Connector
1	Reversing light switch	See I020 REVERSING LIGHTS SWITCH (GEARBOX BRIDGE)

2. Undo the bolts and move the clutch control actuator aside.3. Undo the nut and disconnect the earth lead.

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

1. Disconnect the gear selector and engagement cables.2. Move the locking bush (2a) backwards and remove the gear selector cable (2b).3. Move the locking bush (3a) backwards and remove the gear engagement cable (3b). 1. Fit the tool (1a) complete with support mountings (1b).

Tool	Description	Function	Validity
1870595000	Crossmember	Power unit mount	1.2 8v1.4 8v1.4 16v1.3 Multijet

Tool	Description	Function	Validity
1870650000	Support blocks	Power unit mount	1.2 8v1.4 8v1.4 16v1.3 Multijet

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	1.2 8v1.4 8v1.4 16v1.3 Multijet

Tool	Description	Function	Validity
1871001300	Vertical mount	Power unit mount	1.2 8v1.4 8v1.4 16v1.3 Multijet

1. Undo the bolts fixing the flexible mounting to the gearbox side rigid power unit support.2. Undo the upper bolt securing the gearbox side power unit rigid support. 1. Undo the upper bolts securing the gearbox to the engine.2. Undo the front bolt securing the starter motor to the gearbox. 1. Open the protective cover (1a), loosen the nut (1b) and disconnect the wiring (1c) from the starter motor.

	Description	Connector
1c	Starter motor	See A020 STARTER MOTOR

2. Undo the bolt (2a) and remove the starter motor (2b). 1. Undo the bolt (1a) and move the ABS sensor (1b) from the pillar.2. Undo the bolt securing the front suspension left track control arm to the steering knuckle3. Unscrew the nut (3a), fit the tool (3b) and disconnect the left steering link (3c) from the knuckle.

Tool	Description	Function	Validity
1871000700	Extractor	Extracting steering rod from strut

- Proceed in the same way for the right side.1. Disconnect the left driveshaft from the differential and secure it appropriately. 1. Disconnect the right driveshaft from the differential and secure it appropriately. 1. Undo the lower bolts and remove the power unit rigid support from the gearbox. 1. Undo the bolts and remove the shield. 1. Support the gearbox as illustrated using the brackets (1a) and the hydraulic jack (1b).

Tool	Description	Function	Validity
1870847000	Brackets	Gearbox support

Tool	Description	Function	Validity
1870835001	Hydraulic lift	Gearbox support

2. Undo the nut (2a) and the remaining bolts (2a) and remove the gearbox (2c). Refitting ( Removing ) - Place the gearbox and differential back in its housing using the hydraulic jack and the support tool.- Tighten the bolts and the nut securing the gearbox to the specified torque.

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

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

- Place the shield in position and secure it using the bolts.- Place the power unit rigid support in position on the gearbox and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side power unit rigid support to gearbox casing	Bolt	M10	6.3 ÷ 7.7	1.2 8v1.4 8v1.4 16v1.3 Multijet 75 CV1.3 Multijet 90 CV 5 speed

- Place the right driveshaft back in its housing.- Place the left driveshaft back in its housing.- Connect the left steering rod to the knuckle and tighten the nut to the recommended torque.

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

- Tighten the bolt securing the front suspension left track control arm to the steering knuckle

Component	Fastening	dia	Value (daNm)	Validity
Front suspension lower wishbone - strut side	Bolt	M10	5.4 ÷ 6.6

- Connect the ABS sensor to the knuckle and secure it using the bolt.- Place the starter motor in its housing and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Starter motor	Bolt	M8	2.25 ÷ 2.75

- Connect the starter motor electrical wiring, tighten the nut and close the protective cover.- Tighten the upper bolt securing the gearbox side rigid support to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side power unit rigid support to gearbox casing	Bolt	M8	1.8 ÷ 2.2	1.2 8v1.4 8v1.4 16v

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

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side support flexible mounting to rigid support	Bolt	M12	9.5 ÷ 10.5	1.2 8v1.4 8v1.4 16v1.3 Multijet

- Remove the tools fitted previously for supporting the engine.- Place the gear selector and engagement cables complete with centering bushes back in their housings.- Connect the gear selector and engagement cables.- Connect the battery earth lead to the gearbox casing and secure it using the nut.- Place the clutch control actuator in its housing and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Hydraulic clutch actuator	Bolt	M8	1.8 ÷ 2.2	1.2 8v1.4 8v1.4 16v1.3 Multijet 75CV

- Connect the electrical connection for the reversing switch.- Connect the exhaust pipe to the flange and to the flexible mountings.    Op. 2110A60 MANUAL GEARBOX/ENGINE COUPLING BRACKET - R+R     Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.    Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.    Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R     Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 5530B10 BATTERY - R+R     Op. 0010T40 CHANGE MANUAL GEARBOX OIL