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

2584581 - 2110A10 manual gearbox and differential - r + r

) Position the car on the ramp.Carry out Op. 5530B10 BATTERY - R+R.Carry out Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R.1. Disconnect the electrical connection from the air flow meter.2. Loosen the band and disconnect the the turbocharger air inlet sleeve from the rigid pipe, air flow meter side.

	Name	Connector
1	Air flow meter	See K041 AIR FLOW METER

1. Loosen the band (1a) and disconnect flexible hose (1b) from the air intake.2. Remove the air filter (2a) complete with air flow meter (2b) by releasing from the underlying pins and then from the rear fastenings.

Open the clips and remove the engine compartment junction unit cover.1. Undo the nut and disconnect the positive supply lead from the engine compartment junction unit.

	Name	Connector
1	Engine compartment junction unit	See B1A ENGINE COMPARTMENT JUNCTION UNIT ( BATTERY POSITIVE )

2. Use a screwdriver to remove the safety pin and disconnect the electrical connections (2a) and (2b) from the engine compartment junction unit.

	Name	Connector
2a	Front/engine coupling	See D4A FRONT/ENGINE COUPLING ( FRONT )

	Name	Connector
2b	Front/engine coupling	See D4B FRONT/ENGINE COUPLING ( CONNECTORS )

3. Undo the retaining clip to prise up the spark plug fuse block (MAXI FUSE) from the junction unit in the engine bay.

	Name	Connector
3	Spark plugs (MAXI FUSE) fuse	See B37 SPARK PLUGS (MAXI FUSE) FUSE ( ENGINE )

1. Rotate the engine compartment junction unit on its hinges.2. Disconnect the electrical connection from the engine compartment junction unit.

	Name	Connector
2	Engine compartment junction unit	See B1F ENGINE COMPARTMENT JUNCTION UNIT ( ENGINE )

1. Undo the bolts (1a) and move the clutch operating cylinder (1b) aside without disconnecting the pipe.

1. Disconnect the gear engagement/selector cables.2. Remove the stops and release the gear engagement/selector cables from the mounting bracket.

Carry out Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R..Carry out Op. 0010T20 ENGINE COOLANT - CHANGE.1. Disconnect the electrical connection from the reversing lights switch.

	Name	Connector
1	Reversing lights switch	See I20 REVERSING LIGHTS SWITCH ( FRONT )

2. Undo the bolt (2a) and disconnect the battery earth lead (2b) from the gearbox.

	Name	Connector
2b	Battery earth	See C1 BATTERY EARTH ( BATTERY NEGATIVE )

1. Disconnect the electrical connection for the speedometer and prise up the electrical lead from the anchorage clip.

	Name	Connector
1	Speedometer sensor	See K84 SPEEDOMETER SENSOR ( ENGINE )

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

	Name	Connector
1	Data not available yet

2. Prise up the electrical lead from the anchorage clip and move aside.

Carry out .Carry out Op. 4450B12 FRONT WHEELS (TWO) - R.R..Carry out Op. 7055B42 FRONT WHEEL ARCH LINER (ONE), LEFT OR RIGHT - R.R..Carry out Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R.Carry out Op. 2710A40 DRIVESHAFT (ONE) LEFT OR RIGHT - R.R..1. Use the appropriate tool to loosen the band (1a) and disconnect the coolant return pipe to the heat exchanger (1b).

	Name	Country
1a	Pliers	1.881.138.000

Carry out .1. Undo the gearbox oil drain plug and drain the oil into a suitable container.

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

	Name	Country
1a	Crossmember	1.870.595.000

	Name	Country
1b	Support mountings	1.870.650.000

2. Undo the bolts securing the wiring.

1. Disconnect the electrical connections from the injectors.

	Name	Connector
1	Injector	See N070 INJECTOR

2. Fasten the chain to the engine mounts as shown in the figure.

Carry out Op. 2110A60 MANUAL GEARBOX/ENGINE COUPLING BRACKET - R+R.1. Undo the nut fixing the gearbox side power unit rigid support to the flexible mounting.

1. Undo the top bolts securing the manual gearbox with differential to the crankcase.

Carry out Op. 1008a42 GEARBOX SIDE POWER UNIT RIGID SUPPORT - R.R..Position a hydraulic jack under the gearbox1. Undo the bolt fixing the power unit lower reaction rod to the front suspension crossmember.2. Undo the bolt fixing the lower reaction rod for the gearbox side power unit assembly.

To extract the bolt, manually rotate the power unit pushing it slightly forwards.

Take care not to force the exhaust pipe flexible joint without affecting the flexible mounts.3. Remove the lower reaction rod for the power unit.Remove the hydraulic jack from under the gearbox.

1. Fit the tool (1a) supporting the manual gearbox with differential using the bolt (1b) securing the gearbox casing.

	Name	Country
1a	Gearbox mount	1.860.873.000

2. Position a hydraulic jack under the tool supporting the manual gearbox with differential.3. Undo the remaining bolt (3a) and nut (3b) securing the manual gearbox with differential to the engine block.4. Remove the manual gearbox with differential, first moving it away from the engine and then lowering it with the hydraulic jack.

Refitting ( Removing

) Place the manual gearbox and differential back in its housing using the hydrauilc jack and support tool.1. Tighten the bolts (1a) and nut (1b) securing the manual gearbox with differential to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	MANUAL GEARBOX	M12	(Crankcase side) 7.2 ÷ 8.8

	Fastening	Component	Ø	Value(daNm)
1b	Nut	MANUAL GEARBOX	M12	(Crankcase side) 7.2 ÷ 8.8

2. Remove the manual gearbox and differential support tool (2a) and the hydraulic jack (2b).

	Name	Country
2a	Gearbox mount	1.860.873.000

Tighten the bolt securing the gearbox casing used for fittign the tool to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	GEARBOX GEAR CASING	M8	(Bellhousing support side) 2.3 ÷ 2.8

Position a hydraulic jack under the gearboxPlace the power unit lower reaction rod back in its housing and fix it to the gearbox using the bolt without tightening it.

To fi the above bolt the power unit must be rotated manually, pushing it slightly forwards, without affecting the flexible mountings.

Faste the power unit lower reaction rod to the front suspension crossmember without tightenint the bolt.1. Tighten the bolt securing the power unit lower reaction rod to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	LOWER ROD ON ENGINE	M12	(Gearbox side) 7.2 ÷ 8.8

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	LOWER ROD ON ENGINE	M12	(Front suspension crossmember side) 11.4 ÷ 12.6

Carry out Op. 1008a42 GEARBOX SIDE POWER UNIT RIGID SUPPORT - R.R..1. Undo the nut fixing the gearbox side rigid power unit support to the flexbile mounting to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Nut	POWER UNIT GEAR BOX END RIGID MOUNT	M12	(Flexible mounting side) 8.1 ÷ 9.9

Carry out Op. 2110A60 MANUAL GEARBOX/ENGINE COUPLING BRACKET - R+R.Remove the chain from the engine mounting.Connect the electrical connections to the injectors.

	Name	Connector
-	Injector	See N070 INJECTOR

Tighten the bolts securing the wiring.Remove the beam and support blocks.Tighten the manual gearbox and differential fluid drain plug to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Drain plug	GEAR CASING PADS	M22 x 1.25	(Differential side) 3.6

Carry out .Connect the coolant return pipe to the heat exchanger and secure the clip.Carry out Op. 0010T41 MANUAL GEARBOX OIL - CHECK LEVEL AND TOP UP IF NECESSARY.Carry out Op. 2710A40 DRIVESHAFT (ONE) LEFT OR RIGHT - R.R..Carry out Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R.Carry out Op. 7055B42 FRONT WHEEL ARCH LINER (ONE), LEFT OR RIGHT - R.R..Carry out Op. 4450B12 FRONT WHEELS (TWO) - R.R..Carry out .Connect the electrical connection to the engine coolant temperature sensor and fit the wire into the anchorage clip.

	Name	Connector
-	Data not available yet

Connect the electrical connection to the speedometer sensor and fit the wire to the anchorage clip.

	Name	Connector
-	Speedometer sensor	See K84 SPEEDOMETER SENSOR ( ENGINE )

Connect the battery earth lead to the gearbox.

	Name	Connector
-	Battery earth	See C1 BATTERY EARTH ( BATTERY NEGATIVE )

Connect the electrical connection for the reversing lights switch.

	Name	Connector
-	Reversing lights switch	See I20 REVERSING LIGHTS SWITCH ( FRONT )

Carry out Op. 0010T20 ENGINE COOLANT - CHANGE.Carry out Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R..Position the two gearbox transmission cables on the mounting bracket.Fasten the two transmission cables to the bracket, engaging the two springs.Secure the gear selection and engagement flexible cable ends on the relay unit.Fit the slave cyilnder and tighten the fixing bolts.Connect the electrical connection to the engine compartment junction box.

	Name	Connector
-	Engine compartment junction unit	See B1F ENGINE COMPARTMENT JUNCTION UNIT ( ENGINE )

Turn the junction unit and position in its seat.1. Connect the positive supply lead to the engine compartment junction unit and fasten it using the nut.

	Name	Connector
1	Engine compartment junction unit	See B1A ENGINE COMPARTMENT JUNCTION UNIT ( BATTERY POSITIVE )

2. Disconnect the electrical connections (2a) and (2b) from the engine compartment junction unit.

	Name	Connector
2a	Front/engine coupling	See D4A FRONT/ENGINE COUPLING ( FRONT )

	Name	Connector
2b	Front/engine coupling	See D4B FRONT/ENGINE COUPLING ( CONNECTORS )

3. Position the spark plug fuse block (MAXI FUSE) to the junction unit in the engine bay.

	Name	Connector
3	Spark plugs (MAXI FUSE) fuse	See B37 SPARK PLUGS (MAXI FUSE) FUSE ( ENGINE )

Fit the junction unit cover.Fit the air filter complete with air flow meter in its seat and secure to the rear fastening and then to the underlying pins.Connect the flexible sleeve to the air intake on the beam and tighten the retaining clip.Connect the air intake sleeve to the turbocharger, air flow meter side, and tighten the band.Connect the electrical connection to the air flow meter.

	Name	Connector
-	Air flow meter	See K041 AIR FLOW METER

Carry out Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R..Carry out Op. 5530B10 BATTERY - R+R.Remove the car from the ramps.