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

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

) Place the car on a ramp. Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R. Op. 4450B12 FRONT WHEELS (TWO) - R.R. Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R.R. Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R.1. Undo the bolts (1a) fixing the mounting bracket, disconnect the electrical connection (1b) from the integrated throttle body actuator, disconnect the cold air intake pipe (1c) from the filter casing and also disconnect the vacuum intake pipe from the attachment on the shutter valve.2. Remove the filter casing.

	Name	Connector
1b	Butterfly casing solenoid valve	See L62 BUTTERFLY CASING SOLENOID VALVE ( ENGINE )

1. Lift up the fuse box protective cover.2. Disconnect the electrical connections (2a) and remove the fuse box (2b).

	Name	Connector
2a	Front/engine coupling	See D004 FRONT/ENGINE COUPLING

3. Undo the nut and disconnect the positive terminal lead from the fuse box.4. Turn the fuse box over and disconnect the comb type connection.

	Name	Connector
4	Engine compartment junction unit	See B001 JUNCTION UNIT

1. Undo the retaining bolts.2. Place the operating cylinder outside the working area.3. Undo the nut (3a) and disconnect the earth lead (3b) from the gearbox.

	Name	Connector
3b	Battery earth	See C1 BATTERY EARTH ( BATTERY NEGATIVE )

4. Disconnect the electrical connection from the reversing lights switch.

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

1. Remove the gear selection and engagement flexible transmission cable ends from the relay unit.2. Remove the two retaining clips.3. Remove the two transmission cables from the mounting bracket.

Raise the vehicle.1. Remove the staking on the wheel hub nuts on both sides and then undo them.2. Undo the bolts securing the struts to the damper.3. Undo the nuts (3a) and use tool (3b) to remove the steering balljoint head from the strut.4. Then withdraw the half-axles from the hubs and secure to the power unit using twine.

	Name	Country
3b	Head extractor	1.847.035.000

1. Undo the nuts fixing the reinforcement bracket on the oil sump.2. Remove the reinforcement bracket.3. Undo the nuts securing the exhaust pipe to the manifold.4. Undo the bolts securing the pipe to the catalytic converter.5. Undo the fixing bolt and release the rubber mounting, complete with bodyshell pin.6. Remove the front exhaust pipe section.

Position a hydraulic lift under the gearbox in order to be able to work safely.1. Undo the centre bolt fixing the reaction rod to the bodyshell.

1. Undo the nuts (1a) and disconnect the starter motor electrical wiring (1b).

	Name	Connector
1b	Starter'' motor	See A020 STARTER MOTOR

2. Undo the engine and gearbox side fixing bolts (2a) and remove the starter motor (2b) from the lower part of the engine compartment.3. Disconnect the electrical connection for the speedometer sensor.

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

1. Undo the retaining bolts.2. Remove the engine flywheel guard.

Lower the vehicle.1. Position the bracket (1a) and secure the crossmember hook (1b).2. Position the crossmember for supporting the engine and secure the hook to the crossmember.

	Name	Country
2	Crossmember	1.870.595.000

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

1. Undo the nut fixing the flexible mounting to the gearbox side rigid engine support.Raise the vehicle.2. Undo the fixing bolts (2a) and remove the gearbox side engine support (2b).

1. Undo the bolt securing the bellhousing.2. Using a hydraulic jack, position the tool for supporting and manoeuvring the gearbox-differential unit during the removal operations.3. Secure the tool using the bolt loosened previously and a bolt for securing the tool at the back.

	Name	Country
2	Gearbox mount	1.860.873.000

1. Undo the remaining nuts and bolts and release the gearbox from the centring pins.2. Lower the assembly, taking care not to damage any interfering components and remove the gearbox-differential assembly (2a), complete with driveshafts (2b).

Refitting ( Removing

) Position the gearbox-differential unit, secured to the tool used for the removal, in the engine compartment and lift it slowly using the hydraulic jack, taking care not to damage the surrounding components.Centre the gearbox-differential unit on the centring pins and secure it, tightening the lower nuts and bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MANUAL GEARBOX	M12 x 1.25	(below gearbox) 8

	Fastening	Component	Ø	Value(daNm)
-	Nut	MANUAL GEARBOX	M12 x 1.25	(below gearbox) 8

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MANUAL GEARBOX	M10 x 1.25	(Join with oil sump) 5

Remove the tool positioned previously for manoeuvring the gearbox during the removal stage.

	Name	Country
-	Gearbox mount	1.860.873.000

Fit the gearbox side engine support.Tighten the bolts fixing the rigid support to the gearbox to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10 x 1.25	(Gearbox) 5

Tighten the nut fixing the gearbox side engine mounting to the rigid support to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	POWER UNIT GEAR BOX END RIGID MOUNT	M12 x 1.25	(Flexible mounting side) 9

Tighten the upper bolts fixing the gearbox to the crankcase to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	MANUAL GEARBOX	M12 x 1.25	(upper gearbox) 8

Remove the crossmember for supporting the power unit and the attachment brackets.

	Name	Country
-	Crossmember	1.870.595.000

Raise the vehicle.Fit the engine flywheel shield and tighten the fixing bolts.Connect the starter motor electrical wiring.

	Name	Connector
1b	Starter'' motor	See A020 STARTER MOTOR

Position the starter motor in the housing in the gearbox and tighten the fixing bolts to torque.

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

Connect the electrical connection of the speedometer sensor.

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

Tighten the centre bolt fixing the reaction rod to the bodyshell to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	REACTION ROD	M12 x 1.25	12

Fit the exhaust pipe gasket.Fit the front section of the exhaust pipe.Secure the pin to its rubber block.Tighten the nuts securing the exhaust pipe to the catalytic converter.

	Fastening	Component	Ø	Value(daNm)
-	Nut	EXHAUST PIPE TO ENGINE	M8	(catalytic converter) 3

Tighten the nuts securing the exhaust pipe to the manifold.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	EXHAUST PIPE TO ENGINE	M8	(Exhaust manifold) 3

Tighten the nuts securing the reinforcement brackets to the studs on the oil sump.Tighten the bolts fixing the shock absorber to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	FRONT HUB STEERING KNUCKLE.	M12 x 1.25	12.

Fit the steering tie-rod end in its seating.Tighten the fixing nut to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	ADJUSTABLE LINK BALL JOINTS	M10 x 1.25	4.9

Tighten the wheel hub nut to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	FRONT HUB WITH BEARINGS	M22	7 + 55°

1. Stake the nut in accordance with the illustration below.

Lower the lift.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.Connect the earth lead to the gearbox.

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

Fit the operating cylinder in the special housing on the gearbox and tighten the fixing bolt to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CLUTCH CONTROL HYDRAULIC ACTIVATOR	M8	2.8

Turn the fuse box over and connect the connections disconnected previously.

	Name	Connector
-	Engine compartment junction unit	See B001 JUNCTION UNIT

Connect the positive terminal lead to the fuse box.Position the fuse box protective cover.Fit the complete air filter casing.Connect the integrated throttle body actuator vacuum pipe .Tighten the bolts fixing the filter mounting bracket and connect the cold air intake pipe to the casing.Connect the electrical connection to the integrated throttle body actuator.

	Name	Connector
2b	Butterfly casing solenoid valve	See L62 BUTTERFLY CASING SOLENOID VALVE ( ENGINE )

Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R.R. Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R. Op. 4450B12 FRONT WHEELS (TWO) - R.R. Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R. Op. 5530B10 BATTERY - R+RRemove the vehicle from the lift.