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

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

) Position the vehicle on a lift. Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R.1. Undo the fixing bolts (1a) and release the filter casing retaining springs (1b).2. Lift up the air filter casing, complete with cold air intake (2a), releasing it from the oil vapour recovery hose (2b), then remove the assembly.

Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R. Op. 4450B12 FRONT WHEELS (TWO) - R.R.Remove the protective cover for the junction unit in the engine compartment.1. Disconnect electrical connections (1a), (1b) and (1c) by releasing the wiring from the retaining clips.

1. Undo nut (1a) and disconnect the earth lead (1b) from the gearbox.2. Disconnect the electrical connection for the reversing lights.3. Undo adjustment nut (3a) and release clutch release cable (3b) from the fitting on gearbox (3c) and place outside the working area.

1. Remove both retaining clips (1a) and prise up the heads of gear engagement and selection cables (1b).2. Withdraw the selection and engagement cables from the bracket and place outside the working area.

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 fixing bolts (1a) and disconnect the front section of the exhaust pipe (1b) from the rear section.2. Undo the bolt fixing the manifold/catalytic converter mounting bracket to the gearbox.

1. Undo the nuts (1a) and disconnect the starter motor electrical wiring.2. Undo the engine and gearbox side fixing bolts (2a) and remove the starter motor (2b) from the lower part of the engine compartment.

Op. 1008C10 POWER UNIT UPPER SUPPORT - R R Op. 2110A60 MANUAL GEARBOX/ENGINE COUPLING BRACKET - R+R1. Undo the fixing bolts (1a) and remove the engine flywheel shield (1b).

1. Disconnect the electrical connection for the speedometer sensor.

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

Lower the vehicle.1. Position the bracket (1a) and fasten a spring catch (1b) to it.2. Position the crossmember (2a) for supporting the engine and attach the hook (2b) to the spring catch.

	Name	Country
2a	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.1. Undo retaining bolts (1a) and remove gearbox side engine mount (1b) .

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 slowly raise the hydraulic jack, taking care not to damage the adjacent 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

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

	Name	Country
2	Gearbox mount	1.860.873.000

Fit the gearbox end engine mount and tighten the fixing bolts to torque.

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

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

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

Tighten to torque the top bolts securing the gearbox to the engine block.

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

Remove the crossmember for supporting the engine positioned previously and the bracket for securing the actual crossmember.

	Name	Country
-	Crossmember	1.870.595.000

Raise the vehicle.Connect the electrical connection of the speedometer sensor.

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

Fit the engine flywheel shield and tighten the fixing bolts. Op. 2110A60 MANUAL GEARBOX/ENGINE COUPLING BRACKET - R+R Op. 1008C10 POWER UNIT UPPER SUPPORT - R RFit the starter motor in the lower part of the engine compartment and tighten the fixing bolts to torque.

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

Connect the electrical connections to the starter motor and secure by tightening the nuts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	BATTERY/MOTOR LEAD	M8	(Motor side) 2.4

	Name	Connector
-	Starter'' motor	See A020 STARTER MOTOR

Fit the exhaust manifold/converter and tighten the bolt fixing the mounting bracket to the gearbox to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CATALYTIC CONVERTER (ONE)	M8	(Collar at gearbox) 2.8

Connect the front section of the exhaust pipe to the rear section and tighten the fixing nuts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	CATALYTIC CONVERTER (ONE)	M8	(Flange connecting intermediate exhaust. pipe) 3

Position the constant velocity joints for both driveshafts in the special housings in the steering knuckles.Fit the track rod ends to the steering knuckles and tighten the fixing nut to torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	ADJUSTABLE STEERING LINKS	M10 x 1.25	4.9

Tighten the bolts securing the struts to the dampers to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	FRONT DAMPER	M10 x 1.25	(Steering knuckle side) 12

Tighten the nuts securing the half-axles to the wheel hubs on both wheels to torque.

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

1. Stake the nuts securing the half-axles to the wheel hubs on both sides as shown in the figure.

Lower the vehicle.Position the gear selection and engagement cables on the bracketSecure the gear selection and engagement cable ends to the ball joints and secure to the bracket by means of the two clips.Connect the clutch release cable to the gearbox and lever and tighten the adjustment nut.Connect the reversing light electrical connection.Connect the earth lead on the gearbox.

	Name	Connector
-	Earth on engine	See C040 ENGINE EARTH

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

Connect the electrical connections to the junction unit and secure the wiring to the retaining clips.

	Name	Connector
-	Engine compartment junction unit	See B001 JUNCTION UNIT

	Name	Connector
-	Engine compartment junction unit	See B001 JUNCTION UNIT

Fit the protective cover and secure it using the springs. Op. 4450B12 FRONT WHEELS (TWO) - R.R. Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R.Fit the air filter unit and secure it using the bolts, taking care to engage the rubber engine oil vapour pipe in the special housing in the filter casing.Secure the air intake pipe to the retaining spring.Secure the retaining clip to the filter casing. Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R.Remove the vehicle from the lift.