323003633 - 2110A11 MANUAL GEARBOX WITH DIFFERENTIAL - R.R. FOR VERSIONS WITH HYDRAULIC SELECTION

Removing ( Refitting ) - Position the vehicle on a lift.    Op. 0010T40 CHANGE MANUAL GEARBOX OIL     Op. 5530B10 BATTERY - R+R     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - R.R     Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.     Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.     Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R.    Op. 2127C22 PIPE FROM HYDRAULIC SPEED SELECTION ACTUATOR UNIT TO FLUID RESERVOIR - R.R.     Op. 2127C12 HYDRAULIC GEAR SELECTION FLUID RESERVOIR - R.R.     Op. 1060G70 VACUUM RESEVOIR - R.R     Op. 5520B10 STARTER MOTOR - R+R     Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R     Op. 7210E10 R.R. FRONT BUMPER     Op. 1088E10 RADIATOR COOLING FAN - R + R     Op. 4450B12 FRONT WHEELS (TWO) - R+R 1. Loosen the band and disconnect the rigid intermediate pipe between the heat exchanger and the throttle body, throttle body side.2. Undo the fixing nut on the engine block.- Release the rigid intermediate pipe from the vehicle.3. Undo the bolts (3a) and disconnect the pipe (3b) from the turbocharger.4. Undo the bolts (4a) and (4b) securing the heat exchanger rigid inlet and outlet pipes.5. Unscrew the radiator supporting crossmember bolts.6. Undo the bolts fixing the heat exchanger.7. Remove the heat exchanger complete with radiator supporting crossmember and pipes. 1. Undo the nut (1a) and disconnect the battery earth lead (1b) from the engine.

	Description	Connector
1b	BATTERY EARTH ON ENGINE	See C002 BATTERY EARTH ON ENGINE

- Disconnect the electrical connection for the robotized gearbox control unit, vehicle wiring side.

	Description	Connector
-	ROBOTIZED GEARBOX CONTROL UNIT	See M054 ROBOTIZED TRANSMISSION CONTROL UNIT

- Disconnect the electrical connections for the heater plugs control unit, engine wiring side.

	Description	Connector
-	GLOW PLUG PREHEATING CONTROL UNIT	See M015 PLUG PREHEATING CONTROL UNIT

- Work on both sides of the vehicle.1. Unscrew the nut, fit the tool and disconnect the steering link from the strut.

Tool	Description	Function	Validity
1871000700	Extractor	Extracting steering rod from strut

2. Undo the bolts securing the front shock absorber to the steering knuckle.3. Undo the bolt and remove the ABS sensor. 1. Undo the bolts (1a) securing the intermediate driveshaft support (1b).- Retract the brake caliper and extract the driveshafts from the differential.- Secure the driveshafts to the bodyshell. 1. Fit the tool (1a) complete with mountings (1b).

Tool	Description	Function	Validity
1870595000	Crossmember	Power unit mount	1.4 8v1.3 Multijet

Tool	Description	Function	Validity
1870650000	Support blocks	Power unit mount	1.4 8v1.3 Multijet

2. Fit the tools (2a) and (2b), then connect them to the brackets on the engine, gearbox side.

Tool	Description	Function	Validity
1860851000	Crossmember	Power unit mount

Tool	Description	Function	Validity
1871001300	Vertical mount	Power unit mount

- Tension firstly the front part of the equipment to rotate the power unit and place the catalytic converter in a vertical position. This condition allows the gearbox to be extracted from the engine compartment. 1. Undo the bolts securing the gearbox side flexible mounting.- Working on the support equipment, tilt the power unit, gearbox side.2. Undo the retaining bolts (2a) and remove the engine side rigid support (2b). 1. Unscrew the upper gearbox fixing bolts. 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	1.4 8v1.4 16v TJET

2. Undo the reamining gearbox securing nut and bolts.3. Working on the support equipment, remove the gearbox. Refitting ( Removing ) - Working on the support equipment, place the gearbox in position.- Tighten the lower bolts and the nut securing the gearbox to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox to engine - crankcase side	Bolt	M10	3.6 ÷ 4.4	1.3 Multijet

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

- Remove the gearbox support tool equipment.

Tool	Description	Function	Validity
1870847000	Brackets	Gearbox support

Tool	Description	Function	Validity
1870835001	Hydraulic lift	Gearbox support	1.4 8v1.4 16v TJET

- Tighten the upper gearbox fixing bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox to engine - crankcase side	Bolt	M10	3.6 ÷ 4.4	1.3 Multijet

- Fit the gearbox side rigid support in place and tighten the bolts to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side power unit rigid support to gearbox casing	Bolt	M10	6.3 ÷ 7.7

- Working on the support equipment, raise the power unit, gearbox side and tighten the bolts fixing the flexible mounting to the rigid support to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Gearbox side support flexible mounting to rigid support	Bolt	M12	6.3 ÷ 7.7	1.4 8v1.3 Multijet

- Reposition the power unit and remove the support equipment and rods/chains.

Tool	Description	Function	Validity
1870595000	Crossmember	Power unit mount	1.4 8v1.3 Multijet

Tool	Description	Function	Validity
1870650000	Support blocks	Power unit mount	1.4 8v1.3 Multijet

Tool	Description	Function	Validity
1860851000	Crossmember	Power unit mount

Tool	Description	Function	Validity
1871001300	Vertical mount	Power unit mount

- Work on both sides of the vehicle.- Fit the driveshaft in place on the differential.- Tighten the new bolts securing the front shock absorber to the strut to the recommended torque.

To tighten to torque, position the torque wrench on the nut and not on the bolt.

Component	Fastening	dia	Value (daNm)	Validity
Front shock absorber - strut side	Bolt (to be replaced)	M12	10.3 ÷ 12.6 + 45°

- Connect the steering link to the knuckle and tighten the nut to the specified torque.

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

- Connect the ABS sensor to the knuckle and secure it using the bolt.- Tighten the bolts fixing the intermdiate driveshaft to the mounting to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Intermediate driveshaft bearing support	Bolt	M8	2.3 ÷ 2.8	1.4 16v TJET

- Connect the electrical connections for the heater plugs control unit.

	Description	Connector
-	GLOW PLUG PREHEATING CONTROL UNIT	See M015 PLUG PREHEATING CONTROL UNIT

- Secure the electrical connection for the robotized gearbox control unit.

	Description	Connector
-	ROBOTIZED GEARBOX CONTROL UNIT	See M054 ROBOTIZED TRANSMISSION CONTROL UNIT

- Connect the battery earth lead to the engine and tighten the fixing nut.

	Description	Connector
-	BATTERY EARTH ON ENGINE	See C002 BATTERY EARTH ON ENGINE

- Place the heat exchanger in position complete with radiator supporting crossmember and pipes.- Tighten the radiator supporting crossmember bolts.- Tighten the bolts fixing the heat exchanger.- Place the heat exchanger inlet and outlet pipes in position and tighten the bolts securing the rigid pipes.- Connect the pipe to the turbocharger and tighten the fixing bolts.- Connect the rigid intermediate pipe between the heat exchanger and the throttle body and tighten the band.- Tighten the fixing nut on the engine block.     Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 1088E10 RADIATOR COOLING FAN - R + R     Op. 7210E10 R.R. FRONT BUMPER     Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R     Op. 5520B10 STARTER MOTOR - R+R     Op. 1060G70 VACUUM RESEVOIR - R.R     Op. 2127C12 HYDRAULIC GEAR SELECTION FLUID RESERVOIR - R.R.     Op. 2127C22 PIPE FROM HYDRAULIC SPEED SELECTION ACTUATOR UNIT TO FLUID RESERVOIR - R.R.     Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R.    Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.     Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.     Op. 1048A23 COLD AIR INTAKE FOR AIR FILTER - 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 - Remove the vehicle from the lift.