323001448 - 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

Removing ( Refitting ) - Position the vehicle on a lift.    Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.     Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.     Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.     Op. 1076B74 FRONT EXHAUST SILENCER WITH FLEXIBLE SECTION - R.R.    Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.    Op. 0010T40 CHANGE MANUAL GEARBOX OIL 1. Undo the nut, fit the tool and disconnect the steering rods.

Tool	Description	Function	Validity
1871000700	Extractor	Extracting steering rod from strut

2. Undo the bolts securing the front shock absorbers to the steering knuckles.3. Undo the bolts and remove the ABS sensors. - Undo the bolts securing the right driveshaft mounting the engine block.- Retract the driveshafts and release them from the differential.- Secure the driveshafts to the vehicle.    Op. 1016A10 SOUND-PROOFING COVER - R.R     Op. 5530B10 BATTERY - R+R     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 1008A45 GEARBOX SIDE RIGID SUPPORT REINFORCEMENT    Op. 5520B10 STARTER MOTOR - R+R     Op. 5520B10 STARTER MOTOR - R+R 1. Unscrew the brake fluid reservoir cap and fit the tool.

Tool	Description	Function	Validity
2000001400	Plug	Brake/ clutch system vacuum

1. Disconnect the electrical connection for the reversing light switch.

	Description	Connector
1	REVERSING LIGHTS SWITCH	See I020 REVERSING LIGHTS SWITCH

2. Undo the bolt and disconnect the battery earth lead.

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

3. Push the clip and disconnect the flexible pipe from the clutch release coaxial actuator. 1. Disconnect the gear selector and engagement cables.2. Move the locking cursors back and remove the gear selector and engagement cables.     Op. 1080D34 ENGINE OIL VAPOUR SEPARATOR - R + R     Op. 1064A31 HEAT SHIELD FOR TURBOCHARGER - R.R.- Undo the nut securing the exhaust manifold and tighten a suitable mounting bracket.1. Fit the tool (1a) complete with support mountings (1b).

Tool	Description	Function	Validity
1870595000	Crossmember	Power unit mount

Tool	Description	Function	Validity
1870650000	Support blocks	Power unit mount

2. Fit the tools (2a) and (2b), then connect them using the rods (2c) to the bracket fitted previously on the exhaust manifold and to the air chamber reinforcement bracket.

Tool	Description	Function	Validity
1860851000	Crossmember	Power unit mount

Tool	Description	Function	Validity
1871001300	Vertical mount	Power unit mount

1. Undo the upper bolts securing the gearbox to the engine block and keep the wiring mounting brackets. - Remove the flexible mounting for the power unit support, gearbox side with reference to    Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE - Remove the rigid support for the power unit, gearbox side with reference to    Op. 1008A42 POWER UNIT RIGID SUPPORT - GEARBOX SIDE - R.R. 1. Undo the front bolt securing the gearbox to the engine block and keep the wiring mounting bracket. 1. Undo the bolts fixing the gearbox to the engine oil sump.2. Undo the nut fixing the gearbox to the engine block.3. Undo the bolts fixing the flywheel guard to the gearbox. 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. Remove the gearbox. Refitting ( Removing ) - Place the gearbox in position using the support tools.- Tighten the nut fixing the gearbox to the engine block to the recommended torque.

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

- Tighten the bolts fixing the gearbox to the engine sump to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox to oil sump	Bolt	M10	3.6 ÷ 4.4	1.4 16v TJET

- Tighten the bolts fixing the flywheel guard to the gearbox.- Fit the wiring mounting bracket in its seat and tighten the front bolt fixing it the gearbox to the engine block to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox to engine - crankcase side	Bolt	M12	4.8 ÷ 7.2	1.4 16v TJET

- Remove the tools used for supporting the gearbox.- Fit the wiring mounting brackets in their seat and tighten the upper bolts fixing it the gearbox to the engine block to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Manual gearbox to engine - crankcase side	Bolt	M12	4.8 ÷ 7.2	1.4 16v TJET

- Refit the gearbox side rigid power unit support with reference to    Op. 1008A42 POWER UNIT RIGID SUPPORT - GEARBOX SIDE - R.R. - Place the flexible mounting for the power unit support, gearbox side in position with reference to    Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE - Remove the tools fitted previously for supporting the engine.    Op. 1064A31 HEAT SHIELD FOR TURBOCHARGER - R.R.    Op. 1080D34 ENGINE OIL VAPOUR SEPARATOR - R + R - Working in the engine compartment, introduce the two quick-fits for the gear selector and engagement cables in the openings in the bracket keeping the cursors retracted and inserting them fully into the seats using manual pressure until they are attached.- Release the cursors.- Using manual pressure, connect the ends of the gear selection and engagement cables to the ball joints for the levers on the gearbox.- Adjust the clip and connect the flexible pipe to the clutch release coaxial actuator.- Connect the battery earth lead and tighten the bolt.

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

- Connect the electrical connection for the reversing light switch.

	Description	Connector
-	REVERSING LIGHTS SWITCH	See I020 REVERSING LIGHTS SWITCH

    Op. 5520B10 STARTER MOTOR - R+R     Op. 1008A45 GEARBOX SIDE RIGID SUPPORT REINFORCEMENT    Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 5530B10 BATTERY - R+R     Op. 1016A10 SOUND-PROOFING COVER - R.R - Place the driveshafts in their seats.- Tighten the bolts securing the right driveshaft mounting the engine block.- Connect the shock absorbers to the steering knuckles and tighten the new bolts to the recommended torque.

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

- Connect the steering rods to the steering knuckles and tighten the nuts to the recommended torque.

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

- Place the ABS sensors in position and tighten the fixing bolts.    Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.    Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.     Op. 1076B74 FRONT EXHAUST SILENCER WITH FLEXIBLE SECTION - R.R.    Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.     Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.     Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 0010T40 CHANGE MANUAL GEARBOX OIL     Op. 0010T64 BRAKE AND/OR CLUTCH FLUID CHECK LEVEL AND TOP UP AS NECESSARY     Op. 0010T65 HYDRAULIC BRAKE SYSTEM - BLEED AIR     Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. - Remove the vehicle from the lift.