1. Position the thrust bearing on the gearbox mainshaft sleeve.2. Check the release lever is positioned correctly in the thrust bearing.3. Insert the release lever retaining shaft.
Engines: 2.0 16V
- Fit the gearbox differential unit and tighten the bolts to torque.- Fit the mounting bracket and support for the gear selection and engagement cables.- Fit the clutch actuator cylinder mounting bracket in place.- Fit the flywheel guard and tighten the fixing bolts.- Fit the starter motor in position and tighten to torque.
1. To remove the fork lever pin, use a M6 x 1 bolt (1a) fitted, in turn, into connector (1b) screwed into driver (1c).
Description
Code
Function
1b
Extractor
1.860.959.000
Clutch control fork lever pin removal
Description
Code
Function
1c
Mallet
1.847.017.001
Clutch control fork lever pin removal
2. Tighten the resulting tool to the pin and exercise a pulling force in the arrowed direction (toward the operator) to remove the fork lever retaining shaft.
1. Position the thrust bearing on the gearbox mainshaft sleeve.2. Check the release lever is positioned correctly in the thrust bearing.3. insert the release lever retaining shaft.
- Fit the gearbox-differential unit and tighten the fixing nuts and bolts to torque.
Value - daNm
Fastening
Component
Ø
.
7
Bolt
MANUAL GEARBOX/DIFFERENTIAL
M12
Value - daNm
Fastening
Component
Ø
.
6
Nut
MANUAL GEARBOX/DIFFERENTIAL
M10
- Fit the gear selection and engagement cable retaining and mount bracket.- Fit the release cylinder bracket to the gearbox.- Position the starter motor spacer.- Fit the starter motor and tighten the fixing bolts to torque.
1. To remove the fork lever pin, use a M6 x 1 bolt (1a) fitted, in turn, into connector (1b) screwed into driver (1c).
Description
Code
Function
1b
Extractor
1.860.959.000
Clutch control fork lever pin removal
Description
Code
Function
1c
Mallet
1.847.017.001
Clutch control fork lever pin removal
2. Tighten the resulting tool to the pin and exercise a pulling force in the arrowed direction (toward the operator) to remove the fork lever retaining shaft.
1. Position the thrust bearing on the gearbox mainshaft sleeve.2. Check the release lever is positioned correctly in the thrust bearing.3. insert the release lever retaining shaft.
- Fit the gearbox-differential unit and tighten the fixing nuts and bolts to torque.
Value - daNm
Fastening
Component
Ø
.
7
Bolt
MANUAL GEARBOX/DIFFERENTIAL
M12
Value - daNm
Fastening
Component
Ø
.
6
Nut
MANUAL GEARBOX/DIFFERENTIAL
M10
- Fit the gear selection and engagement cable retaining and mount bracket.- Fit the release cylinder bracket to the gearbox.- Position the starter motor spacer.- Fit the starter motor and tighten the fixing bolts to torque.
1. Undo retaining bolts (1a) and remove starter motor (1b).
Engines: 2.0 JTD 8V
1. Disconnect the pipe from the band on the turbocharger (1a) and with vapour recovery pipe (1b).2. Remove the turbocharger air intake pipe.
Engines: 2.0 JTD 8V
1. Disconnect the band from the turbocharger.2. Undo the bolts securing the pipe to the mount.3. Remove the rigid air delivery section from turbocharger to engine.
Engines: 2.0 JTD 8V
1. Disconnect the electrical connection for the rpm sensor.
Description
Connector
1
Rpm sensor
K046
Engines: 2.0 JTD 8V
1. Undo fastenings (1a) and remove the gearbox and differential (1b).
- Fit the gearbox-differential unit and tighten the nuts and bolts to torque.
Value - daNm
Fastening
Component
Ø
.
7
Bolt
MANUAL GEARBOX/DIFFERENTIAL
M12
Value - daNm
Fastening
Component
Ø
.
6
Nut
MANUAL GEARBOX/DIFFERENTIAL
M10
- Connect the electrical connection for the rpm sensor.
Description
Connector
.
Rpm sensor
K046
- Fit the rigid air delivery section from turbocharger to engine.- Tighten the bolts securing the pipe to the mount and connect the band to the turbocharger.- Fit the air inlet pipe to the turbocharger and secure to the turbo using a band.- Connect the oil vapour recovery pipe.- Fit the starter motor and tighten the bolts to torque.
