- Position the vehicle on a lift. See in Op. 1048A21 See in Op. 1048A101. Undo the fixing nuts (1a) and remove the hydraulic clutch actuator cylinder (1b) fom the housing on the gearbox.
Engines: 2.0 16V
1. Undo the fixing bolt (1a) and disconnect the earth lead on the gearbox (1b).
Engines: 2.0 16V
1. Disconnect the electrical connection for the reversing light switch.
1. Release the two ends (1a), move the two gear selector and engagement flexible cables (1b) out of the slot in the bracket (1c) and place them outside of the work area.
Engines: 2.0 16V
1. Undo the nut (1a), remove the protective cover (1b) and disconnect the starter motor supply leads (1c).2. Undo the retaining bolts (2a) and remove starter motor (2b).
Engines: 2.0 16V
1. Undo the fixing bolts (1a) and remove the engine flywheel guard (1b).
Engines: 2.0 16V
1. Unscrew the bolts and the nut (1a) for the mounting bracket for the gear selection and engagement cables (1b).
Engines: 2.0 16V
- Position a suitable container for collecting the gearbox fluid.1. Undo the plug, using a suitable spanner, and drain the transmission fluid.
Description
Code
Function
.
Spanner
1.850.182.000
Wrench for slackening/tightening differential fluid plug
- Collect the transmission fluid.
Engines: 2.0 16V
1. Disconnect the electrical connection for the left front brake pad wear sensor cable.2. Undo the bolts fixing the brake caliper to the bracket and move it aside without disconnecting the oil pipe.
Engines: 2.0 16V
1. Undo the nut fixing the track rod end to the steering knuckle.2. Extract the track rod end (2b) from the housing in the steering knuckle using the tool (2a).3. Undo the centering pins (3a) and remove the brake disc (3b).
Description
Code
Function
2a
Head extractor
1.847.038.000
Ball joint removal
Engines: 2.0 16V
1. Undo the bolts fixing the steering knuckle to the shock absorber.2. Undo the retaining bolt.3. Remove the left ABS sensor from the housing and place it outside the work area.
Engines: 2.0 16V
1. Undo the bolts fixing the stub axle to the steering knuckle.
Engines: 2.0 16V
1. Undo the fixing bolt (1a) and remove the casing (1b).
Engines: 2.0 16V
1. Release the inner driveshaft (1a) from the housing on the differential, then remove the driveshaft - steering knuckle assembly (1b).
Engines: 2.0 16V
1. Undo the nut fixing the track rod end to the steering knuckle.2. Extract the track rod end (2b) from the housing in the steering knuckle using the tool (2a).
Description
Code
Function
2a
Head extractor
1.847.038.000
Ball joint removal
Engines: 2.0 16V
1. Undo the bolts fixing the brake caliper to the bracket and move it aside without disconnecting the oil pipe.
Engines: 2.0 16V
1. Undo the bolts fixing the steering knuckle to the shock absorber.2. Undo the retaining bolt.3. Remove the right ABS sensor from the housing and place it outside the work area.
Engines: 2.0 16V
1. Undo the bolts fixing the stub axle to the steering knuckle.
Engines: 2.0 16V
1. Undo the fastening pins (1a) and remove the brake disc (1b).2. Undo the fixing bolt (2a) and remove the guard (2b).
Engines: 2.0 16V
1. Undo the nuts fixing the intermediate driveshaft to the support.2. Remove the intermedate driveshaft - right driveshaft assembly complete with steering knuckle.
Engines: 2.0 16V
1. Place the tool for supporting the power unit, fastened to the suspension crossmember and to the lower crossmember, under the engine oil sump in a central position.2. In order to be able to position the crossmember correctly and safely, the corners of the actual crossmember at the two ends have to be smoothed making sure that they match correctly with the front crossmember and the suspension crossmember.
Description
Code
Function
1
Crossmember
1.870.735.000
Lower engine mounting beam
Engines: 2.0 16V
1. Undo the retaining nuts.2. Remove the operating cylinder mounting bracket on the bellhousing.
Engines: 2.0 16V
1. Release the shaft for the fork lever (1a) using the special tool and release the fork (1b).
Description
Code
Function
.
Extractor
1.870.873.000
Fork pin removal
2. Disconnect the electrical connection for the engine rpm sensor.
Engines: 2.0 16V
1. Remove the cover (1a), undo the nut (1b) and remove the selector unit idler connecting rod (1c).
Engines: 2.0 16V
1. Undo the bolts fixing the gearbox side flexible mounting to the rigid support.2. Undo the bolts and the nut fixing the rigid support to the gearbox.- Gently lower the engine until the stud on the rigid support comes out of the housing in the flexible mounting.3. Remove the gearbox side rigid power unit support.
Engines: 2.0 16V
1. Take a hydraulic lift fitted with a plate and adjustment screws (1a) and fit the two brackets (1b) for securing the gearbox and differential unit on it.
Description
Code
Function
1b
Brackets
1.870.847.000
Removing - refitting gearbox
Description
Code
Function
1a
Adjustable support
1.870.856.000
Removing - refitting gearbox
Engines: 2.0 16V
1. Raise the hydraulic lift, tilt the base and position the bracket in contact with the gearbox-differential unit.
Description
Code
Function
1
Brackets
1.870.847.000
Removing - refitting gearbox
2. Fasten the second bracket to the gearbox unit at the back.
Description
Code
Function
2
Brackets
1.870.847.000
Removing - refitting gearbox
Engines: 2.0 16V
See in Op. 1008C321. Undo the fixing bolts.2. Remove the gearbox-differential unit.
1. Undo the bolts (1a) and remove the pressure plate and the clutch disc (1b).
Engines: 2.0 16V
1. Remove the thrust bearing (1b) from the clutch using the tool (1a).
Description
Code
Function
1a
Extractor
1.870.840.000
Thrust bearing removal
Engines: 2.0 16V
1. Fit the driven disc and the pressure plate and align them using the clutch centering tool.
Description
Code
Function
1
Clutch locating tool
1.875.029.000
Driven plate locating
Engines: 2.0 16V
- Tighten the bolts fixing the clutch to the flywheel to torque.
Value - daNm
Fastening
Component
Ø
.
3.2
Bolt
CLUTCH ASSEMBLY
M8
1. Position the thrust bearing (1a) on the main gearbox shaft hose and fit it on the clutch release lever (1b), then fit the release lever fixing shaft (1c).
Engines: 2.0 16V
- Fit the gearbox-differential unit and tighten the fixing nuts and bolts to torque.- Fit the gearbox side rigid engine support.- Tighten the bolts fixing the gearbox side flexible mounting to the rigid support.
Value - daNm
Fastening
Component
Ø
.
(Rigid mount) 5
Bolt
GEARBOX SIDE RUBBER MOUNT
M10
- Tighten the bolts and the nut fixing the rigid support to the gearbox to torque.
Value - daNm
Fastening
Component
Ø
.
(Gearbox) 9
Nut
GEARBOX SIDE RUBBER MOUNT
M14
Value - daNm
Fastening
Component
Ø
.
(Gearbox) 9
Bolt
GEARBOX SIDE RUBBER MOUNT
M14
- Remove the tool complete with brackets positioned previously for supporting the gearbox.
Description
Code
Function
.
Adjustable support
1.870.856.000
Removing - refitting gearbox
Description
Code
Function
.
Brackets
1.870.847.000
Removing - refitting gearbox
- Fit the idler connecting rod on the gear selector and enagement assembly, tighten the nut and fit the plug.- Fit the operating cylinder mounting bracket on the bellhousing.- Fit the mounting bracket for the gear selector and engagement cables and tighten the fixing bolts and nut.- Connect the electrical connection for the engine rpm sensor.- Connect the electrical connection for the speedometer sensor.- Tighten the fixing bolt and connect the earth lead on the bellhousing.- Connect the electrical connection for the reversing light switch.- Remove the tool for supporting the power unit, fastened to the suspension crossmember and to the lower crossmember, from under the engine oil sump.
Description
Code
Function
.
Engine mounting beam
1.870.735.000
Support power unit
- Fit the starter motor and tighten the retaining bolts to torque.- Connect the starter motor electrical wiring- Place the flywheel guard in position and tighten the fixing bolts.- Connect both ends of the gear selection and engagement cables and secure them to the mounting bracket.- Fit the intermediate driveshaft - right driveshaft assembly complete with steering knuckle and brake disc.- Tighten the nuts fixing the intermediate driveshaft to the support to torque.- Tighten the bolts fixing the stub axle to the steering knuckle to torque.- Fit the right ABS sensor in its housing and tighten the retaining bolt.- Tighten the bolts fixing the steering knuckle to the shock absorber to torque.- Fit the brake caliper - bracket assembly and tighten the bolts fixing the bracket to the left disc to torque.
Value - daNm
Fastening
Component
Ø
.
21
Bolt
FRONT BRAKE CALIPER BRACKET
M16
- Tighten the nut fixing the ball joint to the steering rod to torque.
Value - daNm
Fastening
Component
Ø
.
6.9
Nut
ADJUSTABLE LINK BALL JOINTS
M16
- Fit the left driveshaft assembly and press fit the inner driveshaft in the housing on the left differential.- Tighten the bolts fixing the stub axle to the left hub to torque.- Fit the right ABS sensor in its housing and tighten the retaining bolt.- Tighten the bolts fixing the steering knuckle to the shock absorber to torque.- Tighten the nut fixing the ball joint to the steering rod to torque.
Value - daNm
Fastening
Component
Ø
.
6.9
Nut
ADJUSTABLE LINK BALL JOINTS
M16
- Fit the brake caliper - bracket assembly and tighten the bolts fixing the bracket to the left disc to torque.
