21A-11
MANUAL GEARBOX
Manual gearbox: Removal - Refitting
K4M, and JR5
21A
REMOVAL
I - REMOVAL PREPARATION OPERATION
a Position the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
a Remove:
- the battery (see Battery: Removal - Refitting)
(80A, Battery),
- the battery tray,
- the earth strap nut on the injection computer
mounting,
- the air resonator (see Air resonator: Removal -
Refitting) (12A, Fuel mixture),
- the injection computer (see Petrol injection com-
puter: Removal - Refitting) (17B, Petrol injection),
- the wiring mounting on the injection computer
mounting.
- the wiring mounting on the gearbox,
a Move the engine harness aside.
a Remove the expansion bottle nuts.
a Move aside the expansion bottle from its support.
a Disconnect the vehicle speed sensor connector.
a Remove:
- the crankshaft position sensor (see Crankshaft
position sensor: Removal - Refitting) ,
- the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres).
Special tooling required
Mot. 1453 Engine anchorage support
with multiple adjustments and
retaining straps.
Equipment required
component jack
Tightening torquesm
stud on the engine 8 N.m
stud on the gearbox 8 N.m
gearbox stud nuts 44 N.m
upper and lower gear-
box bolts
44 N.m
stay bolt on the cylinder
block
21 N.m
stay nut on the exhaust
manifold
21 N.m
power-assisted steering
pipe bolt on the sub-
frame
21 N.m
power-assisted steering
pipe bolt on the gear-
box mounting
21 N.m
power-assisted steering
pipe bolt on the gearbox
21 N.m
earth strap bolts on the
gearbox
21 N.m
expansion bottle nuts 8 N.m
earth strap nut on the
injection computer sup-
port
8 N.m
IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair:
- (see Manual gearbox: Precautions for the
repair) ,
- (see Vehicle: Precautions for the repair) .
IMPORTANT
To prevent the vehicle from falling, lash it to the
vehicle lift using a strap.
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