CLUTCH - R + R

Operation 1810A20 · CLUTCH MECHANISM

1.4 16v

Removing

Op. 5530B10 BATTERY - R+R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R + R

Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.

Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.

Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.

Op. 4450B12 FRONT WHEELS (TWO) - R+R

Op. 7055B65 ENGINE COMPARTMENT DUST COVER IN LEFT FRONT WHEEL ARCH - R.R.

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

1. Fit the flywheel lock.

2. Fit a suitable clutch centering tool.

3. Undo the bolts (3a) diagonally and remove the clutch mechanism complete with plate (3b).

Refitting

- Place the clutch mechanism in position complete with plate using a suitable centering tool and tighten the bolts diagonally to the recommended torque.

Op. 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 7055B65 ENGINE COMPARTMENT DUST COVER IN LEFT FRONT WHEEL ARCH - R.R.

Op. 4450B12 FRONT WHEELS (TWO) - R+R

Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.

Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.

Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.

Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R + R

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5530B10 BATTERY - R+R

1.9 JTD 8v, 1.9 JTD 16v

Removing

Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

Op. 4450B12 FRONT WHEELS (TWO) - R+R

Op. 7055B65 ENGINE COMPARTMENT DUST COVER IN LEFT FRONT WHEEL ARCH - R.R.

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 0010T40 CHANGE MANUAL GEARBOX OIL

Op. 5530B10 BATTERY - R+R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 1016A10 SOUND-PROOFING COVER - R.R

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 1048B27 RIGID PIPE FOR AIR INLET TO THROTTLE BODY - R R

Op. 1076B20 REAR EXHAUST SILENCER - R + R

- For versions without DPF only:

Op. 1080B62 CATALYTIC CONVERTER - R + R

- For versions with DPF only:

Op. 1080B81 PARTICULATE FILTER (D.P.F.) - R.R.

Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R

Op. 1048A41 HOSE FROM FLOW METER TO TURBOCHARGER - R.R.

Op. 3310A60 FRONT BRAKE PADS - REPLACE

Op. 1008C30 POWER UNIT LOWER REACTION LINK - R.R.

Op. 1008C33 BRACKET ON ENGINE FOR LOWER REACTION ROD - R.R.

Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R

Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.

Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.

Op. 5520B10 STARTER MOTOR - R+R

Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE

Op. 1008A42 POWER UNIT RIGID SUPPORT - GEARBOX SIDE - R.R.

Op. 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED

Refitting

Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED

Op. 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

Op. 1008A42 POWER UNIT RIGID SUPPORT - GEARBOX SIDE - R.R.

Op. 1008B30 GEARBOX SIDE SUPPORT FLEXIBLE MOUNTING(S) - REPLACE

Op. 5520B10 STARTER MOTOR - R+R

Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.

Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.

Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R

Op. 1008C33 BRACKET ON ENGINE FOR LOWER REACTION ROD - R.R.

Op. 1008C30 POWER UNIT LOWER REACTION LINK - R.R.

Op. 3310A60 FRONT BRAKE PADS - REPLACE

Op. 1048A41 HOSE FROM FLOW METER TO TURBOCHARGER - R.R.

Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R

- For versions without DPF only:

Op. 1080B62 CATALYTIC CONVERTER - R + R

- For versions with DPF only:

Op. 1080B81 PARTICULATE FILTER (D.P.F.) - R.R.

Op. 1076B20 REAR EXHAUST SILENCER - R + R

Op. 1048B27 RIGID PIPE FOR AIR INLET TO THROTTLE BODY - R R

Op. 1048A10 AIR FILTER ASSEMBLY - R.R.

Op. 1016A10 SOUND-PROOFING COVER - R.R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5530B10 BATTERY - R+R

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 7055B65 ENGINE COMPARTMENT DUST COVER IN LEFT FRONT WHEEL ARCH - R.R.

Op. 4450B12 FRONT WHEELS (TWO) - R+R

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - 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

1.4 16v TJet

Removing

- Position the vehicle on a lift.

Op. 4450B12 FRONT WHEELS (TWO) - R+R

Op. 7055B65 ENGINE COMPARTMENT DUST COVER IN LEFT FRONT WHEEL ARCH - R.R.

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.

Op. 0010T40 CHANGE MANUAL GEARBOX OIL

Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R

Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.

Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.

Op. 5520B10 STARTER MOTOR - R+R

Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R

Op. 1016A10 SOUND-PROOFING COVER - R.R

Op. 5530B10 BATTERY - R+R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

1. Fit the flywheel lock.

- Unscrew the three bolts spaced at 120 degrees securing the clutch mechanism.

2. Fit tool (2a) and tool (2b) tightening the pins in the seats for the bolts removed previously.

- Turn the tool handwheel until the pins are in contact with the disc.

3. Undo the remaining bolts securing the clutch mechanism.

- Undo the tool handwheel to discharge the clutch mechanism diaphragm spring.

- Remove the tools fitted previously.

4. Remove the clutch mechanism.

- Remove the clutch plate.

Refitting

1. Fit the tool on the crankshaft.

- Refit the clutch plate in position.

2. Refit the clutch mechanism in position.

Clean any anti-corrosion protection or detergents from the friction surface of the clutch mechanism.

3. Fit the tool using the pins.

- Turn the tool handwheel until the pins are in contact with the disc.

4. Tighten the remaining free clutch fixing bolts by hand.

- Undo the tool handwheel to discharge the clutch mechanism diaphragm spring.

- Remove the tools fitted previously.

- Tighten the remaining clutch retaining bolts by hand.

- Gradually tighten the bolts securing the clutch diagonally until the recommended torque is reached.

5. Remove the flywheel lock.

Op. 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5530B10 BATTERY - R+R

Op. 1016A10 SOUND-PROOFING COVER - R.R

Op. 5520B10 STARTER MOTOR - R+R

Op. 2710A14 RIGHT DRIVESHAFT WITH JOINTS AND INTERMEDIATE DRIVESHAFT - R+R

Op. 1008C34 BRACKET ON GEARBOX FOR LOWER REACTION ROD - R.R.

Op. 1008C32 GEARBOX LOWER REACTION ROD -R.R.

Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R

Op. 4410D17 REINFORCEMENT FOR FRONT SUSPENSION CROSSMEMBER - R.R.

Op. 0010T40 CHANGE MANUAL GEARBOX OIL

- Check the brake-clutch fluid level and, if necessary, bleed the system, with reference to

Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 7055B65 ENGINE COMPARTMENT DUST COVER IN LEFT FRONT WHEEL ARCH - R.R.

Op. 4450B12 FRONT WHEELS (TWO) - R+R

- Remove the vehicle from the lift.