125000868 - 1004D40 ENGINE - POSITION ON STAND AND REMOVE

1. Secure and support the engine (1a) using a hydraulic hoist (1b) fitted with suitable chains (1c). 1. Adjust the moving tensioner to loosen the engine components single drive belt tension.2. Remove the engine components single drive belt. 1. Undo the bolts (1a) and remove the air conditioning compressor (1b).2. Undo the bolts (2a) and remove the air conditioner compressor mounting (2b). 1. Undo the nuts (1a) and remove catalytic converter (1b) complete with gasket (1c).2. Release and rmove the engine oil dipstick.3. Undo the nut (3a) and remove the engine oil dipstick pipe (3b). 1. Remove the air conditioner compressor mounting bracket locating bush.2. Fit the left bracket for supporting the engine on the service stand.

	Name	Country
2	Brackets	1.861.001.141

1. Undo the bolts (1a) and remove the alternator (1b).2. Undo bolts (2a) and remove the rear alternator support bracket (2b).3. Undo the bolt (3a) and remove the alternator protection (3b). 1. Undo the bolts (1a) and remove the power steering pump pulley (1b). 1. Release the coolant return pipe to the coolant reservoir from the attachments from its fastenings.2. Undo the upper bolt securing the power steering fluid reservoir. 1. Undo the remaining bolt securing the power assisted steering fluid reservoir.2. Loosen the band and disconnect the supply pipe from the fluid reservoir to the power assisted steering pump, power assisted steering pump side.3. Remove the power assisted steering fluid reservoir (3a), complete with pipe (3b). 1. Undo the bolts (1a) and remove the power assisted steering pump (1b). 1. Remove the cap (1a), undo the bolt (1b) and remove the single belt fixed tensioner (1c).2. Undo the bolts (2a) and remove the upper protective timing cover (2b). 1. Undo the bolts (1a) and remove the bracket (1b) after releasing it from the electrical wiring. 1. Undo the bolts (1a) and remove the modular intake manifold mounting bracket (1b) after having released it from the electrical wiring. 1. Undo the bolt securing the intermediate drive shaft mounting to the crankcase oil sump. 1. Undo the bolts (1a) and remove the support on the engine for the engine component reaction rod and intermediate driveshaft (1b) complete with single auxiliary drivebelt mobile tensioner (1c). 1. Remove the locating bushes.2. Fit the right brackets for supporting the engine on the service stand.

	Name	Country
2	Brackets	1.861.001.141

1. Position the engine (1a) on the overhaul stand (1b) using the special brackets, then release it from the hydraulic lift. Secure and support the engine using a hydraulic hoist fitted with suitable chains.Undo the fastenings and remove the engine complete with mounting brackets from the service stand.Undo the fixings and remove the mounting brackets from the engine and put them down.

	Name	Country
-	Brackets	1.861.001.141

Refit the locating bushes in their seats.1. Place the mounting on the engine for the reaction rod and various engine components (1a), complete with the moving tensioner for the single drive belt (1b) back in its housing and secure it by tightening the bolts (1c) and (1d) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	ENGINE LINK AND VARIOUS COMPT.MOUNTS	M10	(Engine crankcase side) 4.5 - 5.5

	Fastening	Component	Ø	Value(daNm)
1d	Bolt	ENGINE LINK AND VARIOUS COMPT.MOUNTS	M8	(Engine crankcase side) 2.3 - 2.8

2. Tighten the bolt securing the intermediate drive shaft mounting to the oil sump.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	ENGINE LINK AND VARIOUS COMPT.MOUNTS	M8	(Crankcase sump side) 2.3 ÷ 2.8

Place the modular intake manifold mountingPlace the bracket back in its housing and secure it using the bolts.1. Fit the upper protective timing gear cover (1a) and secure using the bolts (1b).2. Place the engine components single drive belt fixed tensioner (2a) back in its housing and secure by tightening bolt (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	FIXED SINGLE SERVICE BELT TENSIONER	M8	2.2 ÷ 2.8

3. Place the engine components single drive belt fixed tensioner plug back in its seating. 1. Refit the power steering pump (1a) in its seating and tighten its bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER STEERING PUMP	M8	(Support side) 2.3 ÷ 2.8

Refit the power steering reservoir, complete with pipe, back in its housing and secure using the bolts.Connect the pipe from the fluid reservoir to the power assisted steering pump, pump side and tighten the band.Secure the coolant return pipe to the engine coolant reservoir to the fastenings.1. Place the power assisted steering pump pulley (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER STEERING PUMP DRIVE PULLEY	M8	(Power assisted steering pump side) 2.3 ÷ 2.8

1. Place the alternator protection (1a) back in its housing and secure it with bolt (1b).2. Place the rear alternator mounting bracket (2a) back in its housing and secure with the bolts (2b).3. Place the alternator (3a) back in its housing and secure by tightening the bolts (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	ALTERNATOR ASSEMBLY	M10	(Support side) 4.4 ÷ 5.5

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	ALTERNATOR ASSEMBLY	M12	(Support side) 6.3 ÷ 7.7

Refit the air conditioner compressor mounting bracket locating bush.Place the complete engine oil dipstick tube back in its housing and fix it using the bolt.Place the engine oil dipstick back in its seating.Refit the catalytic converter, complete with gasket, back in its housing and secure by tightening the nuts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	-	-	-

1. Place the air conditioning compressor mounting (1a) back in its housing and secure by tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	COMPRESSOR MOUNT (AC)	M10	(Crankcase side) 4.5 ÷ 5.5

2. Refit the air conditioning compressor mounting (2a) back and secure by tightening the bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	AIR CONDITIONER ASSEMBLY COMPRESSOR	M8	(Support side) 2.3 ÷ 2.8

Adjust the moving tensioner and fit the engine components single drive belt.Release the engine from the hydraulic lift.