3315347 - 1004D40 engine - position on stand and remove (Automatic transmission)

Secure and support the engine using a hydraulic hoist fitted with suitable chains.1. Adjust the engine components single drive belt moving tensioner (1a) using the spanner (1b), then insert the tool (1c) in the opening in the tensioner.

	Name	Country
1b	Key	1.860.966.000

	Name	Country
1c	Clip	1.870.645.000

2. Remove the protective plug for the auxiliary shaft drive belt cam tensioner.3. Loosen the bolt fixing the cam tensioner.4. Remove the auxiliary shaft drive belt. 1. Undo the fixing nut (1a) and disconnect the electrical connection from the alternator (1b).

	Name	Connector
1b	Alternator	A10

1. Undo the bolts (1a) and remove the alternator (1b). 1. Undo the fixing bolts (1a) and remove the alternator upper mounting bracket (1b). 1. Undo the bolts (1a) and remove the rear engine support (1b). 1. Disconnect the electrical connection for the engine oil level sensor.

	Name	Connector
1	Engine oil level sensor	K32

2. Fit the rear bracket for positioning the engine on the overhaul stand.

	Name	Country
2	Brackets	1.861.001.039

1. Disconnect the electrical connection from the air conditioning compressor.

	Name	Connector
1	Air conditioning compressor engagement electro-magnet	L20

2. Undo the bolts (2a) and remove the air conditioning compressor and front engine support assembly (2b). 1. Fit the front bracket for positioning the engine on the overhaul stand.

	Name	Country
1	Brackets	1.861.001.039

1. Undo the fixing nuts (1a) and remove the exhaust manifold heat shield (1b). 1. Open the band (1a) and disconnect the oil return pipe from the turbocharger (1b).2. Undo the connector (2a) and disconnect the turbocharger oil supply pipe (2b) from the crankcase. 1. Undo the bolts (1a) fixing the rigid EGR pipe (1b) to the exhaust manifold and remove the gasket (1c).2. Undo the nuts (2a) fixing the exhaust manifold (2b) to the cylinder head. 1. Undo the bolt fixing the turbine mounting bracket to the crankcase.2. Remove the exhaust manifold and turbocharger assembly (2a) and metal gasket (2b). 1. Undo the fixing bolt (1a) and remove the power assisted steering pump protective shield (1b).2. Using a hydraulic lift, position the enigne (2a) on the rotating overhaul stand (2b).

	Name	Country
2b	Rotating stand	1.861.000.000

The following stand can be used as an alternative to the overhaul stand mentioned above:

	Name	Country
-	Rotating overhaul stand	1.871.001.000

Fasten the mounting brackets to the overhaul stand.Release the engine from the hydraulic lift fastenings. To remove the engine from the rotating overhaul stand, proceed as follows.Secure and support the engine using a hydraulic hoist fitted with suitable chains.Undo the fixings and remove the engine complete with mounting brackets.Remove the brackets for positioning the engine on the overhaul stand.

	Name	Country
-	Brackets	1.861.001.039

1. Place the new metal gasket (1a) in position and then fit the exhaust manifold and turbine assembly (1b) in place.2. Tighten the bolt fixing the turbine mounting bracket to the crankcase. 1. Tighten the nuts (1a) fixing the exhaust manifold (1b) to the cylinder head to torque.

	Fastening	Component	Ø	Value(daNm)
1a	Nut	EXHAUST MANIFOLD/S	M8	2.5

2. Place the new gasket (2a) in position and tighten the bolts (2b) fixing the rigid EGR pipe (2c) to the exhaust manifold/turbine to torque. 1. Connect the turbocharger oil return pipe (1a) and secure it using the band (1b).2. Connect the oil supply pipe to the turbocharger (2a) on the crankcase and tighten the connector (2b) to the recommended torque. 1. Place the exhaust manifold heat shield (1a) in position and tighten the fixing nuts (1b) to torque. 1. Place the air conditioning compressor and front engine support assembly (1a) in position and tighten the fixing bolts (1b) to the recommended torque.2. Connect the electrical connection to the air conditioner compressor.

	Name	Connector
2	Air conditioning compressor engagement electro-magnet	L20

1. Connect the electrical connection for the engine oil level sensor.

	Name	Connector
1	Engine oil level sensor	K32

2. Fit the protective shield (2a) for the power assisted steering pump in position and tighten the fixing bolt (2b). 1. Fit the rear engine support (1a) in place and tighten the fixing bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT RIGID REAR MOUNT	M10 x 1.25	5

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT RIGID REAR MOUNT	M8	2.5

1. Fit the upper alternator mounting bracket (1a) and tighten the fixing bolts (1b) to the recommended torque. 1. Fit the alternator (1a) in place and tighten the fixing bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	ALTERNATOR ASSEMBLY	M10 x 1.25	5

	Fastening	Component	Ø	Value(daNm)
1b	Nut	ALTERNATOR ASSEMBLY	M12 x 1.25	7

1. Connect the electrical connection to the alternator.

	Name	Connector
1	Alternator	A10

Fit the single engine component belt by adjusting the moving tensioner using a wrench.Release the engine from the hydraulic lift fastenings.