1004B10 POWER UNIT WITH MANUAL GEARBOX - R + R - Lancia - MUSA - eLearn

184000785 - 1004B10 POWER UNIT WITH MANUAL GEARBOX - R + R

) Position the vehicle on the rampProceed with removal Op. 5530B10 BATTERY - R+R.Proceed with removal Op. 5530B52 BATTERY CRADLE - R R.Proceed with removal 1016A10 sound-proofing cover - r + r . Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE.Proceed with removal Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R.Proceed with removal - 7055B65 Engine compartment DUST PROTECTION in left front wheel arch - R.R. .Proceed with removal Op. 7055B66 ENGINE BAY DUSTGUARD PROTECTION IN RIGHT FRONT WHEEL ARCH R R.Proceed with removal Op. 7055B54 UNDER-ENGINE GUARD - R R.1. Undo the bolts (1a) and disconnect the engine oil inlet and outlet pipes (1b) from the engine oil filter mounting.

Collect the engine oil which comes out in a suitable container.

Loosen the band and disconnect the lower radiator coolant outlet hose from the radiator, radiator side.

Recover the coolant using a suitable container.

1. Loosen the band and disconnect the flexible pipe from the engine coolant reservoir rigid coolant return pipe.2. Loosen the band and disconnect the engine coolant supply pipe, water pump rigid inlet pipe side.

1. Loosen the bands and disconnect the coolant supply and return pipes to the climate control system heater, thermostat side.2. Loosen band and disconnect the upper coolant inlet hose to the radiator, thermostat side.

1. Loosen the band and disconnect the vacuum pipe from the vacuum pump.2. Disconnect the vacuum reservoir vacuum intake pipe, T-connector side.

1. Loosen the band and disconnect the air supply duct from heat exchanger to inlet manifold, heat exchanger side.

1. Loosen the band and disconnect the air supply hose from the heat exchanger to the inlet manifold, electro-pneumatically controlled throttle body side.2. Remove the rigid pipe and the air supply hoses from the heat exchanger to the intake manifold.

1. Remove the clip (1a) and disconnect the flexible pipe (1b) from the clutch hydraulic actuator.

Collect the clutch fluid that comes out.

1. Disconnect the gear selector and engagement cables2. Release the clips and release the gear selector and engagement cables from the mounting bracket.

1. Disconnect the electrical connection from the pre-heating control unit.

	Name	Connector
1	Plug preheating control unit	M15

2. Connect the electrical connections to the diesel electronic injection control unit.

	Name	Connector
2	Engine management control unit	M10

1. Disconnect the engine coupling.

	Name	Connector
1	Front/engine connection	D4

1. Disconnect the electrical connection for the Lambda sensor.

	Name	Connector
1	Lambda sensor on catalyzer	K17

1. Disconnect the rapid connector for the pipe from the fuel filter to the fuel return manifold pipe, fuel return manifold pipe side.2. Disconnect the rapid attachment of the supply pipe from the fuel filter to the pressure pump, pressure pump side.3. Release the fuel pipes from the fastenings and move them aside.

1. Undo the bolt (1a) and disconnect the pipe from the expansion valve to the compressor (1b), compressor side.2. Undo the bolt (2a) and disconnect the pipe from the compressor to the condenser (2b), compressor side.

Seal the disconnected connectors, using suitable plugs, to prevent humidity and impurities from entering the system.

1. Undo the nut (1a) and disconnect the pipe from the expansion valve to the compressor (1b), expansion valve side.

Seal the disconnected connectors, using suitable plugs, to prevent humidity and impurities from entering the system.

Remove the pipe from the expansion valve to the compressor after having released it from the intermediate fastenings.

1. Undo the bolt (1a) and disconnect the earth lead (1b) from the gearbox.

	Name	Connector
1b	Battery earth	C1

1. Disconnect the electrical connection from the reversing lights switch.

	Name	Connector
1	Reversing lights switch	I20

1. Undo the plug and drain the manual gearbox and differential.

Recover the fluid in a suitable container.

Proceed with removal 1076B70 exhaust pipe between pre-catalytic converter and catalytic converter - r r .Proceed with removal 1064A19 TURBOCHARGER - EXHAUST MANIFOLD - EXHAUST PIPE CONNECTING HOSE - R.R. .1. Undo the bolts fixing the intermediate driveshaft to the support.

1. Undo the bolt (1a) and remove the flexible pipe mounting bracket from the right front brake caliper (1b).2. Release the electrical wiring for the right front wheel rpm sensor from the fastening.

1. Remove the staking and undo the nut fixing the right front driveshaft to the steering knuckle.2. Undo the bolts fixing the steering knuckle to the right shock absorber.3. Undo the nut (3a) and disconnect the steering link from the right front steering knuckle using the tool (3b).

	Name	Country
3c	Extractor	1.871.000.700

1. Remove the right driveshaft (1a) complete with intermediate driveshaft (1b).

1. Undo the bolt (1a) and remove the flexible pipe mounting bracket from the right front brake caliper (1b).2. Release the electrical wiring for the right front wheel rpm sensor from the fastening.

1. Undo the bolts fixing the steering knuckle to the left front shock absorber.2. Undo the nut (2a) and disconnect the left steering rod (2b) from the front steering knuckle using the tool (2c).

	Name	Country
2c	Extractor	1.871.000.700

1. Release the differential internal driveshaft (1a) from the differential, then move it sideways together with the left driveshaft (1b).

1. Undo the bolt fixing the power unit lower reaction rod to the front suspension crossmember.

Position a suitable support under the power unit.1. Position a suitable bracket for supporting the power unit as illustrated in the diagram.2. Support the power unit using a hydraulic crane (2a) and tool (2b) connected using special chains to the bracket fitted previously and to the mounting points on the power unit.

	Name	Country
2b	Compensator	1.871.001.700

1. Undo the bolt (1a) and the nut (1b) and remove the engine coolant supply reservoir (1c) complete with pipes.

1. Undo the nuts (1a) and remove the reinforcement bracket (1b).

1. Undo the nuts (1a) and remove the timing side rigid power unit support (1b).2. Recover the bracket.

1. Undo the nut fixing the power unit gearbox side rigid support to the flexible mounting.

Slowly lower the power unit with the hydraulic hoist until it is resting on the support positioned previously.

Refitting ( Removing

) Using a hydraulic hoist fitted with a suitaboe tool, place the power unit back in the engine compartment.

	Name	Country
-	Compensator	1.871.001.700

1. Undo the nut fixing the gearbox side rigid power unit support to the flexbile mounting to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Nut	POWER UNIT GEAR BOX END RIGID MOUNT	M12	(Flexible mounting side) 8.1 ÷ 9.9

1. Place the bracket back in its housing.2. Place the timing side rigid power unit support (2a) back in its housing and secure it tightening the nuts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Nut	ENGINE MOUNT TIMING SIDE	M10	(Bodyshell side) 4.1 ÷ 5.0

	Fastening	Component	Ø	Value(daNm)
2b	Nut	ENGINE MOUNT TIMING SIDE	M10	(Engine side) 4.5 ÷ 5.5

1. Place the reinforcement bracket (1a) back in its housing and tighten the nuts (1b) and (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	ENGINE MOUNT TIMING SIDE	M10	(Engine side) 4.5 ÷ 5.5

	Fastening	Component	Ø	Value(daNm)
1c	Nut	ENGINE MOUNT TIMING SIDE	M10	(Chamber side) 4.5 ÷ 5.5

Refit the coolant reservoir in its seating complete with pipes and secure with the nut and bolt.Remove the safety tools used for supporting the power unit.

	Name	Country
-	Compensator	1.871.001.700

Remove the support positioned under the power unit.1. Tighten the bolt fixing the power unit lower reaction rod to the front suspension crossmember to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	LOWER ROD ON ENGINE	M12	(Front suspension crossmember side) 11.4 ÷ 12.6

Place the differential internal driveshaft together with the left driveshaft back in its housing and connect it to the differential.Secure the electrical wiring for the right front wheel rpm sensor to the fastening.Place the bracket securing the flexible pipe to the right front brake caliper back in its housing and secure it using the nut.1. Connect the right steering rod (1a) to the front steering knuckle and tighten the nut (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	ADJUSTABLE STEERING LINKS	M10	(Steering knuckle side) 3.6 ÷ 4.4

2. Tighten the bolts fixing the steering knuckle to the left shock absorber to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	FRONT HUB STEERING KNUCKLE.	M10	(Shock absorber side) 7.1 ÷ 7.9

Place the right driveshaft, complete with intermediate driveshaft back in its housing.1. Connect the right steering rod (1a) to the front steering knuckle and tighten the nut (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	ADJUSTABLE STEERING LINKS	M10	(Steering knuckle side) 3.6 ÷ 4.4

2. Tighten the bolts fixing the steering knuckle to the right shock absorber to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Connector	FUEL MANIFOLD LINE TO INJECTORS	M12 x 1.5	(Injector side) 2

3. Tighten a new nut (3a) fixing the front wheel hub to the driveshaft to the recommended torque using the angle tightening tool (3b).

	Fastening	Component	Ø	Value(daNm)
3a	Nut	FRONT HUB WITH BEARINGS	M24	(Driveshaft side) 6.7 ÷ 7.4 + 50? ÷ 64 ?

	Name	Country
3b	Protractor	1.860.942.000

1. Stake the collar of the nut twice as shown in the figure.

Secure the right front wheel rpm sensor electrical wiring to the fastening.Place the bracket securing the flexible pipe to the right front brake caliper back in its housing and secure it using the nut.1. Tighten the bolt fixing the intermediate driveshaft to the support to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	-	-	-	-

Proceed with refitting 1064A19 TURBOCHARGER - EXHAUST MANIFOLD - EXHAUST PIPE CONNECTING HOSE - R.R. Proceed with refitting1. Tighten the manual gearbox and differential fluid drain plug to the recommended torque. 1076B70 exhaust pipe between pre-catalytic converter and catalytic converter - r r

	Fastening	Component	Ø	Value(daNm)
1	Drain plug	GEAR CASING PADS	M22	(Differential side) 4.6

Connect the electrical connection to the reversing lights switch.Connect the battery earth lead to the gearbox and fix it using the bolt.Refit the pipe from expansion valve to compressor and secure it.1. Connect the pipe from the expansion valve to the compressor (1a), expansion valve side and fix it tightening the nut (1b) to the recommended torque.

Replace the O-rings for the connectors using green coloured seals only, resistant to R134a refrigerant fluid.

Lubricate the thread of the connectors using anti-freeze.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	EXPANSION VALVE - COMPRESSOR PIPE	M6	(Expansion valve side) 0.7 ÷ 1.1

1. Connect the pipe from the evaporator pipe connector to the compressor (1a), compressor side and fix it tightening the bolt (1b) to the recommended torque.

Replace the O-rings for the connectors using green coloured seals only, resistant to R134a refrigerant fluid.

Lubricate the thread of the connectors using anti-freeze.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	EXPANSION VALVE - COMPRESSOR PIPE	M6	(Compressor side) 0.7 ÷ 1.1

2. Connect the pipe from the compressor to the condenser (2a), compressor side and secure it tightening the bolt (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	PIPES FROM COMPRESSOR TO CONDENSOR	M6	(Compressor side) 0.7 ÷ 1.1

Place the fuel pipes back in their housings and secure them.Connect the rapid attachment of the supply pipe from fuel filter to pressure pump, pressure pump side.Connect the rapid connector for the pipe from the fuel filter to the fuel return manifold pipe, fuel return manifold pipe side.Connect the electrical connection for the Lambda sensor.Connect the engine junction.Connect the electrical connection to the diesel electronic injection control unit.Connect the electrical connection to the pre-heating control unit.Connect the gear selector and engagement cables and secure them to the mounting bracket using the clips.Connect the flexible pipe to the clutch hydraulic actuator and secure it using the clip.Place the rigid pipe and the air supply hoses from the heat exchanger to the intake manifold back in their housings, connect them and tighten the bands.Connect the vacuum reservoir vacuum pipe, T-connector side.Connect the vacuum intake pipe to the vacuum unit.Connect the upper coolant inlet hose to the radiator, thermostat side, and tighten the band.Connect the coolant supply and return pipes to the climate control heater, thermostat side and tighten the bands.Connect the engine coolant supply pipe, water pump rigid inlet pipe side, to the water pump and tighten the band.Connect the flexible pipe to the engine coolant reservoir rigid coolant return pipe and tighten the bands.Connect the engine oil inlet and outlet pipes to the engine oil filter mounting and secure them using the bolts.Proceed with refitting Op. 5530B52 BATTERY CRADLE - R R.Proceed with refitting Op. 5530B10 BATTERY - R+R. Op. 0010T11 ENGINE OIL CHECK LEVEL AND TOP UP. Op. 0010T20 COOLANT CHANGE. Op. 0010T64 BRAKE AND OR CLUTCH FLUID CHECK LEVEL AND TOP UP AS NECESSARY. 0010T67 hydraulic clutch system bleed air . Op. 0010T41 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY. Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE.Proceed with refitting Op. 7055B54 UNDER-ENGINE GUARD - R R.Proceed with refitting Op. 7055B66 ENGINE BAY DUSTGUARD PROTECTION IN RIGHT FRONT WHEEL ARCH R R.Proceed with refitting - 7055B65 Engine compartment DUST PROTECTION in left front wheel arch - R.R. .Proceed with refitting Op. 4450B12 FRONT OR REAR WHEELS (TWO) - R+R.Proceed with refitting 1016A10 sound-proofing cover - r + r .Remove the car from the ramps.