1020B10 COVER OF TIMING SYSTEM WITH CHAIN DRIVE - R + R REPLACE OIL SEAL AND GASKET - Lancia - MUSA - eLearn

184000829 - 1020B10 COVER OF TIMING SYSTEM WITH CHAIN DRIVE - R + R REPLACE OIL SEAL AND GASKET

) Position the vehicle on a lift.Make sure that the ignition key is in the OFF position, then disconnect the negative battery terminal (-).

	Description	Connector
-	Battery	A1B

Drain the air conditioning refrigerant circuit Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE.1. Disconnect the electrical connection from the air flow meter.

	Description	Connector
1	Air flow meter	K41

2. Loosen the collar and disconnect the air intake sleeve to the turbocharger, air flow meter side.

1. Remove the air filter (1a) complete with air flow meter (1b) releasing it firstly from the pegs underneath and then from the rear fastening.

1. Loosen the collar and disconnect the lower coolant input sleeve from the radiator, radiator side.

Drain the coolant into a suitable container.

1. Remove plug (1a) and replace it with tool (1b) on the exhaust side camshaft.

Fit the tool and position with its millings horizontal. Ensure it fits nto the seat on the camshaft.

	Description	Code
1b	Template	1.871.000.900

2. Fit a suitable (8 mm diameter) peg via the special opening in the gearbox.

Check that the peg is correctly inserted in the housing in the flywheel.

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

Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.

1. Loosen the band and disconnect the coolant return pipe, engine coolant reservoir side.2. Loosen the band and disconnect the supply pipe, engine coolant reservoir side.3. Undo the nut (3a) and the bolt (3b) and remove the engine coolant supply reservoir (3c).

Proceed with the removal Op. 4450B04 RIGHT FRONT WHEEL R R.Proceed with the removal Op. 7055B66 ENGINE COMPARTMENT DUST SHIELD PROTECTION IN RIGHT FRONT WHEEL ARCH - R.R..Proceed with the removal Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R..Proceed with the removal 1092G10 CINGHIA unica comando organi motore - S.R. .Proceed with the removal Op. 1092A10 CRANKSHAFT SERVICES PULLEY - R.R..1. Loosen the lower bolts fixing the alternator to the mounting.

1. Loosen the upper bolt fixing the alternator to the mounting.2. Undo the bolt (2a) and disconnect the connector (2b) for the engine oil vapour recovery pipe from the chain drive timing cover.3. Fit a suitable bracket for supporting the power unit and fasten it using the upper bolt securing the alternator to the mounting.

Tighten the lower bolts fixing the alternator to the mounting.1. Fit the tool (1a) complete with support mountings (1b), then connect them to the bracket fitted previously using the rod (1c).

	Description	Code
1a	Crossmember	1.870.595.000

	Description	Code
1b	Support mountings	1.870.650.000

1. Undo the nut fixing the air conditioning system pipe mounting bracket to the power unit flexible mounting, timing side.2. Undo the nuts (2a) and (2b), then remove the timing side power unit flexible mounting (2c).

1. Undo the bolts fixing the air conditioning pipe mounting brackets to the timing side rigid engine support.

1. Undo the bolts (1a) and remove the timing side rigid engine support (1b) complete with engine lifting bracket (1c).

1. Using the tools (1a) and (1b) for counter-torque, unscrew the left-threaded bolt (1c) fixing the pulley mounting flange to the crankshaft.

	Description	Code
1a	Counter-torque	1.871.000.200

	Description	Code
1b	Support for counter-torque	1.860.831.000

2. Remove the pulley support flange on the crankshaft.

1. Undo the bolt (1a) and remove the engine components single belt moving tensioner (1b).

1. Undo the nuts (1a) and remove the coolant pump (1b) complete with gasket.

Proceed with the removal Op. 7055B54 UNDER-ENGINE GUARD - R R.Proceed with the removal Op. 2110A60 MANUAL GEARBOX/ENGINE COUPLING BRACKET - R+R.Proceed with the removal Op. 1020A20 CRANK CASE OIL SUMP - R + R CLEAN SEALS FOR SEALANT APPLICATION.1. Release electrical wiring (1a) from collars (1b).2. Unscrew the upper bolts securing the cover for the chain-driven timing system3. Keep the brackets.

1. Unscrew bolts (1a) and nuts (1b) securing the cover for the chain-driven timing system.2. Remove the cover from the chain-driven timing system (2a) complete with engine oil suction head (2b) and engine oil pump.3. Remove the chain-driven timing system cover gasket.

1. Working at the bench, unscrew bolts (1a) and separate the engine oil intake (1b) with gasket (1c) from the chain-driven timing system cover.

1. Remove the crankshaft from oil seal from the chain-driven timing system cover.

Take care not to damage the oil seal seat during its removal.

Refitting ( Removing

) 1. Replace a new crankshaft front oil seal (1a) in its seat on the chain-driven timing system cover using tool (1b).

	Description	Code
1b	Fitting tool	1.860.878.000

Refit the engine oil intake chamber with gasket in its seat on the chain-driven timing system cover and secure with bolts.1. Refit a new gasket for the chain-driven timing system cover.2. Fit the tool to the chain-driven timing system cover.

	Description	Code
2	Hose	1.879.900.600

3. Refit the chain-driven timing system cover (3a) with engine oil suction head (3b) and engine oil pump in its seat and then secure provisionally with bolt (3c). 1. Tighten bolts (1a) and nuts (1b) securing the timing cover to the specified torque.

Follow the order shown in the figure for each tightening sequence. The tightening to 0.8 - 1.0 daNm is performed in two stages: a pretightening to 0.4 daNm followed by an additional tightening of 0.8 - 1.0 daNm.

	Fastening	Component	Ø	Value (daNm)
1a	Bolt	FRONT COVER CRANKSHAFT	M6	0.8 - 1.0 daNm

	Fastening	Component	Ø	Value (daNm)
1b	Nut	FRONT COVER CRANKSHAFT	M6	0.8 - 1.0 daNm

- Unscrew the bolt and remove the tool from the chain-driven timing system cover.

	Description	Code
-	Hose	1.879.900.600

Secure the electrical wiring to the collars.Proceed with the refitting Op. 1020A20 CRANK CASE OIL SUMP - R + R CLEAN SEALS FOR SEALANT APPLICATION.Proceed with the refitting Op. 2110A60 MANUAL GEARBOX/ENGINE COUPLING BRACKET - R+R.1. Place the water pump (1a), complete with gasket in position, then tighten the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	COOLANT PUMP	M6	(Engine upper crankcase side) 0.8 - 1.0

1. Position the auxiliary drivebelt moving tensioner (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	SINGLE BELT MOVING TENSIONER VARIOUS	M10	(Engine upper crankcase side) 4.5 - 5.5

1. Refit the pulley mounting flange to crankshaft (1a) and tighten the left-threaded bolt (1b) to the specified torque using tools (1c) and (1d) as countertorque.

	Fastening	Component	Ø	Value(daNm)
1a	Anticlockwise bolt	PULLEY SUPPORT FLANGE ON CRANKSHAFT	M14	(Crankshaft side) 21.9 - 24.2

	Description	Code
1c	Counter-torque	1.871.000.200

	Description	Code
1d	Support for counter-torque	1.860.831.000

1. Place the timing side rigid engine support (1a) in its housing with the engine lift bracket (1b) and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	RIGID ENGINE MOUNT, TIMING SIDE	M10	(Engine upper crankcase side) 5.7 - 6.3

Tighten the bolts fixing the air conditioning pipe mounting brackets to the timing side rigid engine support.1. Place the timing side power unit flexible mounting (1a) back in its housing and secure it tightening the nuts (1b) and (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	FRONT FLEXIBLE MOUNTING BLOCKS, POWER UNIT	M10	(Rigid support side) 4.5 - 5.5

	Fastening	Component	Ø	Value(daNm)
1c	Nut	FRONT FLEXIBLE MOUNTING BLOCKS, POWER UNIT	M10	(Bodyshell side) 4.1 - 5.0

2. Tighten the nut fixing the air conditioning system pipe mounting bracket to the power unit flexible mounting, timing side.

Remove the tools used for supporting the power unit safely.

	Description	Code
-	Crossmember	1.870.595.000

	Description	Code
-	Support mountings	1.870.650.000

Undo the upper bolt, loosen the lower bolts fixing the alternator and remove the bracket used for supporting the power unit.Tighten the bolts fixing the alternator to the mounting to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ALTERNATOR ASSEMBLY	M8	(Mount side) 2.3 - 2.8

Connect the connector for the engine oil vapour recovery pipe to the timing cover with drive chain and tighten the bolt.

Ensure the o-ring is present and correctly positioned.

Proceed with the refitting Op. 1092A10 CRANKSHAFT SERVICES PULLEY - R.R..Proceed with the refitting 1092G10 CINGHIA unica comando organi motore - S.R. .Proceed with the refitting Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R..Proceed with the refitting Op. 7055B66 ENGINE COMPARTMENT DUST SHIELD PROTECTION IN RIGHT FRONT WHEEL ARCH - R.R..Proceed with the refitting Op. 4450B04 RIGHT FRONT WHEEL R R.Fit the engine coolant reservoir in place and secure it using the nut and the bolt.Connect the system supply pipe, engine coolant reservoir side and tighten the band.Connect the coolant return pipe to the engine coolant reservoir to the coolant reservoir and tighten the band.1. Connect the pipe from the expansion valve to the compressor (1a) compressor side and tighten the bolt (1b) to the recommended torque.

Replace any O-Rings for the connectors using green coloured seals only which are resistant to the R134a refrigerant fluid.Lubricate the connector threads using anti-freeze. .

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

Remove the peg from the opening in the gearbox.Remove the exhaust camshaft timing tool and tighten the plug.

	Description	Code
-	Template	1.871.000.900

Connect the lower coolant input sleeve to the radiator, thermostat side, and tighten the band.Refit the air filter with air flow meter in its seat.Connect the air intake sleeve to the turbocharger, air flow meter side, and tighten the collar.Connect the electrical connection to the air flow meter.Connect the negative battery terminal (-).Refill the engine oil lubrication system Op. 0010T11 ENGINE OIL CHECK LEVEL AND TOP UP.Refill the engine cooling system Op. 0010T20 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY.Refill the air conditioning refrigerant circuit Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE.Proceed with the refitting Op. 7055B54 UNDER-ENGINE GUARD - R R.Remove the vehicle from the lift.