3025983 - 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. Release and rmove the engine oil dipstick.2. Undo the bolt (2a) and the connector (2b), then remove the engine oil dipstick pipe (2c). 1. Undo the nuts (1a) and remove the left exhaust manifold with the catalytic preconverter (1b) incorporated.2. Remove gaskets. 1. Use a spanner on the moving tensioner and remove the single drive belt to loosen the belt tension.2. Remove the engine components single drive belt. 1. Undo the bolt (1a) and remove the fixed single drive belt tensioner (1b). 1. Undo the nut (1a) fixing the electrical wiring mounting bracket (1b).2. Disconnect the electrical connection for the insufficient engine oil pressure sensor.

	Name	Connector
2	Engine oil pressure sensor	K30

1. Undo the bolts (1a) and remove the alternator (1b) complete with electrical wiring (1c). 1. Undo the bolts (1a) and remove the alternator mounting (1b). 1. Remove the engine oil filter using a suitable tool.2. Undo the bolts (2a) and the nuts (2b) and remove the engine oil filter/intermediate driveshaft mounting (2c).3. Remove the gasket. 1. Disconnect the electrical connection for the air conditioning compressor electromagnet coupling.

	Name	Connector
1	Air conditioning compressor engagement electro-magnet	L20

1. Undo the bolts (1a) and remove the air conditioning compressor (1b). 1. Fit the brackets for supporting the engine on the service stand.

	Name	Country
1	Brackets	1.820.145.000

Position the engine on the overhauling stand 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.1. Place the air conditioning compressor (1a) back in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	AIR CONDITIONER ASSEMBLY COMPRESSOR	M10	(Support side) 4.5 ÷ 5.5

Connect the electrical connection to the air conditioning compressor electromagnet coupling.1. Place the engine oil filter/intermediate driveshaft mounting (1a), complete with gasket (1b) back in its housing and secure it tightening the bolts (1c) and the nuts (1d) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	DRIVE SHAFT OIL FILTER/BEARING MOUNT	M8	(Engine crankcase side) 2.3 ÷ 2.8

	Fastening	Component	Ø	Value(daNm)
1d	Nut	DRIVE SHAFT OIL FILTER/BEARING MOUNT	M8	(Engine crankcase side) 2.3 ÷ 2.8

2. Fit the engine oil filter and tighten it fully by hand. 1. Place the alternator mounting (1a) back in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	ALTERNATOR SUPPORT	M8	(Engine crankcase side) 1.9 ÷ 2.3

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	ALTERNATOR SUPPORT	M10	(Engine crankcase side) 4.3 ÷ 5.3

1. Place the alternator (1a), complete with electrical wiring (1b), back in its housing and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	ALTERNATOR ASSEMBLY	M8	(Support side) 2.3 ÷ 2.8

Connect the electrical connection to the engine oil pressure warning sensor.Tighten the nut securing the electrical wiring mounting bracket.1. Place the engine components single drive belt fixed tensioner (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FIXED SINGLE SERVICE BELT TENSIONER	M8	2.3 ÷ 2.8

Place the single engine components belt back in its housing keeping the moving tensioner in a slack belt position using a suitable spanner.1. Place the left exhaust manifold with the catalytic preconverter (1a) incorporated complete with gaskets (1b) back in its housing and secure it tightiening the nuts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Nut	EXHAUST MANIFOLD/S	M8	(Cylinder head side) 2.4 ÷ 3.0

Place the complete engine oil dipstick tube back in its housing and fix it using the connector and the bolt.Place the engine oil dipstick back in its seating.Release the engine from the hydraulic lift.