3363546 - 1004D40 ENGINE - POSITION ON STAND AND REMOVE

1. Loosen the bolt fixing the alternator/air conditioningn compressor drive belt tensioner.2. Loosen the tension for the alternator/air conditioning compressor drive belt using the screw.3. Release and remove the alternator/air conditioning compressor drive belt.
1. Undo the nuts (1a), loosen the band (1b) and remove the pipe (1c) between the supply pipe and the water pump rigid inlet pipe.2. Undo the bolts (2a) and (2b) and remove the air conditioning compressor (2c).
1. Disconnect the electrical connections from the alternator.
DescriptionConnector
1Alternator    A10
2. Undo the bolts (2a) and remove the alternator (2b).
1. Release the electrical wiring from the band on the injection/ignition control unit mounting.
1. Disconnect the electrical connection from the insufficient engine oil pressure sensor.
DescriptionConnector
1Engine oil pressure sensor (switch)    K30
2. Undo the bolt (2a) and the nut (2b) and remove the modular intake manifold mounting bracket (2c).
1. Undo the nuts (1a) and remove the exhaust manifold heat shields (1b).
1. Undo the nuts (1a) and remove the exhaust manifold (1b) complete with gasket.
1. Undo the bolts fixing the alternator/air conditioning compressor drive belt tensioner to the timing side rigid engine support.2. Undo the bolts (2a) and remove the timing side rigid engine support (2b).
1. Undo the bolt connecting the intermediate driveshaft bearing support to the crankcase sump.2. Undo the bolts (2a) and remove the intermediate driveshaft bearing support (2b).
Undo the fastenings and remove the engine oil dipstick assembly.1. Fit the tool for positioning the engine on the overhaul stand.
DescriptionCode
1Brackets1.861.001.039
Position the engine on the overhaul stand using a hydraulic hoist fitted with suitable chains.REMOVAL FROM THE STANDRemove the engine from the overhaul stand using a hydraulic hoist fitted with suitable chains.Remove the tool for positioning the engine on the overhaul stand.
DescriptionCode
-Brackets1.861.001.039
Place the engine oil dipstick in its housing and secure it using the fastenings.
FasteningComponentØ  Value(daNm)
--OIL LEVEL DIPSTICK PIPE-0.8 - 1.2
1. Place the intermediate driveshaft bearing support (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.
FasteningComponentØ  Value(daNm)
1bBoltFRONT DRIVE SHAFT BEARING MOUNTM10(Engine crankcase side) 4.6 - 6.6
2. Tighten the bolt connecting the intermediate driveshaft bearing support to the crankcase sump.
1. Place the timing side rigid engine support (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.
FasteningComponentØ  Value(daNm)
1bBoltRIGID ENGINE MOUNT, TIMING SIDEM10(Engine crankcase side) 4.6 - 6.6
2. Tighten the bolts fixing the alternator/air conditioning compressor drive belt tensioner to the timing side rigid engine support.
FasteningComponentØ  Value(daNm)
2BoltALT./AUXILIARY DRIVEBELT MOBILE VARIOUSM8(Timing side rigid engine support side) 2.3 - 3.3
1. Place the exhaust manifold (1a), complete with gasket, back in its housing and secure it tightening the nuts (1b) to the recommended torque.
FasteningComponentØ  Value(daNm)
1bNutEXHAUST MANIFOLD/SM8(Cylinder head side) 2.3 - 3.3
Place the exhaust manifold heat shields in their housings and secure them using the nuts.Place the power assisted steering pump complete with pipes and electrical wiring in its housing.Place the modular intake manifold mounting bracket in its housing and secure it using the nut and the bolt.Connect the electrical connection to the insufficient engine oil pressure sensor.Fasten the electrical wiring to the band on the injection/ignition control unit mounting.1. Place the alternator (1a) in its housing and fasten it tightening the bolts (1b) to the recommended torque.
FasteningComponentØ  Value(daNm)
1bBoltALTERNATOR ASSEMBLYM104.6 - 6.6
FasteningComponentØ  Value(daNm)
-BoltALTERNATOR ASSEMBLYM126.4 - 9.3
2. Connect the electrical connections to the alternator.
1. Place the air conditioning compressor (1a) in its housing and fasten it tightening the bolts (1b) and (1c) to the recommended torque.
FasteningComponentØ  Value(daNm)
1bBoltAIR CONDITIONER ASSEMBLY COMPRESSORM8(Mount side) 2.3 - 3.3
FasteningComponentØ  Value(daNm)
1cBoltAIR CONDITIONER ASSEMBLY COMPRESSORM8(Mount side) 2.3 - 3.3
2. Place the pipe (2a) from the supply pipe to the water pump rigid inlet pipe in its housing and secure it using the nuts (2b).
FasteningComponentØ  Value(daNm)
2bNutCOOLANT PUMP RIGID INLET PIPE-0.8 - 1.2
1. Fit the alternator/air conditioning compressor drive belt.2. Tension the alternator/air conditioning compressor drive belt using the screw.Using the C.TRONIC G2 105.5 equipment or similar, check that the alternator/air conditioning compressor drive belt tension corresponds to the recommended figures.
MeasurementValue
-Hydraulic tappet housing diameter (mm)33.000 - 33.025
If the tension does not correspond to the recommended figures, regulate the adjustment screw.3. Tighten the bolt fixing the alternator/air conditioning compressor drive belt tensioner.
1. Fit the power assisted steering pump drive belt.2. Tension the power assisted steering pump drive belt using a polygonal spanner on the tensioner screw (2a), then tighten the bolts (2b) to the recommended torque.
FasteningComponentØ  Value(daNm)
2bBoltMOVING TENSIONER FOR POWER ASSISTED STEERING PUMP DRIVE BELTM8(Timing side rigid power unit support side) 2.3 - 3.3
Using the tool, check that the power assisted steering pump belt tension corresponds to the recommended figures.
DescriptionCode
-Torque wrench1.895.762.000
MeasurementValue
-Tension (daN)45 - 62
If the tension does not correspond to the recommended figures, repeat the above operations.