194000229 - 1004D40 ENGINE - POSITION ON STAND AND REMOVE

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

	Description	Code	Function
1b	Spanner	1.860.966.000	Tensioning auxiliary shaft belt

	Description	Code	Function
1c	Lock	1.870.645.000	Tensioning auxiliary shaft belt

2. Remove the protective plug for the auxiliar shaft drive belt cam tensioner.3. Undo the bolt retaining 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).

	Description	Connector
1b	Alternator	A010A

	Description	Connector
1b	Alternator	A010B

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.

	Description	Connector
1	Engine oil level sensor	K032

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

	Description	Code	Function
2	Brackets	1.861.001.039	Engine support on overhaul stand

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

	Description	Connector
1	Air conditioning compressor engagement electro-magnet	L020

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.

	Description	Code	Function
1	Brackets	1.861.001.039	Engine support on overhaul stand

1. Undo the fixing nuts (1a) and remove the heat shield (1b) for the exhaust manifold. 1. Open the band (1a) and disconnect the fluid return pipe from the turbocharger (1b).2. Undo the connector (2a) and disconnect the oil supply pipe (2b) to the turbocharger 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) securing 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 the metal gasket (2b). 1. Undo the fixing bolt (1a) and remove the power assisted pump protective shield (1b).2. Using a hydraulic lift, place the engine (2a) on the overhaul stand (2b).

	Description	Code	Function
2b	Overhaul stand	1.861.000.000	Support the engine

It is possible to use the following stand as an alternative to the overhaul stand mentioned above:

	Description	Code	Function
.	Overhaul stand	1.871.001.000	Support the engine

Fasten the mounting brackets to the overhaul stand.Release the engine from the hydraulic lift. Proceed as follows to remove the engine from the overhaul stand.Secure and support the engine using a hydraulic lift fitted with chains.Undo the fastenings and remove the engine complete with mounting brackets.Remove the brackets for positioning the engine on the overhaul stand from the crankcase.

	Description	Code	Function
.	Brackets	1.861.001.039	Engine support on overhaul stand

1. Place a new metal gasket (1a) in position and then fit the exhaust manifold and turbine assembly (1b).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 and check the torque.

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

2. Place the new gasket (2a) in position and tighten the bolts (2b) fixing the rigid EGR pipe (2c) to the exhaust manifold/turbine tightening to torque. 1. Connect the oil return pipe from the turbocharger (1a) and secure it using the band (1b).2. Connect the turbocharger oil supply pipe (2a) to 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) checking the 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 for the air conditioning compressor.

	Description	Connector
2	Air conditioning compressor engagement electro-magnet	L020

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

	Description	Connector
1	Engine oil level sensor	K032

2. Fit the protective shield (2a) for the power assisted steering pump in place 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.

	Value daNm	Fastening	Component	Ø
1b	5	Bolt	RIGID REAR SUPPORT POWER UNIT	M10 X 1.25

	Value daNm	Fastening	Component	Ø
1b	2.5	Bolt	RIGID REAR SUPPORT POWER UNIT	M8

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.

	Value daNm	Fastening	Component	Ø
1b	5	Nut	ALTERNATOR ASSEMBLY	M10 X 1.25

	Value daNm	Fastening	Component	Ø
1b	7	Nut	ALTERNATOR ASSEMBLY	M12 X 1.25

1. Connect the electrical connection to the alternator.

	Description	Connector
1	Alternator	A010A

	Description	Connector
1	Alternator	A010B

Place the engine components single belt in position using a spanner on the moving tensioner.Release the engine from the hydraulic lift.