1004D40 ENGINE - POSITION ON STAND AND REMOVE - Lancia - THESIS - eLearn

74570 - 1004D40 ENGINE - Position on stand and Remove

1. Loosen the bolts fixing the power assisted steering pump drive belt tensioner, where fitted.2. Release and remove the power assisted steering pump drive belt.

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.

	Description	Connector
1	Alternator	A010A

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. Undo the fixing bolts (1a) and nuts (1b) and disconnect the earth lead (1c).

	Description	Connector
1c	Earth on engine	C040

- Lower the lift.2. Release the wiring from the springs and remove the chamber mounting bracket.

1. Undo the bolts fixing the supply/return pipes to the power assisted steering pump.

1. Undo the bolt (1a) fixing the power assisted steering pump using a suitable pin (1b) for counter-torque.2. Remove the power assisted steering pump pulley.

1. Release and remove the power assisted steering pump (1a) complete with pipes (1b) and electrical wiring (1c).

1. Undo the bolts (1a) and remove the exhaust manifold heat shields (1b).

1. Undo the nuts securing the exhaust manifold to the cylinder head.2. Remove the turbocharger (2a) complete with exhaust manifold (2b).3. Remove the exhaust manifold gasket from the studs on the cylinder head.

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 exhaust side rigid engine support assembly (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.

	Description	Code	Function
1	Brackets	1.861.001.039	Brackets for securing engine to universal stand

- Position the engine on the overhaul stand using a hydraulic hoist fitted with suitable chains.- REMOVAL FROM THE STAND.- Remove 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.

	Description	Code	Function
1	Brackets	1.861.001.039	Brackets for securing engine to universal stand

- Place the engine oil dipstick in its housing and secure it using the fastenings.1. Place the intermediate driveshaft bearing support (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	4.6 ÷ 6.6	Bolt	FRONT DRIVE SHAFT BEARING MOUNT	M10

2. Tighten the bolt connecting the intermediate driveshaft bearing support to the crankcase sump.

1. Place the exhaust side rigid engine support (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	4.6 - 6.6 (crankcase side)	Bolt	RIGID ENGINE SUPPORT, TIMING SIDE	M10

2. Tighten the bolts fixing the alternator/air conditioning compressor drive belt tensioner to the exhaust side rigid engine support.

	Value - daNm	Fastening	Component	Ø
2	(Timing side engine support side) 2.3 - 3.3	Bolt	ALT./AUXILIARY DRIVEBELT MOBILE VARIOUS	M8

1. Place the exhaust manifold (1a), complete with gasket, back in its housing and secure it tightening the nuts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	2.3 - 3.3 (cylinder head side)	Nut	EXHAUST MANIFOLD/S	M8

- 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.1. Place the power assisted steering pump pulley (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque using a suitable pin (1c) for counter-torque.

	Value - daNm	Fastening	Component	Ø
1b	2.3 - 3.3 (power assisted steering pump side)	Bolt	POWER STEERING PUMP DRIVE PULLEY	M8

	Value - daNm	Fastening	Component	Ø
.	(Power assisted steerign pump side) 9.2 - 13.3	Nut	POWER STEERING PUMP DRIVE PULLEY	M16

- Tighten the bolts fixing the supply/return pipes to the power assisted steering pump.- 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.

	Value - daNm	Fastening	Component	Ø
1b	4.6 - 6.6	Bolt	ALTERNATOR ASSEMBLY	M10

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.

	Value - daNm	Fastening	Component	Ø
1b	4.6 ÷ 6.6	Bolt	COMPLETE AIR CONDITIONING COMPRESSOR	M10

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).

1. Fit the alternator/air conditioning compressor drive belt.2. Tension the alternator/air conditioning compressor drive belt using the special screw. Tension the alternator/air conditioning compressor drive belt using the special 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.

	Subject	Value
.	Alternator/air conditioning compressor drive belt	Nm
-	Tension	63 - 80

- 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.

	Value - daNm	Fastening	Component	Ø
2b	4.6 - 6.6 (Timing side rigid power unit support)	Bolt	MOVING TENSIONER FOR POWER ASSISTED STEERING PUMP DRIVE BELT	M8

- Using the tool, check that the power assisted steering pump belt tension corresponds to the recommended figures.

	Description	Code	Function
.	Tension	1.895.762.000	Power steering pump drive belt tensioning

	Subject	Value
.	Power assisted steering pump drive belt	Nm
-	Tension	45 - 62

- If the tension does not correspond to the recommended figures, repeat the above operations.