1004B18 POWER UNIT WITH MANUAL GEARBOX, WITH FRONT SUSPENSION SUBFRAME - R.R. - Lancia - THESIS - eLearn

851158 - 1004B18 POWER UNIT with manual gearbox, with front suspension subframe - R.R.

) See in Op. 1016A10 SOUND-PROOFING COVER - R.R. See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.1. Ensure the wheels are perfectly straight and the ignition key is out, then undo bolt (1a) securing steering column (1b) to the power steering box pinion.

- Position the vehicle on a lift.- Open the boot, remove the cover on the left side and disconnect the battery negative lead. See in Op. 4450B04 Right FRONT WHEEL (one) - R.R. See in Op. 4450B02 Left FRONT WHEEL (one) - R.R.- Raise the car on a stand. See in Op. 7055B54 PROTECTION/GUARD under engine - R.R. See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.- Right and left side See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.- Right and left side- Position a tank to collect the coolant1. Disconnect the lower radiator pipe.

- Lower the vehicle. See in Op. 1088B10 Engine coolant SUPPLY RESERVOIR - R.R. See in Op. 1008C10 Power unit REACTION ROD - Replace See in Op. 1048B44 RIGID air supply PIPE from heat exchanger to intake manifold - R.R. See in Op. 1048A56 UPPER RESONATOR - R.R. See in Op. 1048A50 air inlet pipe to turbocharger - r + r See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R. See in Op. 1048A10 COMPLETE AIR FILTER -R.R. See in Op. 1060G80 Diesel electronic injection system CONTROL UNIT - R.R.1. Disconnect the upper coolant pipe from the thermstat.2. Disconnect the single-acting valve from the brake servo.

1. Release the retainers (1a) and disconnect the gearbox flexible cables (1b) from the gearbox and bracket.

1. Disconnect the supply pipe to the pressure pump from the fuel filter.2. Disconnect the supply pipe to the fuel return manifold from the fuel filter.3. Disconnect the electrical connections for the diesel heater resistances.

	Description	Connector
3	Diesel pre-heating resistance	O020A

	Description	Connector
3	Diesel pre-heating resistance	O020B

- Disconnect the electrical connection for the water presence sensor.

	Description	Connector
.	Water in diesel filter sensor	K031

4. Disconnect the two heater coolant supply and return pipes.5. Disconnect the front engine coupling.

	Description	Connector
5	Front/engine coupling	D004

1. Remove the safety seal on the electrical connector, then disconnect the brake system control unit electrical connector (NFR).

	Description	Connector
1	Braking system control unit (NFR)	M051

2. Undo the nuts securing the brake system control unit (NFR) to the bracket.

- Position a hydraulic lift under the gearbox to support the power unit.1. Undo the nuts securing the engine mounting block to the bracket.- Gently lower the hydraulic lift until the gearbox bell housing is resting on the crossmember.

- Raise the vehicle- Position a suitable container for collecting the power assisted steering fluid1. Open the retaining band (1a) and disconnect the flexible return pipe (1b) to the power assisted steering fluid reservoir, then leave the system to drain.

See in Op. 5050B32 Front windscreen WIPER ARM/S - R.R. See in Op. 7055A18 Winsdcreen base TRIM - R.R.1. Disconnect the breather pipe (1a) from the reservoir cap (1b).2. Undo the bolt (2a) fixing the power assisted steering fluid reservoir (2c) retaining band (2b).3. Open the reservoir pipe (3b) retaining bands (3a), then disconnect the actual pipes, releasing them from the engine compartment bulkhead.

See in Op. 1088E10 Radiator cooling FAN - R.R. See in Op. 0010T84 AIR CONDITIONING system COOLANT - Dry and repressurize1. Tighten the bolt (1a) fixing the compressor pipes connector (1b).

1. Disconnect the section (1b) of the air conditioning pipe on the engine support frame from the springs (1a).2. Unscrew bolts (2a) and disconnect oil delivery and return pipes (2b) to the engine oil cooling radiator.- Remove the engine oil radiator with hoses from the left front wheel side.3. Disconect the air pipe from the turbocharger.

- Position a suitable container for collecting the power assisted steering fluid1. Open the bands (1a) retaining the power assisted steering pipes (1b) to the heat exchanger (1c) and disconnect them.

1. Undo the two fixing nuts (1a) and remove the air filter casing mounting bracket (1b)2. Unscrew the nut and release the power steering fuel pipes from the chassis.

1. Undo the fixing nut (1a) and disconnect the gearbox earth lead (1b).2. Lift up the fastening clip (2a) and disconnect the clutch release oil pipe (2b).

- Working on the gearbox side, release the left suspension as described below:1. Remove the staking from the nut fixing the gearbox side wheel hub and undo it.

1. Undo the nut (1a) fixing the steering box track rod end (1b) and disconnect it using the extractor (1c).

	Description	Code	Function
1c	Head extractor	1.847.035.000	Extracting steering rod pin from stub axle

1. Undo the bolt (1a) fixing the vibration sensor bracket (1b) and move it aside.2. Undo the nut (2a) fixing the anti-roll bar connecting rod (2b).3. Undo the upper bolt (3a) fixing the selector fork (3b) to the shock absorber (3c) and the lower bolt (3d) fixing it to the front suspension arm (3e), then remove the selector fork.

1. Undo the four fastenings (1a) securing the front track control arm (1b) to the frame.

1. Undo the fastening (1a) securing the lower rear track control arm (1b) to the frame.

1. Release the front suspension arm (1a) and the rear suspension arm (1b) from the frame, keeping the thrust washers.

1. Release the wheel hub (1a) from the left driveshaft (1b) leaving the latter secured to the gearbox.

- Proceed in the same way on the engine side to release the right suspension.1. Disconnect the electrical connection (1a) for the headlamp alignment adjustment sensor (1b).

	Description	Connector
1a	Headlamp alignment corrector front potentiometer (CAF)	K001

1. Unscrew nuts (1a) securing bracket (1b) supporting the front exhaust pipe section.

1. Unscrew the bolts securing the front exhaust pipe section to the catalytic preconverter.

1. Remove both exhaust pipe front section flexible blocks from the fastening pins.2. Undo the catalytic converter bolts.3. Remove the front section of the exhaust pipe.- Recover the front exhaust pipe section seals.

- Secure the engine coolant radiator with air-air heat exchanger to the body.1. With the vehicle raised, unscrew the bumper bolts.2. Unscrew nuts (2a) and remove lower engine radiator support brackets (2b).

1. Position the tool for supporting the power unit-chassis assembly (1a), complete with hydraulic jack, under the housings in the engine support frame (1b).

	Description	Code	Function
1a	Power unit support frame	1.870.835.000	Removing-refitting power unit

1. Undo the two rear bolts (1a) and the front bolt (1b) fixing each of the two rear chassis reinforcement brackets (1c).

1. Undo the nut (1a) fixing the timing side engine support (1b).

1. Undo the nut (1a) fixing the rear rear engine support (1b).

- Lower the jack and withdraw the power unti with half-axle and chassis.

Refitting ( Removing

) - Making sure that there are no obstacles and no interference, raise the jack and centre the power unit in the engine compartment without fully raising it.1. Tighten the nut (1a) fixing the engine support (1b) to the flexible mounting on the chassis to torque.

	Value - daNm	Fastening	Component	Ø
1a	4,5	Nut	POWER UNIT REAR RIGID MOUNT	M10 X 1.25

1. Tighten the nut (1a) fixing the timing side engine support (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1a	(Engine support) 4.5	Nut	RIGID ENGINE MOUNT, TIMING SIDE	M10 X 1.25

1. Tighten the two rear bolts (1a) and the front bolt (1b) fixing each of the two rear engine mounting brackets (1c).

	Value - daNm	Fastening	Component	Ø
1a	5	Bolt	FRONT SUSPENSION SUBFRAME	M10 X 1.25

	Value - daNm	Fastening	Component	Ø
1b	13	Bolt	FRONT SUSPENSION SUBFRAME	M12 X 1.25

- Remove the tool supporting the power unit - chassis assembly- With the vehicle raised, position the radiator mounting brackets and tighten the nuts fastening it to the engine frame

	Value - daNm	Fastening	Component	Ø
.	0.5	Nut	COOLANT RADIATOR SUPPORT BEAM	M6

1. Join the front exhaust pipe section flange to the catalytic preconverter flange by tightening the bolts.- During this operation, it is good practice to fit a new gasket between the two flanges.2. Tighten the fixing bolts to torque.

	Value - daNm	Fastening	Component	Ø
2	(Preconverter) 2.8	Bolts	EXHAUST PIPE TO ENGINE	M8

- Tighten the nuts securing the bracket for the first section of the exhaust pipe to the oil sump to torque.1. Secure both exhaust pipe front section flexible blocks to the fastening pins.2. Tighten the fixing bolts to the catalytic converter to torque.

	Value - daNm	Fastening	Component	Ø
2	(catalytic converter) 2.8	Bolts	EXHAUST PIPE TO ENGINE	M8

- Connect the electrical connection for the headlamp alignment adjustment sensor.

	Description	Connector
.	Headlamp alignment corrector front potentiometer (CAF)	K001

- Fit the wheel hub on the left driveshaft.- Positioning the thrust washers, fit the front and rear suspension arms in the housings in the frame.1. Tighten the bolt (1a) fixing the lower rear track control arm (1b) to the frame to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2	10	Bolt	LOWER REAR TRACK CONTROL ARMS	M12 X 1.25

1. Tighten the bolts (1a) fixing the lower front track control arm (1b) to the frame to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1a	7.4	Bolt	LOWER FRONT TRACK CONTROL ARMS	M10 X 1.25

	Value - daNm	Fastening	Component	Ø
.	9	Bolt	LOWER FRONT TRACK CONTROL ARMS	M12 X 1.25

- Position the fork, then tighten the upper bolt fixing the fork to the shock absorber and the lower bolt fixing it to the front suspension arm to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	11.6	Bolt	FRONT DAMPER FORK ON WISHBONE	M12 X 1.25

- Secure the anti-roll bar connecting rod and tighten the fixing nut.

	Value - daNm	Fastening	Component	Ø
.	5,5	Nut	FRONT ANTI-ROLL BAR	M10 X 1.25

- Position the vibration sensor bracket and tighten the fixing bolt.

	Value - daNm	Fastening	Component	Ø
.	0.4	Bolt	JOLTING SENSOR	M5

- Connect the steering track rod end to the steering knuckle and tighten the fixing nut to torque.

	Value - daNm	Fastening	Component	Ø
.	4.5	Nut	ADJUSTABLE LINK BALL JOINTS	M10 x 1.25

- Tighten the nut securing the driveshaft to the wheel hub to the recommended torque using the angular tightening tool (1b), then stake the nut.

	Value - daNm	Fastening	Component	Ø
.	7	Nut	FRONT HUBS COMPLETE WITH BEARING	M24

	Description	Code	Function
.	Torque wrench	1.820.622.000	Angular tightening of driveshaft nut to wheel hub

- Proceed in the same way for the engine side suspension.- Lower the vehicle.- Connect the clutch release oil pump, checking the spring is properly inserted.- Connect the gearbox earth lead to the bodyshell by tightening the nut.- Position the air filter casing mounting bracket, then tighten the two fixing nuts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	0.5	Nut	AIR CLEANER CASE MOUNT	M6

- Position the power steering pipes on the chassis and tighen the nut.- Connect the power assisted steering pipes to the heat exchanger, then close the retaining bands.- Fit the engine oil cooling radiator and connect the delivery and return hoses to the rigid sections and tighten the bolts.- Connect the air pipe to the turbocharger.- Secure the engine air conditioning system pipe to the chassis with the clips.1. Tighten the front section air condtioner pipe to the rear section.

It is advisable to replace the rubber gasket.

	Value - daNm	Fastening	Component	Ø
1a	3.5	Nut	COMPRESSOR PIPE CONNECTORS	M10X1.25

See in Op. 1088E10 Radiator cooling FAN - R.R.- Connect the power assisted steering pipes to the reservoir, then tighten the band retaining the reservoir to the bodyshell. See in Op. 7055A18 Winsdcreen base TRIM - R.R. See in Op. 5050B32 Front windscreen WIPER ARM/S - R.R.- Connect the power assisted steering pipes to the heat exchanger, then close the retaining bands.1. Raise the jack positioned under the gearbox casing and tighten the two nuts fixing the gearbox side engine support to the bracket to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1	(Mount) 5.8	Nuts	GEARBOX SIDE RUBBER MOUNT	M10X1.25

- Tighten the nuts securing the brake system control unit (NFR) to the bracket.

	Value - daNm	Fastening	Component	Ø
.	1.5	Nuts	HYDRAULIC AND ELECTRONIC CONTROL UNIT	M8

- Connect the electrical connection for the brake system electronic control unit (NFR).

	Description	Connector
.	Braking system control unit (NFR)	M051

- Connect the two heater coolant supply and return pipes.- Connect the electrical connections for the diesel heater coils.

	Description	Connector
.	Diesel pre-heating resistance	O020A

	Description	Connector
.	Diesel pre-heating resistance	O020B

- Disconnect the electrical connection for the water presence sensor.

	Description	Connector
.	Water in diesel filter sensor	K031

- Connect the supply pipe to the pressure pump to the fuel filter.- Connect the supply pipe to the fuel return manifold to the fuel filter.- Position the gear control hoses and secure the retaining devices to the bracket on the gearbox.- Press-fit both cable heads.- Connect the single-acting valve to the brake servo.- Connect the upper coolant pipe to the thermstat. See in Op. 1060G80 Diesel electronic injection system CONTROL UNIT - R.R. See in Op. 1048A10 COMPLETE AIR FILTER -R.R. See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R. See in Op. 1048A50 air inlet pipe to turbocharger - r + r See in Op. 1048A56 UPPER RESONATOR - R.R. See in Op. 1048B44 RIGID air supply PIPE from heat exchanger to intake manifold - R.R. See in Op. 1008C10 Power unit REACTION ROD - Replace See in Op. 1088B10 Engine coolant SUPPLY RESERVOIR - R.R.- Raise the vehicle.- Connect the lower pipe with the rapid connector for the engine coolant radiator. See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.- Left and right sides See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.- Left and right sides See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.- Lower the vehicle See in Op. 4450B02 Left FRONT WHEEL (one) - R.R. See in Op. 4450B04 Right FRONT WHEEL (one) - R.R.- Connect the negative battery lead, then close the boot.- Tighten the bolt fixing the steering column to the steering box to the recommended torque.

	Value - daNm	Fastening	Component	Ø
-	2	Bolt	STEERING SHAFT MOUNTING	M8

See in Op. 0010T70 POWER ASSISTED STEERING FLUID - Replace See in Op. 0010T20 Engine REFRIGERANT FLUID - Change See in Op. 4450A10 FRONT WHEEL GEOMETRY - Check using optical equipment - Includes front wheel toe-in adjustment if necessary- Remove the vehicle from the lift.