4410D10 FRONT SUSPENSION FRAME - R.R. - Lancia - THESIS - eLearn

177582 - 4410D10 Front suspension FRAME - R.R.

) - Position the vehicle on a lift.- Open the boot, remove the cover on the left hand side and disconnect the negative battery lead. See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R. See in Op. 4450B12 Front WHEELS (two) - R.R. See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.- (both sides). See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.- (both sides). See in Op. 7055B54 PROTECTION/GUARD under engine - R.R. See in Op. 7210E10 FRONT BUMPER See in Op. 1016A10 SOUND-PROOFING COVER - R.R. 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. 1088B10 Engine coolant SUPPLY RESERVOIR - R.R. See in Op. 1008C10 Power unit REACTION ROD - Replace 1. Remove the bands (1a) and disconnect the power assisted steering system pipes (1b) from the cooling coil.

Collect the power assisted steering fluid that comes out in a suitable container.

1. Undo the connector on the steering box for the pressurized fluid supply pipe from the pump.- Release the power assisted steering system pipes from the retaining bands.

See in Op. 1076B50 Exhaust PIPE attachment to engine/manifold - R.R. 1. Disconnect the band connector the flexible section of the return pipe to the power assisted steering fluid reservoir to the rigid section.

- Secure the radiator-condenser-fan assembly to the upper crossmember.1. Release the retaining band for the cable loom on the left suspension turret and place the wiring to the side to allow the subsequent fitting of the power unit supporting crossmember.

1. Fit a suitable bracket on the cylinder head for supporting the power unit.2. Fit a suitable hook (2a) on one side of the power assisted steering pump mounting bracket for support and a drilled plate (2b) on the other side, then fasten the two components using a large bolt.

Take care not to damage the rubber support mounting for the power assisted steering pump.

3. Fit the tool (3a), complete with support mountings (3b), in the area in front of the suspension turret.

	Description	Code	Function
3a	Crossmember	1.870.595.000	Power unit support

	Description	Code	Function
3b	Support mountings	1.870.650.000	Power unit support

4. Fit the tools (4a) and (4b), then connect them to the bracket on the cylinder head using the rod (4c). Make a hole in the bracket (4b) to allow the positioning of the bracket (4d) and the bolt retaining it to the lower crossmember.

	Description	Code	Function
4a	Crossmember	1.860.851.003	Power unit support

	Description	Code	Function
4b	Vertical support	1.870.748.000	Power unit support

5. Position a rod (5a) and connect it to the exhaust manifold using chains (5b).

Loosen the heat shield upper fastenings to allow the attachment of the chains to the exhaust manifold.

6. Position a rod and connect it to the bracket fitted on the power assisted steering pump mounting.7. Join the crossmembers fitted for supporting the power unit using bolts.

Do not alter the attachment points for different engine types. Always keep the mounting points in the positions illustrated to keep the engine balanced.

1. Undo the nuts fixing the track control arms to the steering knuckle.

1. Extract the front track control arm head (1a) from the steering knuckle using a USAG-FACOM U.16A32 type extractor (1b) or a similar tool.

1. Extract the rear track control arm head (1a) from the steering knuckle using a USAG-FACOM U.16A32 type extractor (1b) or a similar tool.

1. Undo the fixing bolts.2. Undo the upper fixing nut (2a) and disconnect the end of the anti-roll bar connecting rod (2b).3. Undo the fixing bolt (3a) and move the accelerometer sensor (3b), complete with mounting bracket, aside.4. Remove the suspension fork.

1. Undo the nut.2. Extract the steering rod end (2a) using the extractor (2b).

	Description	Code	Function
2b	Head extractor	1.847.035.000	Extracting steering rod pin from stub axle

1. Disconnect the electrical connector for the headlamp alignment potentiometer.

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

1. Working from inside the vehicle, undo the bolt fixing the lower steering conttol shaft to the steering box pinion.

1. Undo the nut (1a) fixing the timing side rigid engine support (1b) to the flexible mounting.

1. Undo the nut (1a) fixing the rigid rear support (1b) to the flexible mounting.

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 engine mounting brackets (1c).

1. Undo the two front bolts (1a) fixing the frame (1b) to the bodyshell.

1. At the bench, undo the bolts (1a), disconnect the connector (1b) for the return pipe, then remove the power assisted steering box (1c).

1. Undo the bolts (1a) fixing the u-bolts (1b) retaining the anti-roll bar.2. Undo the nuts fixing the headlamp alignment corrector potentiometer connecting rod.- Remove the anti-roll bar

1. Undo the fixing nuts and remove the air filter mounting bracket.2. Undo the fixing nuts and remove the engine cooling radiator mounting brackets.

1. Undo the bolt (1a) and the nuts (1b) retaining the power assisted steering pipes mounting brackets.2. Remove the power assisted steering system pipes.

1. Undo the bolts (1a) and remove the front flexible mounting (1b) and the rear flexible mounting (1c).

1. Undo the bolts (1a) and remove the track control arms (1b).2. Undo the bolts (2a) and remove the headlamp alignment corrector potentiometer (2b).

Refitting ( Removing

) - Proceed with refitting the components removed at the bench.- Fit the headlamp alignment corrector potentiometer.- Fit the track control arms.

	Value - daNm	Fastening	Component	Ø
.	(to the chassis) 10	Bolt	LOWER FRONT TRACK CONTROL ARMS	M12 X 1.25

- Position the power assisted steering pipes and secure them using the mounting brackets.- Position the engine cooling radiator mounting brackets.- Position the air filter assembly mounting bracket and secure it to the crossmember using the fixing nuts.- Connect the nut fixing the headlamp alignment corrector potentiometer connecting rod.- Position the anti-roll bar and the retaining u-bolts, then tighten the fixing bolts on the crossmember to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	3.5	Bolt	FRONT ANTI-ROLL BAR SUPPORTS	M8

- Position the power assisted steering box and fasten it to the frame tightening the bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	11	Bolt	COMPLETE POWER ASSISTED STEERING BOX	M12 X 1.25

	Value - daNm	Fastening	Component	Ø
.	1.5	Bolt	COMPLETE POWER ASSISTED STEERING BOX	M8

- Connect the connector for the return pipe to the reservoir to the steering box.

	Value - daNm	Fastening	Component	Ø
.	3	Bolt	RETURN PIPE TO POWER STEERING RESERVOIR	M12 X 1.5

- Position the front suspension crossmember, supported by the special tool, in the vehicle.

Fit the steering box pinion in the opening in the bodyshell.

- Position the reinforcement brackets, then tighten the bolts fixing the front suspension crossmember to the bodyshell to the recommended torque.

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

- Remove the tool supporting the front suspension frame.

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

- Position a hydraulic lift under the engine, raise it slightly to allow the timing side flexible mounting to be fitted on the support, then tighten the bolts fixing it to the frame to the recommended torque.

The hydraulic lift only has to be raised slightly. Proceed very cautiously.

	Value - daNm	Fastening	Component	Ø
.	(to the chassis) 5	Bolt	FRONT FLEXIBLE MOUNTING BLOCKS, POWER UNIT	M10X 1.25

- Position a hydraulic lift under the engine, raise it slightly to allow the rear flexible mounting to be fitted on the support, then tighten the bolts fixing it to the frame to the recommended torque.

The hydraulic lift only has to be raised slightly. Proceed very cautiously.

	Value - daNm	Fastening	Component	Ø
.	(to the chassis) 5	Bolt	INTERM RUBBER MOUNT	M10X 1.25

- Tighten the nut fixing the timing side engine support to the flexible mounting.

	Value - daNm	Fastening	Component	Ø
.	(to the flexible mounting) 5	Nut	RIGID ENGINE MOUNT, TIMING SIDE	M10X 1.25

- Tighten the nut fixing the rear engine support to the flexible mounting.

	Value - daNm	Fastening	Component	Ø
.	(to the flexible mounting) 5	Nut	RIGID REAR SUPPORT POWER UNIT	M10 X 1.25

- Tighten the bolt fixing the lower steering conttol shaft to the steering box pinion.

	Value - daNm	Fastening	Component	Ø
.	(to the steering box pinion) 2	Bolt	FIXED ELEMENTS STEERING SHAFT STEERING	M8

- Connect the electrical connector for the headlamp alignment potentiometer.

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

- Connect the steering rod ends and tighten the nuts fixing them to the steering knuckles to torque.

	Value - daNm	Fastening	Component	Ø
.	(to the steering knuckle) 4.5	Bolt	ADJUSTABLE STEERING ROD ENDS	M10 X 1.25

- Tighten the upper nut securing the anti-roll bar connecting rod end.

	Value - daNm	Fastening	Component	Ø
.	5.5	Nut	FRONT ANTI-ROLL BAR JOINTS	M10 X 1.25

- Tighten the bolts fixing the fork to the steering knuckle.

	Value - daNm	Fastening	Component	Ø
.	(to the lower front rod) 9	Bolt	FRONT DAMPER FORK ON WISHBONE	M12 x 1.25

	Value - daNm	Fastening	Component	Ø
.	(to the shock absorber) 11.6	Bolt	FRONT DAMPER FORK ON WISHBONE	M12 X 1.25

- Position the bracket complete with accelerometer sensor and secure it using the bolt.- Fit the front and rear track control arm heads to the steering knuckle and tighten the fixing nuts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	(to the steering knuckle) 9	Nut	LOWER FRONT TRACK CONTROL ARMS	M14 X 1.5

	Value - daNm	Fastening	Component	Ø
.	(to the steering knuckle) 8.8	Nut	LOWER FRONT TRACK CONTROL ARMS	M12 X 1.25

- Remove the tools and the power unit mounting brackets.

	Description	Code	Function
.	Crossmember	1.870.595.000	Power unit support

	Description	Code	Function
.	Support mountings	1.870.650.000	Power unit support

	Description	Code	Function
.	Crossmember	1.860.851.003	Power unit support

	Description	Code	Function
.	Vertical support	1.870.748.000	Power unit support

- Reposition the cable loom on the left front suspension turret and secure it to the retaining band.- Release the radiator-condenser-fan assembly from the upper crossmember.- Connect the flexible and rigid sections of the return pipe to the power assisted steering reservoir; secure the pipes using the retaining band See in Op. 1076B50 Exhaust PIPE attachment to engine/manifold - R.R. - Connect the connector on the steering box for the pressurized fluid supply pipe from the pump.

	Value - daNm	Fastening	Component	Ø
.	4	Bolt	PIPE BTWN PUMP + POWER STEERING BOX	M14 X 1.5

- Connect the power assisted steering system pipes to the cooling coil. See in Op. 1008C10 Power unit REACTION ROD - Replace See in Op. 1088B10 Engine coolant SUPPLY RESERVOIR - R.R. See in Op. 1048B14 air delivery pipe between turbo charger and heat exchanger - replace 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. 1016A10 SOUND-PROOFING COVER - R.R. See in Op. 4130B14 Power assisted steering fluid reservoir cap - R.R. - Check fluid level and top up if necessary See in Op. 7210E10 FRONT BUMPER See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R. See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R. See in Op. 4450B12 Front WHEELS (two) - R.R.- Connect the negative battery lead. See in Op. 0010T20 Engine REFRIGERANT FLUID - Change See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.- Remove the vehicle from the lift.- The power assisted steering system is self-bleeding, proceed as described below.- Start the engine and carry out 4 -5 complete steering wheel rotation cycles (left and right).- Top up the power assisted steering fluid level in the reservoir See in Op. 4450A10 FRONT WHEEL GEOMETRY - Check using optical equipment - Includes front wheel toe-in adjustment if necessary