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

74570 - 1004D40 ENGINE - Position on stand and Remove

1. Disconnect the electrical connection for the left head Lambda sensor

	Description	Connector
1	Lambda sensor on pre-catalyzer	K015

2. Undo the three nuts (2a) fixing the left pre-converter heat shield (2b) and remove it

1. Undo the bolt (1a) fixing the engine oil dipstick pipe (1b) to the left head, then undo the connector (1c) on the crankcase and remove the pipe- Undo the nuts fixing the left pre-catalyzer and remove it

1. Positino the two mounting brackets (1a) securing them to the studs (1b) for the exhaust manifolds and secure the engine using a suitable hoisting system (1c).

1. Undo the bolt fixing the reinforcement bracket (1a), then undo the connector (1b) for the gearbox oil/water heat exchanger rigid coolant supply pipe and remove the pipe.

1. Undo the fixing nut (1a) and disconnect the energizing cable (1b) from the alternator.

	Description	Connector
1b	Alternator	A010A

	Description	Connector
1b	Alternator	A010B

1. Disconnect the electrical connector for the insufficient oil pressure sensor.

	Description	Connector
1	Insufficient engine oil pressure sensor	K030

2. Remove the oil filter cartridge using a suitable tool.

1. Undo the bolt fixing the coolant connectors on the alternator and disconnect the connectors.2. Open the band retaining the pipe from the crankcase to the engine oil/water heat exchanger and disconnect the pipe from the heat exchanger.3. Undo the centre nut fixing the engine oil/water heat exchanger and remove the heat exchanger

1. Using a spanner as illustrated in the diagram, move the moving tensioner (1a) for the auxiliary shaft drive belt and fit a 4 mm diameter pin (1b) to keep the tensioner in position, then remove the belt (1c).

1. Undo the bolt (1a) fixing the fixed tensioner (1b) and remove it.2. Undo the two bolts (2a) fixing the alternator (2b) and remove it.

1. Undo the fastenings (1a) and remove the rear engine support (1b).

1. Remove the gasket under the support.

1. Disconnect the connection for the air conditioning compressor electro-magnet coupling wiring.

	Description	Connector
1	Air conditioning compressor engagement electro-magnet	L020

1. Undo the two fastenings (1a) for the air conditioning system compressor (1b) and remove it

1. Position the mounting brackets (1a) and secure the engine to the stand (1b), then remove the hoists and support.

	Description	Code	Function
1a	Engine mounting brackets	1.861.001.038	Engine fastening to support stand

- Proceed with the removal of the engine from the stand, following the instructions given below:- Position suitable hoisting and support systems, then release it from the rotating stand and remove the mounting brackets- Position the air conditioning system compressor and tighten the two fixing bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	5	Bolt	AIR CONDITIONER ASSEMBLY COMPRESSOR	M10 X 1.25

- Connect the connection for the air conditioning compressor electro-magnet coupling wiring.

	Description	Connector
.	Air conditioning compressor engagement electro-magnet	L020

- Position the gasket under the rear engine support.- Position the rear engine support and tighten the fastenings to the crankcase to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	(to the cylinder block/crankcase) 2	Bolt	RIGID REAR SUPPORT POWER UNIT	M8

- Position the alternator and tighten the two fixing bolts.

	Value - daNm	Fastening	Component	Ø
.	6,7	Bolt	ALTERNATOR ASSEMBLY	M10

	Value - daNm	Fastening	Component	Ø
.	8,6	Bolt	ALTERNATOR ASSEMBLY	M12

- Position the single drive belt fixed tensioner and tighten the fixing bolt.

	Value - daNm	Fastening	Component	Ø
.	2.2	Bolt	SINGLE BELT MOVING TENSIONER VARIOUS	M8

- Fit the belt and remove the moving tensioner retaining pin.- Position the engine oil heat exchanger and tighten the centre fixing nut to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	3	Connector	ENGINE OIL HEAT EXCHANGER	M18 X 1,5

- Connect the pipe between the heat exchanger and the cylinder block/crankcase and secure the retaining band.- Secure the connectors, complete with gaskets, on the alternator using the fixing bolt.

Always replace the seals on the alternator cooling pipe connectors.

- Position the oil filter, tightening it manually- Connect the electrical connector for the insufficient oil pressure sensor.- Position the alternator energizing cable and tighten the fixing nut.

	Value - daNm	Fastening	Component	Ø
.	0.5	Nut	ALTERNATOR	M8

- Position the rigid pipe and copper washers and partly tighten the connector securing them to the crankcase.- Tighten the bolt fixing the gearbox oil/water heat exchanger rigid coolant supply pipe support plate to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	1.5	Bolt	PIPE TO CYLINDER BLOCK/CRANKCASE FIXING, BOLT	M8

- Tighten the connector fixing the pipe to the cylinder block/crankcase to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	4	Connector	CRANKCASE RIGID WATER RETURN PIPE	M16 X 1.5

- Connect the flexible and rigid pipes and close the band.- Remove the engine mounting brackets.- Position the pre-catalyzer and gasket and tighten the fixing nuts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2,7	Nut	EXHAUST MANIFOLD/S	M8

- Position the oil dipstick pipe tightening the connector fixing it to the cylinder block/crankcase to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	8	Connector	OIL LEVEL DIPSTICK PIPE	M14 X 1.5

- Tighten the bolt fixing the oil dipstick pipe to the left head to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2,5	Bolt	OIL LEVEL DIPSTICK PIPE	M16 X 1.5

- Position the heat shield and tighten the three fixing nuts.- Connect the electrical connection for the left head Lambda sensor

	Description	Connector
.	Lambda sensor on pre-catalyzer	K015