1004B17 POWER UNIT WITH AUTOMATIC TRANSMISSION, COMPLETE WITH SUPPORT FRAME, FRONT SUSPENSION- R.R. FOR VERSIONS WITH AIR CONDITIONING - Lancia - THESIS - eLearn

183463 - 1004B17 POWER UNIT with automatic transmission, complete with support frame, front suspension- R.R. for versions with air conditioning

) 1. Make sure that the wheels are perfectly straight and that the ignition key is not inserted, then undo the bolt (1a) fixing the steering column (1b) to the power assisted steering box pinion.

- 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. 4450B04 Right FRONT WHEEL (one) - R.R. See in Op. 4450B02 Left FRONT WHEEL (one) - R.R.- Raise the vehicle on the lift. 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.- < R1 > Left and right sides See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.- < R1 > Left and right sides- Position a suitable container for collecting the engine coolant.1. Disconnect the lower radiator pipe.

- Lower the vehicle. See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R. See in Op. 1088B10 Engine coolant SUPPLY RESERVOIR - R.R. See in Op. 1008C10 Power unit REACTION ROD - Replace See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R. See in Op. 1048A28 vacuum air circuit resonator pipe - r+r See in Op. 1016A42 LEFT CYLINDER HEAD IGNITION COIL COVER - R.R. See in Op. 1048A11 COMPLETE AIR FILTER -R.R.1. Open the protective flap (1a) and undo the nut (1b) fixing the starter motor supply lead (1c) to the junction node and move the lead between the junction node and the motor aside.

	Description	Connector
1c	Contact board	A005A

	Description	Connector
1c	Contact board	A005B

1. Release the retainers (1a) and disconnect the gearbox bowden cable (1b).

1. Position a hydraulic jack under the gearbox casing and undo the two nuts (1a) fixing the gearbox side engine support (1b) to the bracket (1c), then lower the jack until the gearbox casing is resting on the suspension frame.

See in Op. 1088E10 Radiator cooling FAN - R.R. See in Op. 5040A10 Air conditioning coolant circuit - Drying and Repressurizing1. Disconnect the connections for the engine oil level sensor (1a) and the compressor supply.

	Description	Connector
1a	Engine oil level sensor	K032

	Description	Connector
1b	Air conditioning compressor engagement electro-magnet	L020

2. Undo the bolt (2a) fixing the compressor pipes connector (2b).

1. Disconnect the section (1b) of the air conditioning pipe on the engine support frame from the springs (1a).

- 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 from the duplex pipes, 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.

1. Open the band (1a) and disconnect the connecting pipe (1b) betweean the engine coolant reservoir and the thermostat unit (1c).

1. Disconnect the rapid connector (1a) for the fuel vapour recovery pipe (1b).2. Open the band (2a) for the brake servo vacuum intake pipe (2b) and disconnect the pipe.3. Disconnect the upper connector for the engine management control unit.

	Description	Connector
3	Engine management control unit	M010B

1. Open the container (1a) cover and disconnect the connectors (1b) and (1c) for the rear Lambda sensors, the connector (1d) for the detonation sensor and the coupling 91e) between the injection/ignition system wiring and the engine compartment front wiring.

	Description	Connector
1b	Lambda sensor on catalyzer	K017

	Description	Connector
1c	Lambda sensor on catalyzer 2	K018

	Description	Connector
1d	Detonation sensor - 2	K050

1. Disconnect the rapid connector (1a) for the fuel pipe (1b) from the tank, undo the bolt (1c) fixing the pipe retaining duct (1d), then open the duct and release the pipe.

1. Disconnect the main gearbox wiring connectors.

	Description	Connector
1	Automatic transmission solenoid valves	L050A

	Description	Connector
1	Automatic transmission solenoid valves	L050B

	Description	Connector
1	Automatic transmission solenoid valves	L050C

1. Open the bands (1a) retaining the heater unit coolant supply (1b) and return (1c) pipes.

- 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)

1. Undo the three fixing nuts (1a) on both sides of the brackets (1b) securing the radiator to the chassis.

1. Undo the nut fixing the band (1a) retaining the gearbox bowden cable (1b) to the gearbox casing.

- 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. Undo the nuts (1a) fixing the flanges for the pipes (1b) between the pre-catalyzers and the catalyzer and remove the actual pipes complete with the gaskets underneath.

1. Working on the gearbox side, disconnect the electrical connection (1a) for the servotronic actuator (1b) located on the steering box.

	Description	Connector
1a	Servotronik solenoid valve	L070

- Secure the engine coolant radiator to the bodyshell, as appropriate.1. With the vehicle raised, undo the bolts (1a) fixing the bumper to the radiator mounting brackets (1b), then remove the actual brackets.

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

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

1. Partly lower the jack and, working on the rear part of the engine, release the bracket (1a) retaining the gearbox bowden cable (1b).

1. Completely lower the jack (1a) and remove the power unit (1b) from the engine compartment.

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.- Working on the rear part of the engine, secure the bracket retaining the gearbox bowden cable and tighten the fixing nut.1. Tighten the nut (1a) fixing the centre rear engine support (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1a	(to the flexible mounting) 4	Nut	RIGID REAR SUPPORT POWER UNIT	M10

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

- Position the radiator on the mounting brackets.- Tighten the bolts fixing the bumper to the mounting brackets.1. Working on the gearbox side, connect the electrical connection (1a) for the servotronic actuator (1b) located on the steering box.

	Description	Connector
1a	Servotronik solenoid valve	L070

1. Position the pipes between the pre-catalyzers and the catalyzer, complete with seals, then tighten the nuts (1a) fixing the pipe flanges (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1a	2.8	Nut	EXHAUST PIPE MOUNTS/FASTENERS	M8

1. Connect the electrical connection (1a) for the headlamp alignment adjustment sensor (1b).

	Description	Connector
1a	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
1a	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

- Position the selector fork (1a), then tighten the uppwer bolt (1b) fixing the fork to the shock absorber (1c) and the lower bolt (1d) fixing it to the front suspension arm (1e) to the recommended torque.

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

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

- Secure the anti-roll bar connecting rod (2a) and tighten the fixing nut (2b).

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

- Position the vibration sensor bracket (3a) and tighten the fixing bolt (3b).

	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	1.860.942.000	Angular tightening of driveshaft nut to wheel hub

- Proceed in the same way for the engine side suspension.- Lower the vehicle.- 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

- Connect the power assisted steering pipes to the heat exchanger, then close the retaining bands.- Close the bands retaining the heater unit coolant supply and return pipes.- Connect the main gearbox wiring connectors.- Connect the rapid connector for the fuel pipe from the tank, then position the pipe and tighten the bolt fixing the retaining duct.- Connect the connectors (1b) and (1c) for the rear Lambda sensors, the connector (1d) for the detonation sensor and the coupling (1e) between the injection/ignition wiring and the engine compartment front wiring, then close the container (1a) cover and

	Description	Connector
1b	Lambda sensor on catalyzer	K017

	Description	Connector
1c	Lambda sensor on catalyzer 2	K018

	Description	Connector
1d	Detonation sensor - 2	K050

- Connect the upper connector for the engine management control unit.

	Description	Connector
	Engine management control unit	M010B

- Connect the brake servo vacuum intake pipe and close the band.- Connect the rapid connector for the fuel vapour recovery pipe.- Connect the connecting pipe between the engine coolant reservoir and the thermostat unit, then close the band.- 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.- Lower the vehicle- Secure the air conditioning system pipe to the retaining spring on the frame.1. Tighten the bolt (1a) fixing the compressor pipes connector (1b).

	Value - daNm	Fastening	Component	Ø
1a	3.5	Bolt	COMPRESSOR PIPE CONNECTORS	M10 X 1.25

2. Disconnect the connections for the engine oil level sensor (2a) and the air conditioning compressor supply (2b).

	Description	Connector
2a	Engine oil level sensor	K032

	Description	Connector
2b	Air conditioning compressor engagement electro-magnet	L020

See in Op. 5040A10 Air conditioning coolant circuit - Drying and Repressurizing See in Op. 1088E10 Radiator cooling FAN - R.R.- 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
.	5	Nut	POWER UNIT GEAR BOX END RIGID MOUNT	M10 X 1.25

- Position the gearbox bowden cable and secure the retainers.- Connect the lead between the junction node and the starter motor to the actual node and tighten the fixing nut, then close the protective flap.

	Value - daNm	Fastening	Component	Ø
.	0.5	Nut	TERMINAL/MOTOR LEAD	M8

See in Op. 1048A11 COMPLETE AIR FILTER -R.R. See in Op. 1016A42 LEFT CYLINDER HEAD IGNITION COIL COVER - R.R. See in Op. 1048A28 vacuum air circuit resonator pipe - r+r See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R. See in Op. 1008C10 Power unit REACTION ROD - Replace See in Op. 1088B10 Engine coolant SUPPLY RESERVOIR - R.R. See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - 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.- < R1 > Left and right sides See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.- < R1 > 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
1a	2	Bolt	STEERING SHAFT MOUNTING	M8

- Remove the vehicle from the lift. See in Op. 0010T70 POWER ASSISTED STEERING FLUID - Replace- See in Op. 0010T21 ENGINE COOLANT - Check density and top up if necessary