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

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

) - Working from inside the vehicle, follow the instructions below making sure that the wheels are perfectly straight and that the ignition key is not inserted:1. Undo the bolts fixing the trim under the dashboard, driver's side.2. Remove the trim under the dashboard, driver's side.

1. Release the steering column universal joint (1a) undoing the fixing bolt (1b).

- 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. 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.- Left side. See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.- Left side.- Position a suitable container for collecting the engine coolant.1. Open the rapid attachment band (1a) and disconnect the lower pipe (1b) from the radiator (1c).

- 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.

- Lower the lift.- [5050A12] 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. See in Op. 1088E10 Radiator cooling FAN - R.R.1. Release the air conditioning system pipe (1b) from the retaining spring (1a) on the frame.2. Undo the nuts (2a) fixing the coolant radiator mounting plates (2a) on the frame.

1. Open the bands (1a) retaining the power assisted steering pipes (1b) to the heat exchanger (1c) and disconnect them.

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. Undo the two fixing nuts (1a) and remove the air filter casing mounting bracket (1b).

- 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 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

See in Op. 5505A38 BODYSHELL POWER UNIT EARTH LEAD - R.R.- Secure the engine coolant radiator to the bodyshell, as appropriate.1. With the vehicle raised, undo the bolts (1a) fixing the bumper (1b) to the radiator mounting brackets, then remove the actual brackets.

- Position a container for collecting the power assisted steering fluid1. Undo the connectors on the power assisted steering pump for the fluid return (1a) and supply (1b) pipes, keeping the copper washers underneath.

1. Open the retaining clip (1a) on the timing belt protective covers and release the power assisted steering pipes (1b).

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. Secure a suitable bracket (1b) for supporting the power unit using the hook (1c) to the bracket (1a) on the engine for the rod (1d).2. Fit the tool (2a), complete with support mountings (2b), in the area in front of the suspension turret.

	Description	Code	Function
2a	Crossmember	1.870.595.000	Power unit support

	Description	Code	Function
2b	Support mountings	1.870.650.000	Power unit support

3. Fit the tools (3a) and (3b), then drill the latter to allow the positioning of the bracket (3c) and the bolt retaining it to the lower crossmember.

	Description	Code	Function
3a	Crossmember	1.860.851.003	Power unit support

	Description	Code	Function
3b	Vertical support	1.870.748.000	Power unit support

- Acting on the rod, tension the lifting system.

- Raise the lift1. Undo the fixing bolts (1a) and remove the heat shield (1b).

1. Open the retaining clip (1a) for the supply pipe (1b) from the pump to the steering box on the casing.

1. Undo the bolt (1a) fixing the supply pipe to the steering box (1b).2. Undo the connector and disconnect the supply pipe to the steering box, keeping the gaskets that are underneath.

Secure the pipe to the bodyshell, as best as possible, in order to prevent power assisted steering fluid leaks and to facilitate the subsequent operation of removing the frame.

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. 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. Completely lower the jack and release the front suspension frame (1a), complete with steering box (1b) and pipes with the exception of the supply pipe from the pump to the steering box.

Refitting ( Removing

) - Position the front suspension frame, complete with steering box and pipes, and raise the jack.1. Tighten the two front bolts (1a) fixing the frame (1b) to the bodyshell to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1a	13	Bolt	FRONT SUSPENSION SUBFRAME	M12 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 assembly1. 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 bolt (1a) fixing the rigid section of the supply pipe (1b) to the steering box to the recommended torque.2. Tighten the connector for the supply pipe to the power assisted steering box to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1a	0.5	Bolt	PIPE BTWN PUMP + POWER STEERING BOX	M6

	Value - daNm	Fastening	Component	Ø
2	4	Connector	PIPE BTWN PUMP + POWER STEERING BOX	M14 x1.5

- Close the retaining clip for the supply pipe from the pump to the steering box on the casing.- Position the heat shield and tighten the fixing bolts.- Lower the lift.- Remove the power unit support system.- Position the cable loom on the left suspension turret and secure the retaining band.- Secure the power assisted steering pipes to the timing belt covers closing the retaining band.1. Connect the connectors for the pump return (1a) and supply (1b) pipes, positioning the copper washers, then tighten them to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1a	4	Connector	POWER STEERING PUMP SUPPLY PIPE	M18 X 1.5

	Value - daNm	Fastening	Component	Ø
1b	4	Connector	POWER ASSISTED STEERING PUMP/BOX PIPE	M16 X 1.5

- With the vehicle raised, position the radiator mounting brackets, then tighten the bolts fixing the bumper to the mounting brackets.- Position the radiator on the mounting brackets. See in Op. 5505A38 BODYSHELL POWER UNIT EARTH LEAD - R.R.1. Working on the gearbox side, connect the electrical connection for the servotronic actuator 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 FRONT TRACK CONTROL ARMS	M12 x1.25

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	M10x.1.25

1. 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
1b	11.6	Bolt	FRONT DAMPER FORK ON WISHBONE	M12 X 1.25

	Value - daNm	Fastening	Component	Ø
1d	9	Bolt	LOWER FRONT TRACK CONTROL ARMS	M12 X 1.25

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

	Value - daNm	Fastening	Component	Ø
2b	5,5	Nut	FRONT ANTI-ROLL BAR	M10 X 1.25

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

	Value - daNm	Fastening	Component	Ø
3b	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
1b	Torque wrench	1.820.622.000	-

- Proceed in the same way for the engine side suspension.1. Position the air filter casing mounting bracket (1b), then tighten the two fixing nuts (1a) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1a	0.5	Nut	AIR CLEANER CASE MOUNT	M6

- 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.1. Connect the power assisted steering pipes (1b) to the heat exchanger (1c), then close the retaining bands (1a).

1. Secure the air conditioning system pipe (1b) to the retaining spring (1a) on the frame.2. Tighten the nuts (2a) fixing the coolant radiator mounting plates (2a) on the frame to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2a	0.5	Nut	COOLANT RADIATOR SUPPORT BEAM	M6

See in Op. 1088E10 Radiator cooling FAN - R.R. See in Op. 1048A11 COMPLETE AIR FILTER -R.R. See in Op. 1048A23 Cold AIR INTAKE for 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.- [5050A12]- Connect the flexible return pipe to the power assisted sterring fluid reservoir from the duplex pipes and tighten the retaining band. See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.- Left side See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.- Left side 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

- 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- See in Op. 4450A10 FRONT WHEEL GEOMETRY - Check using optical equipment - Includes front wheel toe-in adjustment if necessary See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.