1004D20 POWER UNIT (AUTOMATIC TRANSMISSION), REMOVED - SEPARATE AND REASSEMBLE - Lancia - THESIS - eLearn

183469 - 1004D20 POWER UNIT (automatic transmission), removed - Separate and reassemble

) - Position a container for collecting the transmission fluid1. Undo the transmission fluid drain plug.

1. Disconnect the electrical connection for the right Lambda sensor

	Description	Connector
1	Lambda sensor on pre-catalyzer	K015

1. Undo the fixing nuts (1a) and remove the right head pre-catalyzer (1b) complete with Lambda sensor and gasket underneath.

1. Undo the fixing nuts (1a) and diconnect the starter motor electrical leads (1b).

	Description	Connector
1a	Starter motor	A020A

	Description	Connector
1a	Starter motor	A020B

2. Undo the fixing bolts and remove the motor, taking care to use the spanner (2b) for the bolt (2a).

	Description	Code	Function
2b	Spanner	1.850.095.001	Tightening starter motor fixing bolt

1. Undo the fixing bolts (1a) and remove the intermediate driveshaft (1b).

1. Undo the six bolts (1a), one at a time, fixing the torque converter to the engine flywheel (1b), turning it manually.

1. Open the bands (1a) and disconnect the rubber coolant supply pipe (1b) to the automatic transmission (1c) water/oil heat exchanger.

1. Lift the power unit and undo the two bolts (1a) fixing the protection (1b) and the rpm sensor underneath, then undo the three fixing bolts (1c) and remove the flywheel guard (1d).

	Description	Connector
.	Rpm sensor	K046

1. Undo the two fixing bolts (1a) and remove the gearbox bowden cable bracket (1b).2. Undo the six front bolts on the bellhousing securing it to the engine.

1. Undo the rear bolt fixing the gearbox to the engine

- Remove the gearbox with the help of a second mechanic.1. If necessary, remove the converter using two threaded bolts for assistance.

Refitting ( Removing

) 1. If the torque converter has been removed previously, place it in the bellhousing, taking care to ensure that the gearbox side of the converter is correctly positioned, then remove the bolts used for assistance.

- Refit the gearbox with the help of a second mechanic.- Tighten the rear bolt fixing the gearbox to the engine to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	5.5	Rear bolt	AUTO TRANSMISSION	M10 X 1.5

- Tighten the six front bolts on bellhousing fixing it to the engine to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	5,5	Rear bolt	AUTO TRANSMISSION	M10

- Position the gearbox bowden cable bracket, then tighten the two bolts fixing it to the gearbox to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2,5	Bolt	GEAR ENGAGEMENT CABLE	M8

- Position the flywheel guard and tighten the three fixing bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	0,8	Bolt	PROP SHAFT RETAINING STUD	M6

- Position the rpm sensor and the protective plate, tightening the fixing bolts.

	Description	Connector
	Rpm sensor	K046

- Connect the automatic transmission water/oil heat exchanger rubber coolant supply pipe and close the retaining band.- Tighten the six bolts (1a), one at a time, fixing the torque converter to the engine flywheel, turning it manually.

	Value - daNm	Fastening	Component	Ø
.	3,2	Bolt	AUTO TRANSMISSION TORQUE CONVERTER	M8

- Position the intermediate driveshaft and tighten the fixing bolts.

	Value - daNm	Fastening	Component	Ø
	2,9	Bolt	INTERMEDIATE DRIVE SHAFT	M8

- Position the starter motor and tighten the fixing bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
	2.7	Bolt	STARTER MOTOR	M8

- Position the starter motor leads and tighten the fixing nuts.

	Description	Connector
.	Starter motor	A020A

	Value - daNm	Fastening	Component	Ø
.	0.5	Nut	STARTER MOTOR	M8

	Value - daNm	Fastening	Component	Ø
.	0.9	Nut	STARTER MOTOR	M8

	Description	Connector
.	Starter motor	A020B

- Position the right head pre-catalyzer, complete with Lambda sensor and gasket underneath, then tighten the nuts fixing it to the cylinder block/crankcase to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2,8	Bolt	EXHAUST MANIFOLD/S	m8

- Connect the electrical connection for the right Lambda sensor

	Description	Connector
.	Lambda sensor on pre-catalyzer	K015

- Connect the electrical connection for the right Lambda sensor.- Fit the gearbox oil drain plug tightening it to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	-	-	AUTO TRANSMISSION FLUID