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. See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R. See in Op. 5040A10 Air conditioning coolant circuit - Drying and Repressurizing- 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 See in Op. 7210E10 FRONT BUMPER- Position a suitable container for collecting the engine coolant.- Raise the lift.1. Disconnect the lower radiator pipe.

See in Op. 1016A40 Ignition COIL COVER on cylinder head - R.R. See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R. See in Op. 1048A23 Cold AIR INTAKE for air filter - R.R. See in Op. 1048A28 vacuum air circuit resonator pipe - r+r1. Undo the fixing nuts (1a) and remove the bonnet lock (1b) from the housing in the crossmember.2. Undo the lower bolt (2a) and remove the lock reinforcement bracket (2b).

1. Undo the retaining bolts.2. Remove the front crossmember.

1. Disconnect the upper radiator pipe.- Remove the container placed under the engine for collecting the drained coolant.

To disconnect both pipes, press the springs, manually, and release the rapid pipe connector from the attachments on the radiator.

See in Op. 1048A10 COMPLETE AIR FILTER -R.R.1. Undo the fixing bolt on the compressor (1a) and the bolt fixing the flange (1b) and remove the climate control system coolant return pipe (1c).

- Disconnect the electrical connections for the horns.

	Description	Connector
.	High tone horn	P010

	Description	Connector
.	High tone horn	P010

	Description	Connector
.	Low tone horn	P011

	Description	Connector
.	Low tone horn	P011

1. Disconnect the electrical connections (1a) and (1b) for the engine cables/fan-radiator cables coupling.

	Description	Connector
1a	Front/radiator coupling	D009A

	Description	Connector
1b	Front/radiator coupling	D009B

2. Disconnect the electrical connection from the air conditioning system pressure switch.

	Description	Connector
2	Linear sensor (for climate control)	K120

3. Undo the bolt fixing the air conditioning system pipe to the drier filter.

1. Undo the nut (1a) and disconnect the earth lead (1b) from the bodyshell.

	Description	Connector
1b	Right front earth	C011

1. Release the fastening band (1a) and disconnect the engine coolant pipe (1b) on the cylinder head.

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. Disconnect the retaining band for the hose connected to the resonator from the throttle casing.2. Disconnect the engine oil vapour recovery pipe (2a) from the cylinder head, disconnect the vacuum intake pipe (2b) from the brake servo, then remove the hose (2c).

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. Disconnect the electrical connection from the engine management control unit; release the electrical wiring from the retaining bands.

	Description	Connector
1	Engine management control unit	M010B

1. Disconnect the electrical connection for the engine/dashboard cable loom coupling.2. Disconnect the vacuum intake pipe from the brake servo.

1. Disconnect the engine coolant supply pipe (1a) and the return pipe (1b) to the passenger compartment heater; release the pipes from the retaining bands on the bodyshell.

1. Undo the bolt (1a), loosen the bolt (1b) and rotate the reaction rod connecting rod.2. Remove the band (2a) and disconnect the engine coolant recovery pipe (2b).

1. Disconnect the connector for the anti-evaporation system pipe.- Discharge the fuel pressure with the tool connected to the valve on the single fuel manifold pipe.

	Description	Code	Function
.	Rapid attachment connector	1.870.684.000	Single fuel manifold pipe complete with injectors

2. Disconnect the rapid attachment connector for the fuel supply pipe on the fuel manifold; release the pipe from the retaining band on the intake chamber.

1. Undo the bolts (1a) and remove the protective cover (1b), undo the power assisted steering fluid reservoir cap (1c) and draw off the fluid in the reservoir using a special syringe.

1. Undo the nuts (1a) and lift the power assisted steering fluid reservoir (1b).2. Disconnect the pump supply pipe (2a) from the power assisted steering fluid reservoir and the return pipe from the power assisted steering box (2b).

- Raise the vehicle on the lift.1. Undo the nut (1a) and disconnect the earth lead (1b) from the bellhousing.

	Description	Connector
1b	Left front earth	C010B

1. Loosen the bolts fixing the brake caliper to the steering knuckle.2. Remove the brake pipe retaining band.3. Disconnect the electrical connection for the brake pad wear sensor.

	Description	Connector
3	Left brake pad wear sensor (switch)	K020

	Description	Connector
3	Right brake pad wear sensor (switch)	K021

Take great care not to damage the brake fluid pipes and the electrical leads for the sensors, if necessary, release them from the bands on the steering knuckles.

- Undo the retaining bolt and remove the ABS flywheel sensor.1. Undo the retaining bolt.2. Undo the upper fixing nut (2a) and disconnect the end of the anti-roll bar connecting rod (2b).3. Undo the fixing nut (3a) and move the bodyshell accelerometer sensor (3b), complete with mounting bracket aside.

1. Undo the fixing bolts.2. Separate the two heads from the suspension housing.

1. Undo the fixing bolts loosened previously fixing the brake caliper.2. Remove the brake caliper and move it away from the work area securing it to the bodyshell without disconnecting the brake pipe connected to it.

Take care not to exert any pulling force on the brake pipe.

- Repeat the operations on the brake caliper and the suspension damper on the opposite side.- Disconnect the electrical connection for the headlamp alignment adjustment sensor (on both sides).

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

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. 1076B68 EXHAUST PIPE FLEXIBLE SECTION - R.R.- Lower the vehicle on the lift.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. If necessary, place a wooden block between the gearbox and the chassis.- Release the automatic transmission breather pipe from the retaining band.

1. Remove the protective plugs (1a) in the rear of the frame (1b).2. Position the tool for supporting the power unit-chassis assembly (2a), complete with hydraulic jack, under the housings in the engine support frame. Fit the rear pins (2b) for the tool by the openings underneath the protective plugs removed previously; rest the front pins (2c) for the tool in the front crossmember (2d).

	Description	Code	Function
2a	Power unit support frame	1.870.835.000	Removing-refitting power unit

1. Undo the bolts fixing the front supports.2. Undo the bolts (2a) fixing the rear supports and the bolts (2b) fixing the reinforcement brackets.3. Remove the reinforcement brackets.

1. Gradually lower the power unit complete with frame taking care not to damage the surrounding components.

Refitting ( Removing

) - Make sure that there are no obstacles or interference, raise the hydraulic jack and centre the power unit-frame in the engine compartment ensuring that the front and rear flexible mountings for the frame are aligned with the housings in the bodyshell.- Fit the frame reinforcement brackets and tighten the fixing bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.5	Bolt	CHASSIS RETAINING BRACKET	M8

- Tighten the rear bolts fixing the frame to the bodyshell to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	(to the bodyshell) 13	Rear bolt	FRONT SUSPENSION SUBFRAME	M12 X 1.25

- Tighten the front bolts fixing the frame to the bodyshell to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	(to the bodyshell) 13	Front bolt	FRONT SUSPENSION SUBFRAME	M12 X 1.25

- Remove the tool supporting the power unit - chassis assembly.

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

- Position the protective plugs in the rear of the frame.- Lower the vehicle.- Position a hydraulic jack under the bellhousing, then raise the power unit until the studs for the gearbox side flexible mounting are inserted in the openings in the bracket on the bodyshell.- Tighten the nuts fixing the gearbox side flexible mounting to the bracket on the bodyshell.

	Value - daNm	Fastening	Component	Ø
.	5	Nut	GEARBOX SIDE RUBBER MOUNT	M10X 1.25

- Secure the automatic transmission breather pipe to the retaining band.- Raise the vehicle on the lift. See in Op. 1076B68 EXHAUST PIPE FLEXIBLE SECTION - R.R.- Working on the gearbox side, connect the electrical connection for the servotronic actuator located on the steering box.

	Description	Connector
.	Servotronik solenoid valve	L070

- Connect the electrical connection for the headlamp alignment adjustment sensor (on both sides).

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

- Fit the brake caliper on both sides and screw in the fixing bolts without tightening them.- Connect the two ends of the suspension on both sides and secure them using the fastening bolts.

	Value - daNm	Fastening	Component	Ø
.	3.4	Bolt	UPPER FRONT TRACK CONTROL ARMS	M8

- Tighten the upper nut securing the anti-roll bar connecting rod on both sides.

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

- Tighten the bolt fixing the fork to the steering knuckle on both sides.

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

- Position the bracket complete with bodyshell accelerometer sensor on both sides and secure it using the bolt.- Fit the ABS sensor on both sides and position the cable in the special cable duct.- Connect the electrical connection for the brake pad wear sensor.

	Description	Connector
.	Left brake pad wear sensor (switch)	K020

	Description	Connector
.	Right brake pad wear sensor (switch)	K021

- Fasten the brake pipe retaining band.- Tighten the bolts fixing the brake calipers to the mounting brackets.

	Value - daNm	Fastening	Component	Ø
.	-	Bolt	FRONT DISC BRAKE CALIPERS COMPLETE

- Tighten the nut fixing the earth lead to the bellhousing.

	Description	Connector
.	Left front earth	C010B

- Connect the lower radiator pipe.- Lower the vehicle on the lift.- Connect the power assisted steering fluid reservoir supply pipe to the upmp and the return pipe to the power assisted steering box; fasten the pipes using the bands.- Position the power assisted steering fluid reservoir in the housing and secure it using the nuts.- Connect the rapid attachment connector for the fuel supply pipe on the fuel manifold; secure the pipe to the retaining band on the intake chamber.- Connect the connector for the fuel system pipe.- Connect the engine coolant recovery pipe and fasten it using the band.- Rotate the reaction rod connecting rod and tighten the fixing bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	(to bracket on bodyshell) 5	Bolt	POWER UNIT REACTION ROD	M10 X 1.25

	Value - daNm	Fastening	Component	Ø
.	(to engine support) 5	Bolt	POWER UNIT REACTION ROD	M10 X 1.25

- Connect the engine coolant supply pipe and the return pipe to the passenger compartment heater; secure the pipes to the retaining bands on the bodyshell.- Connect the vacuum intake pipe to the brake servo.- Connect the electrical connection for the engine/dashboard cable loom coupling.- Connect the electrical connection for the engine management control unit; secure the electrical wiring to the retaining bands.

	Description	Connector
.	Engine management control unit	M010B

- Connect the main gearbox wiring connectors.

	Description	Connector
.	Automatic transmission solenoid valves	L050A

	Description	Connector
.	Automatic transmission solenoid valves	L050B

	Description	Connector
.	Automatic transmission solenoid valves	L050C

- Position the hose joining the throttle casing to the resonator, then connect the engine oil vapour recovery pipe and the brake servo vacuum pipe to the cylinder head.- Position the gearbox bowden cable and secure the fasteners.- 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.

	Description	Connector
.	Contact board	A005A

	Description	Connector
.	Contact board	A005B

- Connect the engine coolant pipe to the cylinder head.- Tighten the nut fixing the earth lead to the bodyshell.

	Description	Connector
.	Right front earth	C011

- Tighten the bolt fixing the air conditioning system pipe to the drier filter.- Connect the electrical connection for the air conditioning system pressure switch.

	Description	Connector
.	Linear sensor (for climate control)	K120

- Connect the electrical connections for the engine cables/fan-radiator cables coupling.

	Description	Connector
.	Front/radiator coupling	D009A

	Description	Connector
.	Front/radiator coupling	D009B

- Connect the electrical connections for the horns.

	Description	Connector
.	High tone horn	P010

	Description	Connector
.	High tone horn	P010

	Description	Connector
.	Low tone horn	P011

	Description	Connector
.	Low tone horn	P011

- Position the climate control system coolant return pipe and secure the connectors to the compressor and the intermediate flange.- Connect the upper radiator pipe.- Fit the upper front crossmember and tighten the fixing bolts.- Fit the bonnet lock and the reinforcement bracket. See in Op. 1048A28 vacuum air circuit resonator pipe - r+r See in Op. 1048A23 Cold AIR INTAKE for air filter - R.R. See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R. See in Op. 1016A40 Ignition COIL COVER on cylinder head - R.R.- Raise the lift. See in Op. 7210E10 FRONT BUMPER

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