1004B10 POWER UNIT WITH MANUAL GEARBOX - R.R. - Lancia - THESIS - eLearn

74556 - 1004B10 POWER UNIT with manual gearbox - R.R.

) - 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.- Raise the vehicle on the lift. See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.- Position a suitable container for collecting the engine coolant.- Raise the lift.1. Disconnect the lower radiator pipe.

See in Op. 4450B12 Front WHEELS (two) - 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 nuts.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.

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. Undo the nut (2a) and disconnect the earth lead (2b) from the bodyshell.

	Description	Connector
2b	Right front earth	C011

1. Undo the retaining bolt.2. Disconnect the air conditioning system compressor pipe from the compressor.

1. Undo the bolts fixing the air conditioning system pipes to the drier filter.2. Undo the nuts fixing the filter to the condenser.3. Remove the drier filter.

1. Release the power assisted steering system cooling coil from the condenser.

See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R. See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R. See in Op. 7210E10 FRONT BUMPER1. Release the radiator-condenser-fan assembly from the lower fastenings and remove it through the top of the engine compartment.

See in Op. 1048A10 COMPLETE AIR FILTER -R.R. See in Op. 1016A40 Ignition COIL COVER on cylinder head - R.R.1. Disconnect the coolant pipe retaining band on the cylinder head.2. Undo the nut fixing the expansion tank (this nut also fastens the windscreen washer fluid reservoir).3. Disconnect the electrical connection for the engine coolant level.

	Description	Connector
3	Engine coolant level sensor	K026

4. Disconnect the pipe (4a) and lift up the expansion tank (4b) and remove it.

1. Undo the bolts fixing the headlamp washer jets to the crossmember.2. Move the headlamp washer jets away from the working area.

- Release the electrical wiring positioned under the crossmember, disconnecting the electrical connections for the horns.

	Description	Connector
	High tone horn	P010

	Description	Connector
.	Low tone horn	P011

	Description	Connector
.	High tone horn	P010

	Description	Connector
.	Low tone horn	P011

1. Undo the nuts (1a) fastening the Cruise Control to the crossmember, disconnect the electrical connection (1b) and remove the device.

	Description	Connector
1b	Cruise control system control unit (NAC)	M087

2. Undo the nuts fixing the crossmember to the strut.3. Remove the lower crossmember.

1. Undo the fixing bolt and disconnect the pipe from the connector on the compressor.2. Undo the fixing nut and separate the front section of the pipe from the rear section.3. Remove the front section of the air conditioning system high pressure pipe.

1. Disconnect the electrical connector (1a) for the front Lambda sensor and the compressor coupling (1b) from the compressor; disconnect the electrical connector (1c) for the rear Lambda sensor.

	Description	Connector
1a	Lambda sensor on catalyzer	K017

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

	Description	Connector
	Lambda sensor on catalyzer	K017

2. Undo the three nuts (2a) and the bolt (2b), then remove the exhaust manifold heat shield (2c).

1. Undo the nuts fixing the catalytic converter to the exhaust manifold.

1. Lift up the retaining spring (1a) and release the oil pipe (1b) for the hydraulic clutch release cylinder.2. Undo the nut (2a) and disconnect the earth lead (2b) from the gearbox.

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 from the ABS electronic control unit.

	Description	Connector
1	Braking system control unit (NFR)	M051

2. Disconnect the retaining band for the hose connected to the resonator from the throttle casing.3. Disconnect the engine oil vapour recovery pipe (3a) from the cylinder head, then remove the hose (3b).

1. Disconnect the coolant supply pipe (1a) to the engine oil heat exchanger and the heater supply pipe (1b) from the thermostat.

1. Open the protective cover (1a), loosen the nut (1b) and disconnect the starter motor supply lead (1c).

	Description	Connector
1c	Starter motor	A020A

1. Undo the three nuts (1a) fastening the flexible cables mounting bracket to the gearbox and the nut (1b) securing the starter motor earth lead mounting bracket.2. Press the two tabs (2a) and lift up the head (2b) until it is released from the ball joint.- Carry out this operation on the other flexible cable.3. Position the bracket, complete with flexible cables, outside of the working area.

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

1. Undo the bolt fixing the engine oil dipstick pipe.2. Remove the bolt (2a) and loosen the bolt (2b) securing the reaction rod; rotate the reaction rod forwards.

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

1. Disconnect the retaining band for the fluid supply pipe from the reservoir on the power assisted steering pump.2. Undo the connector on the power assisted steering pump supplying pressurized fluid to the power assisted steering box

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.

- Raise the lift.1. Undo the nuts fixing the flange joining the front and rear sections of the exhaust pipe.2. Undo the fastenings for the mounting bracket (2a) and remove the front section of the exhaust pipe (2b).

1. Disconnect the band for the left and right driveshafts secured to the differential and the intermediate driveshaft.

1. Undo the fixing bolts.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 accelerometer sensor (3b), complete with mounting bracket, aside.

1. Undo the fixing bolts.2. Separate the two heads from the suspension housing.3. Remove the suspension fork.- Move the steering knuckle backwards and release the three-lobe joints for the driveshafts from the housing in the differential and the intermediate shaft.

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.

1. Undo the nut (1a) fixing the timing side engine support (1b) to the supporting crossmember.

1. Undo the nut (1a) fixing the rear engine support (1b) to the supporting crossmember.

1. Position a bracket (1a) on the cylinder head and secure the chain and hook assembly (1b) to it.2. Position a bracket (2a) on the reaction rod support and secure the chain and hook assembly (1b) to it.3. Secure the chain and hook assembly to the exhaust manifold.4. Secure the chains to the hydraulic lifting device and tension the engine.

1. Undo the nut fixing the engine support to the flexible mounting.2. Undo the bolts fixing the engine support to the gearbox.3. Remove the engine support from the engine compartment.4. Disconnect the electrical connection on the gearbox for the reverse gear engagement sensor.

	Description	Connector
4	Reversing lights switch	I020

- Raise the engine slightly, turn the timing side towards the front of the vehicle and the gearbox side towards the rear, then remove the power unit from the engine compartment.- Position the power unit on a special support and remove the hoist, making sure that the unit is properly balanced.

Refitting ( Removing

) - Secure the power unit with chains for hoisting to the hydraulic lifting device.- Position the power unit in the vehicle, fitting the timing side engine support and the rear support on the flexible mounting bearings.- Tighten the nut fixing the rear engine support to the supporting crossmember.

	Value - daNm	Fastening	Component	Ø
.	(to crossmember) 5	Nut	RIGID REAR SUPPORT POWER UNIT	M10 X 1.25

- Tighten the nut fixing the timing side engine support to the supporting crossmember.

	Value - daNm	Fastening	Component	Ø
.	(to crossmember) 5	Nut	RIGID ENGINE MOUNT, TIMING SIDE	M10 X 1.25

- Position the engine suport and secure it to the bell housing.

	Value - daNm	Fastening	Component	Ø
.	(on gearbox) 5	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10 X 1.25

- Tighten the nut fixing the engine support to the flexible mounting.

	Value - daNm	Fastening	Component	Ø
.	(on flexible mounting) 5	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10 X 1.25

- Connect the electrical connection on the gearbox for the reversing lights switch.

	Description	Connector
.	Reversing lights switch	I020

- Release the engine from the supporting hooks.- Remove the brackets positioned for attaching the engine supporting hooks.- Fit the three-lobe joints for the driveshafts in their housings in the differential and the intermediate shaft.- Connect the two ends of the suspension and secure them using fastening bolts.

	Value - daNm	Fastening	Component	Ø
.	3.4	Bolt	FRONT SHOCK ABSORBERS (S.M.)	M8

- Tighten the upper nut securing the anti-roll bar connecting rod end.

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

- Tighten the bolts fixing the fork to the steering knuckle.

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

	Value - daNm	Fastening	Component	Ø
.	(to the shock absorber) 11.6	Bolt	FRONT DAMPER FORK ON WISHBONE	M12 X 1.25

- Position the bracket complete with accelerometer sensor and secure it using the bolt.- Fit the retaining bands for the left and right driveshaft boots on the differential and on the intermediate driveshaft.- Position the first section of the exhaust pipe and secure it to the flange joined with the rear section using the nuts.

	Value - daNm	Fastening	Component	Ø
.	(to cable centre section) 2.8	Nut	CATALYTIC CONVERTER (ONE)	M8

- Position the mounting bracket for the front section of the exhaust pipe.

	Value - daNm	Fastening	Component	Ø
.	(to catalytic converter) 2.8	Bolt	CATALYTIC CONVERTER MOUNT	M8

	Value - daNm	Fastening	Component	Ø
.	(on engine oil sump) 4	Nut	CATALYTIC CONVERTER MOUNT	M10 X 1.25

- Tighten the nuts fixing the catalytic converter to the exhaust manifold.

	Value - daNm	Fastening	Component	Ø
.	2.8	Nut	CATALYTIC CONVERTER (ONE)	M8

- Fit the exhaust manifold heat shield.- Fit the oil pipe for the hydraulic clutch release cylinder and secure it using the retaining spring.- Connect the earth lead to the bellhousing.- Position the mounting bracket for the gearbox flexible control cables and secure it using the fixing nuts.

	Value - daNm	Fastening	Component	Ø
.	(on bellhousing) 1.7	Nut	MANUAL GEARBOX LEVER SUPPORT (F)	M8

- Connect the ends of the flexible cables to the ball joints.- Fasten the mounting bracket for the starter motor earth lead using the nut.- Connect the electrical connection for the engine/dashboard cable loom coupling.- Connect the vacuum intake pipe to the brake servo.- Connect the starter motor supply lead, then reposition the protective cover.- Connect the electrical connection for the ABS electronic control unit.- 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 hose connected to the resonator to the throttle casing using the band.- Connect the oil vapour recovery pipe to the tappet cover using the band.- Connect the coolant supply pipe to the engine oil heat exchanger and the heater supply pipe to the thermostat.- 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 vapour recovery pipe.- Connect the retaining band for the fluid supply pipe from the reservoir on the power assisted steering pump.- Tighten the connector on the power assisted steering pump supplying pressurized fluid to the power assisted steering box.- Tighten the bolt fixing the engine oil dipstick pipe.- Position the connecting rod for the reaction rod and tighten the fixing bolts.

	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 upper radiator pipe to the thermostat.- Position the front section of the air conditioning system high pressure pipe and connect it to the rear section.- Connect the high pressure pipe connector to the compressor. See in Op. 1048A10 COMPLETE AIR FILTER -R.R.- Position the radiator-condenser-fan assembly on the lower supports.- Fit the drier filter and fasten it to the condenser.- Connect the air conditioning system pipes to the drier filter.- Connect the air conditioning system connector to the compressor.- Connect the electrical connection for the air conditioning compressor coupling.

	Description	Connector
.	Air conditioning compressor engagement electro-magnet	L020

- Connect the electrical connection for the front Lambda sensor.

	Description	Connector
.	Lambda sensor on catalyzer	K017

- Connect the electrical connection for the rear Lambda sensor.- Secure the power assisted steering system cooling coil to the condenser.- 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 earth lead to the bodyshell.- Connect the pipe with the upper rapid connector to the radiator.- Position the expansion tank and secure it using the nut.- Connect the pipe to the cylinder head.- Connect the coolant recovery pipe.- Connect the electrical connection for the engine coolant level.

	Description	Connector
.	Engine coolant level sensor	K026

- Position the lower crossmember and secure it to the strut and the wings.

	Value - daNm	Fastening	Component	Ø
.	2.5	Nut	CROSSMEMBER	M8

- Fit the Cruise Control and secure it to the lower crossmember using the nuts, then connect the electrical connection.

	Description	Connector
.	Cruise control system control unit (NAC)	M087

- Secure the electrical wiring positioned under the crossmember and 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

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