1004D40 ENGINE - POSITION ON STAND AND REMOVE - Lancia - THESIS - eLearn

74570 - 1004D40 ENGINE - Position on stand and Remove

1. Loosen the bolts fixing the power assisted steering pump drive belt tensioner.2. Release and remove the power assisted steering pump drive belt.

1. Loosen the bolt fixing the alternator/air conditioningn compressor drive belt tensioner.2. Loosen the tension for the alternator/air conditioning compressor drive belt using the screw.3. Release and remove the alternator/air conditioning compressor drive belt.

1. Undo the nuts (1a), loosen the band (1b) and remove the pipe (1c) between the supply pipe and the water pump rigid inlet pipe.2. Undo the bolts (2a) and (2b) and remove the air conditioning compressor (2c).

1. Disconnect the electrical connections from the alternator.

	Description	Connector
1	Alternator	A010A

2. Undo the bolts (2a) and remove the alternator (2b).

1. Release the electrical wiring from the band on the injection/ignition control unit mounting.

1. Disconnect the electrical connection from the insufficient engine oil pressure sensor.

	Description	Connector
1	Insufficient engine oil pressure sensor	K030

2. Undo the bolt (2a) and the nut (2b) and remove the modular intake manifold mounting bracket (2c).

1. Undo the bolts fixing the supply/return pipes to the power assisted steering pump.

1. Undo the bolt (1a) fixing the power assisted steering pump using a suitable pin (1b) for counter-torque.2. Remove the power assisted steering pump pulley.

1. Release and remove the power assisted steering pump (1a) complete with pipes (1b) and electrical wiring (1c).

1. Undo the nuts (1a) and remove the exhaust manifold heat shields (1b).

1. Undo the nuts (1a) and remove the exhaust manifold (1b) complete with gasket.

1. Undo the bolts fixing the alternator/air conditioning compressor drive belt tensioner to the timing side rigid engine support.2. Undo the bolts (2a) and remove the timing side rigid engine support (2b).

1. Undo the bolt connecting the intermediate driveshaft bearing support to the crankcase sump.2. Undo the bolts (2a) and remove the intermediate driveshaft bearing support (2b).

- Undo the fastenings and remove the engine oil dipstick assembly.1. Fit the tool for positioning the engine on the overhaul stand.

	Description	Code	Function
1	Brackets	1.861.001.039	Positioning engine on overhaul stand

- Position the engine on the overhaul stand using a hydraulic hoist fitted with suitable chains.- REMOVAL FROM THE STAND- Remove the engine from the overhaul stand using a hydraulic hoist fitted with suitable chains.- Remove the tool for positioning the engine on the overhaul stand.

	Description	Code	Function
.	Brackets	1.861.001.039	Positioning engine on overhaul stand

- Place the engine oil dipstick in its housing and secure it using the fastenings.

	Value - daNm	Fastening	Component	Ø
.	0,8 - 1,2		OIL LEVEL DIPSTICK PIPE

1. Place the intermediate driveshaft bearing support (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	4.6 ÷ 6.6	Bolt	FRONT DRIVE SHAFT BEARING MOUNT	M10

2. Tighten the bolt connecting the intermediate driveshaft bearing support to the crankcase sump.

1. Place the timing side rigid engine support (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Timing side engine support side) 2.3 - 3.3	Bolt	ALT./AUXILIARY DRIVEBELT MOBILE VARIOUS	M8

2. Tighten the bolts fixing the alternator/air conditioning compressor drive belt tensioner to the timing side rigid engine support.

	Value - daNm	Fastening	Component	Ø
2	(Timing side engine support side) 2.3 - 3.3	Bolt	ALT./AUXILIARY DRIVEBELT MOBILE VARIOUS	M8

1. Place the exhaust manifold (1a), complete with gasket, back in its housing and secure it tightening the nuts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	2.3 - 3.3 (cylinder head side)	Nut	EXHAUST MANIFOLD/S	M8

- Place the exhaust manifold heat shields in their housings and secure them using the nuts.- Place the power assisted steering pump complete with pipes and electrical wiring in its housing.1. Place the power assisted steering pump pulley (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque using a suitable pin (1c) for counter-torque.

	Value - daNm	Fastening	Component	Ø
1b	2.3 - 3.3 (power assisted steering pump side)	Bolt	POWER STEERING PUMP DRIVE PULLEY	M8

	Value - daNm	Fastening	Component	Ø
.	(Power assisted steerign pump side) 9.2 - 13.3	Nut	POWER STEERING PUMP DRIVE PULLEY	M16

- Tighten the bolts fixing the supply/return pipes to the power assisted steering pump.- Place the modular intake manifold mounting bracket in its housing and secure it using the nut and the bolt.- Connect the electrical connection to the insufficient engine oil pressure sensor.- Fasten the electrical wiring to the band on the injection/ignition control unit mounting.1. Place the alternator (1a) in its housing and fasten it tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	4.6 - 6.6	Bolt	ALTERNATOR ASSEMBLY	M10

	Value - daNm	Fastening	Component	Ø
.	6.4 - 9.3	Bolt	ALTERNATOR ASSEMBLY	M12

2. Connect the electrical connections to the alternator.

1. Place the air conditioning compressor (1a) in its housing and fasten it tightening the bolts (1b) and (1c) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	2.3 - 3.3 (support side)	Bolt	COMPLETE AIR CONDITIONING COMPRESSOR	M8

	Value - daNm	Fastening	Component	Ø
1c	2.3 - 3.3 (support side)	Bolt	COMPLETE AIR CONDITIONING COMPRESSOR	M8

2. Place the pipe (2a) from the supply pipe to the water pump rigid inlet pipe in its housing and secure it using the nuts (2b).

	Value - daNm	Fastening	Component	Ø
2b	0.8 - 1.2	Nuts	COOLANT PUMP RIGID INLET PIPE	-

1. Fit the alternator/air conditioning compressor drive belt.2. Tension the alternator/air conditioning compressor drive belt using the screw.- Using the C.TRONIC G2 105.5 equipment or similar, check that the alternator/air conditioning compressor drive belt tension corresponds to the recommended figures.

	Subject	Value
.	Alternator/air conditioning compressor drive belt	daNm
-	Tension	63 - 80

- If the tension does not correspond to the recommended figures, regulate the adjustment screw.3. Tighten the bolt fixing the alternator/air conditioning compressor drive belt tensioner.

1. Fit the power assisted steering pump drive belt.2. Tension the power assisted steering pump drive belt using a polygonal spanner on the tensioner screw (2a), then tighten the bolts (2b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2b	(Timing side rigid power unit support) 2.3 ÷ 3.3	Bolt	ALT./AUXILIARY DRIVEBELT POWER ASSISTED STEERING PUMP	M8

- Using the tool, check that the power assisted steering pump belt tension corresponds to the recommended figures.

	Description	Code	Function
.	Torque wrench	1.895.762.000	Power steering pump drive belt tensioning

	Subject	Value
.	Power assisted steering pump drive belt	daNm
-	Tension	45 - 62

- If the tension does not correspond to the recommended figures, repeat the above operations.