Workshop Manuals Factory service & repair Lancia
01 General information02 Specifications03 Manufacturing data and tolerances04 Tightening torques05 Fluids and lubricants06 Maintenance07 Diagnostic checks08 Engine09 Clutch10 Gearbox and differential11 Axles and driveshafts12 Brakes13 Steering14 Suspension and wheels15 Heating, air conditioning and auxiliary units16 Electrical equipment17 Body fittings18 Body panels and frame19 Wiring diagrams and electrical functions20 Wiring harnesses21 Connectors and pin-outs22 Fault diagnosis23 Service news bulletins24 Special tools
Lancia Thesis Factory Service Manual (2002-2009)14 · Suspension and wheels
14 · Steering & suspension

Front suspension FRAME - R.R.

Make
Lancia
Model
Thesis Factory Service Manual
Year
2002–2009
Section
Front suspension › Front suspension FRAME - R.R.
Suspension and wheelsFront suspension FRAME - R.R.

Front suspension FRAME - R.R.

Operation 4410D10 · FRAME AND CROSSMEMBER

3.0 V6, 3.2 V6

Removing

- 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.

Front suspension FRAME - R.R.

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

Front suspension FRAME - R.R.

- 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).

Front suspension FRAME - R.R.

- Position a suitable container for collecting the power assisted steering fluid

1. 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.

Front suspension FRAME - R.R.

- 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.

Front suspension FRAME - R.R.

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

Front suspension FRAME - R.R.

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.

Front suspension FRAME - R.R.

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

Front suspension FRAME - R.R.

- 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.

Front suspension FRAME - R.R.

1. Undo the nut (1a) fixing the steering box track rod end (1b) and disconnect it using the extractor (1c).

DescriptionCodeFunction
1cHead extractor1.847.035.000Extracting steering rod pin from stub axle
Front suspension FRAME - R.R.

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.

Front suspension FRAME - R.R.

1. Undo the fastenings (1a) securing the front track control arm (1b) to the frame.

Front suspension FRAME - R.R.

1. Undo the fastening (1a) securing the lower rear track control arm (1b) to the frame.

Front suspension FRAME - R.R.

1. Release the front suspension arm (1a) and the rear suspension arm (1b) from the frame, keeping the thrust washers.

Front suspension FRAME - R.R.

1. Release the wheel hub (1a) from the left driveshaft (1b) leaving the latter secured to the gearbox.

Front suspension FRAME - R.R.

- 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).

DescriptionConnector
1aHeadlamp alignment corrector front potentiometer (CAF)K001
Front suspension FRAME - R.R.

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.

Front suspension FRAME - R.R.

1. Working on the gearbox side, disconnect the electrical connection (1a) for the servotronic actuator (1b) located on the steering box.

DescriptionConnector
1aServotronik solenoid valveL070
Front suspension FRAME - R.R.

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.

Front suspension FRAME - R.R.

- Position a container for collecting the power assisted steering fluid

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

Front suspension FRAME - R.R.

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

Front suspension FRAME - R.R.

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.

DescriptionCodeFunction
2aCrossmember1.870.595.000Power unit support
DescriptionCodeFunction
2bSupport mountings1.870.650.000Power 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.

DescriptionCodeFunction
3aCrossmember1.860.851.003Power unit support
DescriptionCodeFunction
3bVertical support1.870.748.000Power unit support

- Acting on the rod, tension the lifting system.

Front suspension FRAME - R.R.

- Raise the lift

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

Front suspension FRAME - R.R.

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

Front suspension FRAME - R.R.

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.

Front suspension FRAME - R.R.

1. Undo the bolt (1a) fixing the timing side engine support (1b).

Front suspension FRAME - R.R.

1. Undo the nut (1a) fixing the centre rear engine support (1b).

Front suspension FRAME - R.R.

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).

DescriptionCodeFunction
1aPower unit support frame1.870.835.000Removing-refitting power unit
Front suspension FRAME - R.R.

1. Undo the two rear bolts (1a) and the front bolt (1b) fixing each of the two rear engine mounting brackets (1c).

Front suspension FRAME - R.R.

1. Undo the two front bolts (1a) fixing the frame (1b) to the bodyshell.

Front suspension FRAME - R.R.

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.

Front suspension FRAME - R.R.

Refitting

- 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 - daNmFasteningComponentØ
1a13BoltFRONT SUSPENSION SUBFRAMEM12 X 1.25
Front suspension FRAME - R.R.

1. Tighten the two rear bolts (1a) and the front bolt (1b) fixing each of the two rear engine mounting brackets (1c).

Value - daNmFasteningComponentØ
1a5BoltFRONT SUSPENSION SUBFRAMEM10 X 1.25
Value - daNmFasteningComponentØ
1b13BoltFRONT SUSPENSION SUBFRAMEM12 X 1.25
Front suspension FRAME - R.R.

- Remove the tool supporting the power unit - chassis assembly

1. Tighten the nut (1a) fixing the centre rear engine support (1b) to the recommended torque.

Value - daNmFasteningComponentØ
1a(to the flexible mounting) 4NutRIGID REAR SUPPORT POWER UNITM10
Front suspension FRAME - R.R.

1. Tighten the nut (1a) fixing the timing side engine support (1b) to the recommended torque.

Value - daNmFasteningComponentØ
1a(Engine support) 4.5NutRIGID ENGINE MOUNT, TIMING SIDEM10 X 1.25
Front suspension FRAME - R.R.

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 - daNmFasteningComponentØ
1a0.5BoltPIPE BTWN PUMP + POWER STEERING BOXM6
Value - daNmFasteningComponentØ
24ConnectorPIPE BTWN PUMP + POWER STEERING BOXM14 x1.5
Front suspension FRAME - R.R.

- 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 - daNmFasteningComponentØ
1a4ConnectorPOWER STEERING PUMP SUPPLY PIPEM18 X 1.5
Value - daNmFasteningComponentØ
1b4ConnectorPOWER ASSISTED STEERING PUMP/BOX PIPEM16 X 1.5
Front suspension FRAME - R.R.

- 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.

DescriptionConnector
1aServotronik solenoid valveL070
Front suspension FRAME - R.R.

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 - daNmFasteningComponentØ
1a2.8NutEXHAUST PIPE MOUNTS/FASTENERSM8
Front suspension FRAME - R.R.

1. Connect the electrical connection (1a) for the headlamp alignment adjustment sensor (1b).

DescriptionConnector
1aHeadlamp alignment corrector front potentiometer (CAF)K001
Front suspension FRAME - R.R.

- 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 - daNmFasteningComponentØ
1a10BoltLOWER FRONT TRACK CONTROL ARMSM12 x1.25
Front suspension FRAME - R.R.

1. Tighten the bolts (1a) fixing the lower front track control arm (1b) to the frame to the recommended torque.

Value - daNmFasteningComponentØ
1a7.4BoltLOWER FRONT TRACK CONTROL ARMSM10x.1.25
Front suspension FRAME - R.R.

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 - daNmFasteningComponentØ
1b11.6BoltFRONT DAMPER FORK ON WISHBONEM12 X 1.25
Value - daNmFasteningComponentØ
1d9BoltLOWER FRONT TRACK CONTROL ARMSM12 X 1.25

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

Value - daNmFasteningComponentØ
2b5,5NutFRONT ANTI-ROLL BARM10 X 1.25

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

Value - daNmFasteningComponentØ
3b0.4BoltJOLTING SENSORM5
Front suspension FRAME - R.R.

- Connect the steering track rod end to the steering knuckle and tighten the fixing nut to torque.

Value - daNmFasteningComponentØ
4.5NutADJUSTABLE LINK BALL JOINTSM10 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 - daNmFasteningComponentØ
7NutFRONT HUBS COMPLETE WITH BEARINGM24
DescriptionCodeFunction
1bTorque wrench1.820.622.000

- 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 - daNmFasteningComponentØ
1a0.5NutAIR CLEANER CASE MOUNTM6
Front suspension FRAME - R.R.

- 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).

Front suspension FRAME - R.R.

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 - daNmFasteningComponentØ
2a0.5NutCOOLANT RADIATOR SUPPORT BEAMM6
Front suspension FRAME - R.R.

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 - daNmFasteningComponentØ
2BoltSTEERING SHAFT MOUNTINGM8

- 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.

2.0 TB, 2.4 20V, 2.4 JTD 10V, 2.4 JTD 20V

Removing

- 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. 4450B12 Front WHEELS (two) - R.R.

See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.

- (both sides).

See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.

- (both sides).

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

See in Op. 7210E10 FRONT BUMPER

2.4 20V

See in Op. 1016A40 Ignition COIL COVER on cylinder head - 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. 1048A10 COMPLETE AIR FILTER -R.R.

See in Op. 1088B10 Engine coolant SUPPLY RESERVOIR - R.R.

See in Op. 1008C10 Power unit REACTION ROD - Replace

2.4 JTD 10V

See in Op. 1016A10 SOUND-PROOFING COVER - R.R.

See in Op. 1048A28 vacuum air circuit resonator pipe - r+r

See in Op. 1048A21 Cold AIR INTAKE PIPE for air filter - R.R.

See in Op. 1048A10 AIR FILTER CASING - R.R.

See in Op. 1088B10 Engine coolant SUPPLY RESERVOIR - R.R.

See in Op. 1008C10 Power unit REACTION ROD - Replace

2.0 TB

See in Op. 1016A40 Ignition COIL COVER on cylinder head - R.R.

See in Op. 4130B14 Power assisted steering fluid reservoir cap - R.R. - Check fluid level and top up if necessary

See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R.

See in Op. 1048A50 air inlet pipe to turbocharger - r + r

See in Op. 1048A10 COMPLETE AIR FILTER -R.R.

See in Op. 1088E10 Radiator cooling FAN - R.R.

See in Op. 1048B14 air delivery pipe between turbo charger and heat exchanger - replace

See in Op. 1088B10 Engine coolant SUPPLY RESERVOIR - R.R.

See in Op. 1008C10 Power unit REACTION ROD - Replace

2.4 JTD 20V

See in Op. 1016A10 SOUND-PROOFING COVER - R.R.

See in Op. 1048B44 RIGID air supply PIPE from heat exchanger to intake manifold - R.R.

See in Op. 1048A56 UPPER RESONATOR - R.R.

See in Op. 1048A50 air inlet pipe to turbocharger - r + r

See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R.

See in Op. 1048A10 COMPLETE AIR FILTER -R.R.

See in Op. 1088B10 Engine coolant SUPPLY RESERVOIR - R.R.

See in Op. 1008C10 Power unit REACTION ROD - Replace

2.0 TB, 2.4 20V, 2.4 JTD 10V, 2.4 JTD 20V

1. Remove the bands (1a) and disconnect the power assisted steering system pipes (1b) from the cooling coil.

Collect the power assisted steering fluid that comes out in a suitable container.

Front suspension FRAME - R.R.

1. Undo the connector on the steering box for the pressurized fluid supply pipe from the pump.

- Release the power assisted steering system pipes from the retaining bands.

Front suspension FRAME - R.R.

2.4 20V

See in Op. 1076B68 EXHAUST PIPE FLEXIBLE SECTION - R.R.

2.4 JTD 10V, 2.4 JTD 20V

See in Op. 1076B50 Exhaust PIPE attachment to engine/manifold - R.R.

2.0 TB

See in Op. 1072C44 Exhaust manifold heat shield on BULKHEAD - R.R.

See in Op. 1080B40 CATALYTIC PRECONVERTER - R.R.

See in Op. 1076B70 EXHAUST PIPE BETWEEN PRECATALYZER AND CATALYZER - R.R.

2.0 TB, 2.4 20V, 2.4 JTD 10V, 2.4 JTD 20V

1. Disconnect the band connector the flexible section of the return pipe to the power assisted steering fluid reservoir to the rigid section.

Front suspension FRAME - R.R.

- Secure the radiator-condenser-fan assembly to the upper crossmember.

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.

Front suspension FRAME - R.R.

1. Fit a suitable bracket on the cylinder head for supporting the power unit.

2. Fit a suitable hook (2a) on one side of the power assisted steering pump mounting bracket for support and a drilled plate (2b) on the other side, then fasten the two components using a large bolt.

Take care not to damage the rubber support mounting for the power assisted steering pump.

3. Fit the tool (3a), complete with support mountings (3b), in the area in front of the suspension turret.

DescriptionCodeFunction
3aCrossmember1.870.595.000Power unit support
DescriptionCodeFunction
3bSupport mountings1.870.650.000Power unit support

4. Fit the tools (4a) and (4b), then connect them to the bracket on the cylinder head using the rod (4c). Make a hole in the bracket (4b) to allow the positioning of the bracket (4d) and the bolt retaining it to the lower crossmember.

DescriptionCodeFunction
4aCrossmember1.860.851.003Power unit support
DescriptionCodeFunction
4bVertical support1.870.748.000Power unit support

5. Position a rod (5a) and connect it to the exhaust manifold using chains (5b).

Loosen the heat shield upper fastenings to allow the attachment of the chains to the exhaust manifold.

6. Position a rod and connect it to the bracket fitted on the power assisted steering pump mounting.

7. Join the crossmembers fitted for supporting the power unit using bolts.

Do not alter the attachment points for different engine types. Always keep the mounting points in the positions illustrated to keep the engine balanced.

Front suspension FRAME - R.R.

1. Undo the nuts fixing the track control arms to the steering knuckle.

Front suspension FRAME - R.R.

1. Extract the front track control arm head (1a) from the steering knuckle using a USAG-FACOM U.16A32 type extractor (1b) or a similar tool.

Front suspension FRAME - R.R.

1. Extract the rear track control arm head (1a) from the steering knuckle using a USAG-FACOM U.16A32 type extractor (1b) or a similar tool.

Front suspension FRAME - R.R.

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 bolt (3a) and move the accelerometer sensor (3b), complete with mounting bracket, aside.

4. Remove the suspension fork.

Front suspension FRAME - R.R.

1. Undo the nut.

2. Extract the steering rod end (2a) using the extractor (2b).

DescriptionCodeFunction
2bHead extractor1.847.035.000Extracting steering rod pin from stub axle
Front suspension FRAME - R.R.

1. Disconnect the electrical connector for the headlamp alignment potentiometer.

DescriptionConnector
1Headlamp alignment corrector front potentiometer (CAF)K001
Front suspension FRAME - R.R.

1. Working from inside the vehicle, undo the bolt fixing the lower steering conttol shaft to the steering box pinion.

Front suspension FRAME - R.R.

1. Undo the nut (1a) fixing the timing side rigid engine support (1b) to the flexible mounting.

Front suspension FRAME - R.R.

1. Undo the nut (1a) fixing the rigid rear support (1b) to the flexible mounting.

Front suspension FRAME - R.R.

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).

DescriptionCodeFunction
1aPower unit support frame1.870.835.000Removing-refitting power unit
Front suspension FRAME - R.R.

1. Undo the two rear bolts (1a) and the front bolt (1b) fixing each of the two rear engine mounting brackets (1c).

Front suspension FRAME - R.R.

1. Undo the two front bolts (1a) fixing the frame (1b) to the bodyshell.

Front suspension FRAME - R.R.

1. At the bench, undo the bolts (1a), disconnect the connector (1b) for the return pipe, then remove the power assisted steering box (1c).

Front suspension FRAME - R.R.

1. Undo the bolts (1a) fixing the u-bolts (1b) retaining the anti-roll bar.

2. Undo the nuts fixing the headlamp alignment corrector potentiometer connecting rod.

- Remove the anti-roll bar

Front suspension FRAME - R.R.

1. Undo the fixing nuts and remove the air filter mounting bracket.

2. Undo the fixing nuts and remove the engine cooling radiator mounting brackets.

Front suspension FRAME - R.R.

1. Undo the bolt (1a) and the nuts (1b) retaining the power assisted steering pipes mounting brackets.

2. Remove the power assisted steering system pipes.

Front suspension FRAME - R.R.

1. Undo the bolts (1a) and remove the front flexible mounting (1b) and the rear flexible mounting (1c).

Front suspension FRAME - R.R.

1. Undo the bolts (1a) and remove the track control arms (1b).

2. Undo the bolts (2a) and remove the headlamp alignment corrector potentiometer (2b).

Front suspension FRAME - R.R.

Refitting

- Proceed with refitting the components removed at the bench.

- Fit the headlamp alignment corrector potentiometer.

- Fit the track control arms.

Value - daNmFasteningComponentØ
(to the chassis) 10BoltLOWER FRONT TRACK CONTROL ARMSM12 X 1.25

- Position the power assisted steering pipes and secure them using the mounting brackets.

- Position the engine cooling radiator mounting brackets.

- Position the air filter assembly mounting bracket and secure it to the crossmember using the fixing nuts.

- Connect the nut fixing the headlamp alignment corrector potentiometer connecting rod.

- Position the anti-roll bar and the retaining u-bolts, then tighten the fixing bolts on the crossmember to the recommended torque.

Value - daNmFasteningComponentØ
3.5BoltFRONT ANTI-ROLL BAR SUPPORTSM8

- Position the power assisted steering box and fasten it to the frame tightening the bolts to the recommended torque.

Value - daNmFasteningComponentØ
11BoltCOMPLETE POWER ASSISTED STEERING BOXM12 X 1.25
Value - daNmFasteningComponentØ
1.5BoltCOMPLETE POWER ASSISTED STEERING BOXM8

- Connect the connector for the return pipe to the reservoir to the steering box.

Value - daNmFasteningComponentØ
3BoltRETURN PIPE TO POWER STEERING RESERVOIRM12 X 1.5

- Position the front suspension crossmember, supported by the special tool, in the vehicle.

Fit the steering box pinion in the opening in the bodyshell.

- Position the reinforcement brackets, then tighten the bolts fixing the front suspension crossmember to the bodyshell to the recommended torque.

Value - daNmFasteningComponentØ
13BoltFRONT SUSPENSION SUBFRAMEM12 X 1.25

- Remove the tool supporting the front suspension frame.

DescriptionCodeFunction
Power unit support frame1.870.835.000Removing-refitting power unit

- Position a hydraulic lift under the engine, raise it slightly to allow the timing side flexible mounting to be fitted on the support, then tighten the bolts fixing it to the frame to the recommended torque.

The hydraulic lift only has to be raised slightly. Proceed very cautiously.

Value - daNmFasteningComponentØ
(to the chassis) 5BoltFRONT FLEXIBLE MOUNTING BLOCKS, POWER UNITM10X 1.25

- Position a hydraulic lift under the engine, raise it slightly to allow the rear flexible mounting to be fitted on the support, then tighten the bolts fixing it to the frame to the recommended torque.

The hydraulic lift only has to be raised slightly. Proceed very cautiously.

Value - daNmFasteningComponentØ
(to the chassis) 5BoltINTERM RUBBER MOUNTM10X 1.25

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

Value - daNmFasteningComponentØ
(to the flexible mounting) 5NutRIGID ENGINE MOUNT, TIMING SIDEM10X 1.25

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

Value - daNmFasteningComponentØ
(to the flexible mounting) 5NutRIGID REAR SUPPORT POWER UNITM10 X 1.25

- Tighten the bolt fixing the lower steering conttol shaft to the steering box pinion.

Value - daNmFasteningComponentØ
(to the steering box pinion) 2BoltFIXED ELEMENTS STEERING SHAFT STEERINGM8

- Connect the electrical connector for the headlamp alignment potentiometer.

DescriptionConnector
Headlamp alignment corrector front potentiometer (CAF)K001

- Connect the steering rod ends and tighten the nuts fixing them to the steering knuckles to torque.

Value - daNmFasteningComponentØ
(to the steering knuckle) 4.5BoltADJUSTABLE STEERING ROD ENDSM10 X 1.25

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

Value - daNmFasteningComponentØ
5.5NutFRONT ANTI-ROLL BAR JOINTSM10 X 1.25

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

Value - daNmFasteningComponentØ
(to the lower front rod) 9BoltFRONT DAMPER FORK ON WISHBONEM12 x 1.25
Value - daNmFasteningComponentØ
(to the shock absorber) 11.6BoltFRONT DAMPER FORK ON WISHBONEM12 X 1.25

- Position the bracket complete with accelerometer sensor and secure it using the bolt.

- Fit the front and rear track control arm heads to the steering knuckle and tighten the fixing nuts to the recommended torque.

Value - daNmFasteningComponentØ
(to the steering knuckle) 9NutLOWER FRONT TRACK CONTROL ARMSM14 X 1.5
Value - daNmFasteningComponentØ
(to the steering knuckle) 8.8NutLOWER FRONT TRACK CONTROL ARMSM12 X 1.25

- Remove the tools and the power unit mounting brackets.

DescriptionCodeFunction
Crossmember1.870.595.000Power unit support
DescriptionCodeFunction
Support mountings1.870.650.000Power unit support
DescriptionCodeFunction
Crossmember1.860.851.003Power unit support
DescriptionCodeFunction
Vertical support1.870.748.000Power unit support

- Reposition the cable loom on the left front suspension turret and secure it to the retaining band.

- Release the radiator-condenser-fan assembly from the upper crossmember.

- Connect the flexible and rigid sections of the return pipe to the power assisted steering reservoir; secure the pipes using the retaining band

2.4 20V

See in Op. 1076B68 EXHAUST PIPE FLEXIBLE SECTION - R.R.

2.4 JTD 10V, 2.4 JTD 20V

See in Op. 1076B50 Exhaust PIPE attachment to engine/manifold - R.R.

2.0 TB

See in Op. 1076B70 EXHAUST PIPE BETWEEN PRECATALYZER AND CATALYZER - R.R.

See in Op. 1080B40 CATALYTIC PRECONVERTER - R.R.

See in Op. 1072C44 Exhaust manifold heat shield on BULKHEAD - R.R.

2.0 TB, 2.4 20V, 2.4 JTD 10V, 2.4 JTD 20V

- Connect the connector on the steering box for the pressurized fluid supply pipe from the pump.

Value - daNmFasteningComponentØ
4BoltPIPE BTWN PUMP + POWER STEERING BOXM14 X 1.5

- Connect the power assisted steering system pipes to the cooling coil.

2.4 JTD 20V

See in Op. 1008C10 Power unit REACTION ROD - Replace

See in Op. 1088B10 Engine coolant SUPPLY RESERVOIR - R.R.

See in Op. 1048B14 air delivery pipe between turbo charger and heat exchanger - replace

See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R.

See in Op. 1048A50 air inlet pipe to turbocharger - r + r

See in Op. 1048A56 UPPER RESONATOR - R.R.

See in Op. 1048B44 RIGID air supply PIPE from heat exchanger to intake manifold - R.R.

See in Op. 1016A10 SOUND-PROOFING COVER - R.R.

2.0 TB

See in Op. 1008C10 Power unit REACTION ROD - Replace

See in Op. 1088B10 Engine coolant SUPPLY RESERVOIR - R.R.

See in Op. 1048B14 air delivery pipe between turbo charger and heat exchanger - replace

See in Op. 1088E10 Radiator cooling FAN - R.R.

See in Op. 1048A10 COMPLETE AIR FILTER -R.R.

See in Op. 1048A50 air inlet pipe to turbocharger - r + r

See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R.

See in Op. 4130B14 Power assisted steering fluid reservoir cap - R.R. - Check fluid level and top up if necessary

See in Op. 1016A40 Ignition COIL COVER on cylinder head - R.R.

2.4 JTD 10V

See in Op. 1008C10 Power unit REACTION ROD - Replace

See in Op. 1048A10 AIR FILTER CASING - R.R.

See in Op. 1048A21 Cold AIR INTAKE PIPE for air filter - R.R.

See in Op. 1048A28 vacuum air circuit resonator pipe - r+r

See in Op. 1016A10 SOUND-PROOFING COVER - R.R.

See in Op. 4130B14 Power assisted steering fluid reservoir cap - R.R. - Check fluid level and top up if necessary

2.4 20V

See in Op. 1008C10 Power unit REACTION ROD - Replace

See in Op. 1048A10 COMPLETE AIR FILTER -R.R.

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. 1016A40 Ignition COIL COVER on cylinder head - R.R.

See in Op. 4130B14 Power assisted steering fluid reservoir cap - R.R. - Check fluid level and top up if necessary

2.0 TB, 2.4 20V, 2.4 JTD 10V, 2.4 JTD 20V

See in Op. 4130B14 Power assisted steering fluid reservoir cap - R.R. - Check fluid level and top up if necessary

See in Op. 7210E10 FRONT BUMPER

See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.

See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.

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

- Connect the negative battery lead.

See in Op. 0010T20 Engine REFRIGERANT FLUID - Change

See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.

- Remove the vehicle from the lift.

- The power assisted steering system is self-bleeding, proceed as described below.

- Start the engine and carry out 4 -5 complete steering wheel rotation cycles (left and right).

- Top up the power assisted steering fluid level in the reservoir

See in Op. 4450A10 FRONT WHEEL GEOMETRY - Check using optical equipment - Includes front wheel toe-in adjustment if necessary

Parts & tools for this job Staging For 2002 Lancia Thesis

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