1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL - Lancia - MUSA - eLearn

184000818 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

) Take the cylinder head to the workbench.1. Use a nut and locknut to unscrew the stud.2. Fit tool (2a) to cylinder head (2b) and secure using nuts (2c).

	Name	Country
2a	Support	1.860.470.000

Position the tool in the vice.1. Loosen the manifold side connectors of the pipes leading from the fuel manifold to the injectors.2. Undo the injector side connectors of the pipes leading from the fuel manifold to the injectors.3. Undo the nuts (3a) and remove the fuel distributor manifold (3b), complete with pipes and fuel pressure sensor (3c).

	Name	Connector
3c	Fuel pressure sensor	K83

4. Remove clips (4a) and remove the fuel return pipe for lubricating injectors (4b).Undo the nuts and disconnect the supply wiring from the heater plugs.

	Name	Connector
-	Heater plug	A40

Disconnect the coolant return pipe to the expansion tank and system vent pipe from the thermostat.5. Undo the nuts (5a) and remove the complete air intake manifold (5b).

1. Undo bolts (1a) and remove vacuum pump (1b) complete with gasket.2. Undo bolts (2a) and remove thermostat (2b) complete with pipe, sensors and O-ring.

1. Undo the bolt (1a) for the driven pulley using the tools (1b).

	Name	Country
1b	Support for counter-torque	1.860.831.000

2. Remove the toothed driven pulley.3. Undo bolts (3a) and remove timing sensor (3b).

	Name	Connector
3b	Timing sensor.	K47

4. Undo bolts (4a) and remove water pump (4b) complete with O-ring (4c).

1. Undo nuts (1a) and remove injector bracket (1b).2. Remove injectors (2a) complete with seals (2b).

	Name	Connector
2a	Injector	N70

3. Remove the injector bracket support pads.4. Remove the heater plugs.

	Name	Connector
4	Heater plug	A40

Check that the end float of the camshaft is within the recommended values using a dial gauge.

	Measurement		Value
-	End float (mm)		0.100 - 0.230

If the end float of the camshaft is not within the recommended values, when reassembling the cylinder head, replace the worn components.1. Undo the camshaft cap bolts.2. Remove the camshaft support lubrication pipe.3. Remove the camshaft caps.

When dismantling, mark the camshaft caps with a progressive number so that they can be refitted in the correct order.

4. Remove the camshaft.5. Remove the camshaft front oil seal.6. Remove the cups complete with valve clearance adjustment pads.

When dismantling, mark the cups with a progressive number so that they can be refitted in the correct order.

Release the cylinder head from the vice.Place a wooden board on the cylinder head surface to support the valves and bolt in place.Secure the cylinder head to the clamp.1. Remove cotters (1a) using tool (1b).

	Name	Country
1b	Tool	1.860.644.000

2. Remove the upper valve shim.3. Remove the valve spring.

1. Remove valve guide oil seal (1a) using tool (1b) A.

	Name	Country
1b	Extractor	1.860.989.000

2. Remove the lower shim.Work in the same way on the other valves.Release the cylinder head from the clamp and place on the workbench.Remove the wooden board and recover the valves.

Mark the valves with a progressive number so that they can be refitted in the correct order.

Remove the support tool from the cylinder head.

	Name	Country
-	Support	1.860.470.000

1. Remove valve guides (1a) using tool (1b).

	Name	Country
1b	Extractor	1.860.395.001

Refitting ( Removing

) Clean the residues of the old gasket from the lower surface of the cylinder head.Check that the planarity of the lower cylinder head surface is within the recommended values.

	Measurement		Value
-	Flatness of bottom surface (mm)		0.1

1. If the planarity of the lower cylinder head surface is not within the recommended values, regrind the lower cylinder head surface without exceeding the minimum permissible height.

	Measurement		Value
1	Permissible minimum height (mm)		140.6

Check that the valves do not show signs of scoring or seizing.Check that the diameter of the valve stems is within the recommended values; if this is not the case, replace the worn valves.

	Measurement		Value
-	Stem diameter (mm)		7.974 - 7.992

Check that the outer diameter of the cups is within the recommended values. if this is not the case, replace the worn parts.

	Measurement		Value
-	Outer diameter (mm)		36.975 - 36.995

Check that the diameter of the cup housings are within the recommended values; If this is not the case, replace the cylinder head.

	Measurement		Value
-	Cup seat diameter (mm)		37.000 - 37.025

Check that the length of the uncompressed valve springs is within the recommended values.

	Measurement		Value
-	Free length (mm)		53.9

Use a torque wrench to check that the spring specifications are within specified values; if this is not the case, replace parts that have yielded.

	Measurement		Value
-	Length (mm)		36
	at load of (daN)	36.7 - 39.6

	Measurement		Value
-	Length (mm)		26.5
	at load of (daN)	56.0 - 61.0

Check that the cam journal diameters are within the recommended values; if this is not the case, replace the worn camshat.

	Measurement		Value
-	Journal diameter (mm)		26.000 - 26.015

Check that the nominal lift of the camshaft cams is within the recommended values; if this is not the case, replace the worn camshat.

	Measurement		Value
-	Nominal cam lift (mm)		8.5

1. Fit camshaft caps (1a) in their original positions on the cylinder head and tighten bolts (1b) to torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CAMSHAFT CAPS	M7	1.3 - 1.6

2. Check the diamter of the camshaft mounts is within specified values; If this is not the case, replace the cylinder head.

	Measurement		Value
2	Diameter (mm)		26.045 - 26.070

Unscrew the bolts and remove the camshaft caps.

Check that the outer diameter of the valve guides to be fitted is within the recommended values.

	Measurement		Value
-	Outer diameter (mm)		14.010 ÷ 14.030
	Oversizes (mm)	0.05, 0.10, 0.25

1. Fit the valve guides (1a) using the tool (1b).

Fit the valve guides after heating the cylinder head to 80°¸100° C.

	Name	Country
1b	Fitting tool	1.860.812.000

Ream the inner diameter of the valve guides to the recommended value.

	Measurement		Value
-	Inner diameter (mm)		8.022 ÷ 8.040

Temporarily fit the valves.1. Check the clearance between valve stem and valve guide.

Regrind the valve seats to the recommended dimension if the valves or valve guides have been ground or replaced..

	Measurement		Value
-	Upper section taper (mm)	"to"	70°

	Measurement		Value
-	Valve contact band taper (mm)	"b"	45° +- 5''

	Measurement		Value
-	Lower band taper (mm)	"c"	15°

	Measurement		Value
-	Valve contact band width (mm)	" l "	+- 2

Grind the valve seats using a suitable tool.Temporarily fit the valves.1. Check that the valve recess in relation to the cylinder head is within the recommended values, using a tool fitted with a dial gauge.

	Measurement		Value
1	Recess from cylinder head surface (mm)		0.1 - 0.5

	Name	Country
1	Dial gauge mounting	1.870.404.000

If the valve recess in relation to the cylinder head plane is not within the recommended value, regrind the valve seats.

Fit the support tool to the cylinder head and secure using the nuts.Place a wooden board on the cylinder head to support the valves and bolt in place.Tighten the cylinder head and valves in a vice.Fit the lower shim.1. Fit valve guide oil seals (1a) to the valves using tool (1b).

	Name	Country
1b	Drift	1.860.814.000

1. Press-fit oil seals (1a) to the valve guides using tools (1b) and (1c).

	Name	Country
1b	Fitting tool	1.860.313.000

	Name	Country
1c	Drift	1.867.019.000

Fit the valve spring.Fit the upper valve shim.1. Fit cotters (1a) using tool (1b).

	Name	Country
1b	Tool	1.860.644.000

Work in the same way on the other valves.

Release the cylinder head from the vice.Remove the wooden board supporting the valves.Refit the cylinder head in the vice.Fit the cups complete with valve clearance adjustment pads into their original positions prior to dismantling.Fit the camshaft.1. Fit the camshaft caps into their original positions prior to dismantling.

Spread LOCTITE 573 on the surfaces where camshaft caps 1 and 5 come into contact with the cylinder head.

Fit the camshaft journal lubrication pipe.2. Tighten the camshaft cap bolts to torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	CAMSHAFT CAPS	M7	1.3 - 1.6

1. Fit camshaft front oil seal (1a) using tool (1b).

	Name	Country
1b	Fitting tool	1.860.824.000

2. Fit the glow plugs and tighten them to torque.

	Name	Connector
2	Heater plug	A40

	Fastening	Component	Ø	Value(daNm)
2	-	GLOW PLUGS	M12	1.3 - 1.6

1. Fit the injector bracket support pads.2. Fit injectors (2a) complete with seals (2b).

	Name	Connector
2a	Injector	N70

3. Fit injector brackets (3a) and tighten nuts (3b) to torque.

	Fastening	Component	Ø	Value(daNm)
3b	Nut	INJECTORS(DIESEL)	M8	2.6 - 3.2

4. Fit the fuel return pipe for lubricating the injectors (4a) and fix them using the clips (4b).

1. Fit the water pump (1a), complete with a new O-ring (1b), and tighten the bolts (1c) to torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	COOLANT PUMP	M6	2.1 - 2.6

2. Fit timing sensor (2a) and tighten bolts (2b).

	Name	Connector
2a	Timing sensor.	K47

3. Fit the driven pulley.4. Tighten driven toothed pulley bolt (4a) to torque, using tool (4b).

	Fastening	Component	Ø	Value(daNm)
4a	Bolt	TIMING DUCT PULLEY	M12	10.2 - 12.6

	Name	Country
4b	Support for counter-torque	1.860.831.000

Check that the valve clearance, with the valves in the closed position, is within the recommended values. if not replace the valve clearance adjustment shims as described below.

	Measurement		Value
-	Clearance with valve in closed position (mm)	Exhaust	0.30 - 0.40
Inlet	0.25 - 0.35

1. Lower the tappet in question using the tool.

	Name	Country
1	Lever	1.860.443.000

2. Fit the tool to lock the cup in lowered position.

	Name	Country
2	Lever	1.860.724.000

Remove the tool.

	Name	Country
-	Lever	1.860.443.000

Extract the valve clearance adjustment pad and replace it with another of a suitable size.Remove the tool.

	Name	Country
-	Lever	1.860.724.000

Fit the gasket.1. Fit thermostat (1a), complete with pipes and sensors, and tighten bolts (2b) to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	COOLANT PUMP PULLEY	M6	2.1 - 2.6

2. Fit vacuum pump (2a) with its gasket and tighten bolts (2b) to torque.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	BRAKE SERVO VACUUM PUMP	M6	2.1 - 2.6

1. Fit air intake manifold assembly (1a) and tighten nuts (1b).Connect the coolant return pipe to the expansion tank and the system vent pipe to the engine thermostat.Position the heater plugs supply cable and fix it using the nuts.

	Name	Connector
-	Heater plug	A40

2. Connect the fuel return pipe for lubricating the injectors (2a) to the fuel manifold and secure using clips (2b).3. Fit fuel distribution manifold (3a), complete with pipes and fuel pressure sensor (3b), and tighten nuts (3c).

	Name	Connector
-	Fuel pressure sensor	K83

4. Use a fixed wrench to bring the connectors on the pipes from the fuel manifold to the injectors, injector side, into contact, then tighten to the recommended torque using a fork-type torque wrench.

	Fastening	Component	Ø	Value(daNm)
4	Connector	FUEL MANIFOLD LINE TO INJECTORS	M14	Injector side 1.9 - 2.3

5. Tighten connectors (5a) on the pipes from the fuel manifold to the injectors, manifold side, to torque using tool (5b).

	Fastening	Component	Ø	Value(daNm)
5a	Bolt	CAMSHAFT CAPS	M7	1.3 - 1.6

	Name	Country
5b	Key	1.852.138.000

Release the cylinder head from the vice.Unscrew the bolts and remove the tool from the mount.

	Name	Country
-	Support	1.860.470.000

Retighten the stud.