1016B10 SINGLE CYLINDER HEAD EXTENSION - CHANGE GASKET - Lancia - MUSA - eLearn

184000813 - 1016B10 SINGLE CYLINDER HEAD EXTENSION - CHANGE GASKET

) Position the vehicle on a lift.Drain the air conditioning refrigerant circuit Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE.Proceed with the removal Op. 4450B04 RIGHT FRONT WHEEL R R.Proceed with the removal Op. 7055B54 UNDER-ENGINE GUARD - R R.Proceed with the removal Op. 7055B66 ENGINE COMPARTMENT DUST SHIELD PROTECTION IN RIGHT FRONT WHEEL ARCH - R.R..Proceed with the removal Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R..Proceed with the removal Op. 5530B10 BATTERY - R+R.Proceed with the removal Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R..Proceed with the removal Op. 1060G90 DIESEL INJECTION WIRING HARNESS - R R.1. Disconnect the rapid connector for thecoolant return pipe from the engine coolant reservoir, thermostat side.Undo the fuel filler cap to discharge the pressure in the system and remove it.2. Disconnect the fast-on connector (2a) for the fuel supply pipe from the filter to the pressure pump, pressure pump side and release from fastening (2b)3. Disconnect the fast-on connector (3a) for the fuel return pipe to the tank, single fuel manifold pipe side and release from fastening (3b).

1. Loosen the band and disconnect the coolant return pipe to the engine coolant reservoir, reservoir side.

1. Undo bolts (1a) and remove the duct (1b) complete with coolant return pipe to the engine coolant reservoir (1c).

1. Manually push the clips (1a) and disconnect the return pipe from the injectors to the manifold (1b), injector side.2. Loosen the band and disconnect the fuel return pipe from the pressure pump, pressure pump side.3. Undo the connectors (3a) and remove the pipe from the pressure pump to the fuel manifold (3b).

Use a new pipe from the pressure pump to the fuel manifold when refitting.

4. Unscrew the connectors (4a) and remove the pipes from the fuel manifold to the injectors (4b).

Use new pipes from the fuel manifold to the injectors when refitting.

5. Undo the bolts (5a) and remove the mounting brackets (5b) complete with single fuel manifold pipe (5c).6. Undo the bolt (6a) and remove the cam angle sensor (6b).

1. Undo the injector fastening bracket nut.2. Keep the washer (2a) and the tapered washer (2b).3. Remove the injectors (3a), one at a time, using the tools (3b) and (3c).

If the injectors are being reused, mark the cylinder to which they belong so that they can be correctly refitted.If a new/new injector/s are fitted, run the initialisation procedure using an Examiner.

	Description	Code
3b	Extractor	1.870.900.700

	Description	Code
3c	Extractor	1.870.739.000

Remove the injectors complete with bracket.Repeat the above procedure to remove the remaining pair of injectors.4. Remove the injector seals from the single camshaft housing.

These seals are replaced each time they are dismantled.

1. Loosen the band and disconnect the brake servo vacuum intake pipe, vacuum unit side.

1. Remove the plugs (1a) and fit the tools (1b) on the camshafts in their place.

Fit the tools and position with their millings horizontal. Ensure they fit into the seats on the camshafts.

	Description	Code
1b	Template	1.871.000.900

2. Fit a suitable (8 mm diameter) peg via the special opening in the gearbox.

Check that the peg is correctly inserted in the housing in the flywheel.

1. Use a spanner in an anti-clockwise direction on the moving tensioner (1a) and remove the engine components single drive belt (1b).

1. Undo the bolts (1a) and remove the crankshaft pulley (1b).

1. Using the tools (1a) and (1b) for counter-torque, loosen the left bolt (1c) fixing the pulley mounting flange to the crankshaft.

	Description	Code
1a	Counter-torque	1.871.000.200

	Description	Code
1b	Support for counter-torque	1.860.831.000

1. Loosen the lower bolts fixing the alternator to the mounting.

1. Loosen the upper bolt fixing the alternator to the mounting.2. Undo the bolt (2a) and disconnect the connector (2b) for the engine oil vapour recovery pipe from the chain drive timing cover.3. Fit a suitable bracket for supporting the power unit and fasten it using the upper bolt securing the alternator to the mounting.

Tighten the lower bolts fixing the alternator to the mounting.1. Fit tool (1a) complete with mounting blocks (1b), then connect to the bracket fitted previously using link (1c).

	Description	Code
1a	Crossmember	1.870.595.000

	Description	Code
1b	Support mountings	1.870.650.000

1. Undo the bolt (1a) and disconnect the pipe from the expansion valve to the compressor (1b), compressor side.

Seal the connectors that have been disconnected using suitable plugs to prevent dampness and impurities from entering the system.

1. Loosen the collar and disconnect the supply pipe on the the engine coolant reservoir side.2. Undo the nut (2a) and bolt (2b) and remove the engine coolant supply reservoir (2c).

1. Undo the nut fixing the air conditioning system pipe mounting bracket to the power unit flexible mounting, timing side.2. Undo the nuts (2a) and (2b), then remove the timing side power unit flexible mounting (2c).

1. Undo the bolts fixing the air conditioning pipe mounting brackets to the timing side rigid engine support.

1. Undo the bolts (1a) and remove the timing side rigid engine support (1b) complete with engine lifting bracket (1c).

1. Undo the plug (1a) complete with the o-ring and the bolt (1b) fixing the exhaust side camshaft toothed drive pulley.2. Undo the bolts (2a) and remove the cover (2b) complete with gasket.

Release the exhaust side camshaft toothed pulley working via the opening in the timing cover and rest it on the timing cover inner ribs.

After this operation the timing moving tensioner piston will be fully extracted.

1. Undo the bolts fixing the timing cover to the single camshaft housing.2. Keep the brackets.3. Undo the bolts (3a) and (3b), then remove the single camshaft housing assembly (3c).4. Remove the single camshaft housing gasket.

Refitting ( Removing

) 1. Apply Fiat silicon sealant 71713687 or a similar product to the contact area between the cylinder head and the timing chain cover.2. Position the cylinder head locating bushes on the cylinder head as shown in the figure.

The locating bushes between the cylinder head and cylinder head extension are shorter (13.0 mm) than the bushes between the crankcase and the cylinder head. Take great care not to reverse them as this could impair engine operation.

3. Position the gasket on the cylinder head by fitting it on the locating bushes.4. Apply Fiat 71713687 type silicon sealant or a similar product to the gasket between the lower cylinder head and the camshaft housing by the contact area with the timing cover.5. Also apply a bead of the same sealant to the surface of the timing cover gasket following the black line of silicon on the actual gasket.

Apply a thin layer of sealant to the timing cover gasket so that it is not too thick and avoid excess sealant inside the timing cover.

Working with the camshaft timing tools fitted, position the single camshaft housing taking care not to move the rocker arms out of position.Screw in the bolts securing the single camshaft housing to the cylinder head without tightening them.1. Screw in and tighten the bolts fixing the timing cover to the single camshaft housing to torque.

During this stage do not tighten the remaining bolts fixing the timing cover.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	TIMING COVER	M6	0.8 ÷ 1.0

1. Tighten the six rear bolts fixing the single camshaft housing to a torque of 0.9 daNm.2. Loosen the bolts (2a) and (2b) fixing the timing cover tightened previously.3. Continue tightening the bolts fixing the camshaft housing to a torque of 0.9 daNm following the order illustrated working gradually towards the timing cover.

1. Tighten the single cylinder head extension bolt M8 (1a) to a pretorque of 1.5 daNm and M7 (1b) to a pretorque of 1.2 daNm2. Tighten bolts (2a) and (2b) securing the single cylinder head extension to the specified torque.

Follow the order shown in the figure for each tightening sequence.

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	CYLINDER HEAD EXTENSION	M8	(Lower cylinder head side) 2.5

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	CYLINDER HEAD EXTENSION	M7	(Lower cylinder head side) 1.8

Fit the remaining bolts fixing the timing cover to the single camshaft housing, then tighten all the bolts fixing the timing cover to the camshaft housing to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	TIMING COVER	M6	0.8 ÷ 1.0

The non alignment between the single camshaft housing and the cylinder head should not exceed the recommended value.

It is only possible for the cylinder head extension to protrude from the cylinder head.

	Measurement		Value
-	Misalignment between cylinder head extension - cylinder head (mm)		0.1

1. Fasten the tool to the timing cover, by the inspection window, so that the peg is against the moving plate rib; using the tool lever, retract the belt tensioner piston so that it is in the locked position.

	Description	Code
1	Lever	1.870.900.400

Fit the toothed pulley on the exhaust side camshaft working via the opening in the timing cover.Position the bolt fixing the gear and screw it in without tightening it in order to prevent the gear from accidentally coming out of the housing.Working on the tool lever, fully retract the belt tensioner piston so that the inner spring can be reloaded and the timing chain tension is correct.Release the chain tensioner piston checking that it is in contact with the moving plate.Remove the tool.

	Description	Code
-	Lever	1.870.900.400

1. Working with the camshaft timing tools fitted, tighten the bolt fixing the exhaust side camshaft drive pulley fixing bolt to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	TIMING DRIVEN PULLEY	M12	(Exhaust camshaft side) 10.8 - 13.2

2. Tighten the plug with its o-ring.3. Place the cover (3a) complete with gasket back in its housing and secure it using the bolts (3b).

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

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	RIGID ENGINE MOUNT, TIMING SIDE	M10	(Engine crankcase side) 5.7 - 6.3

Tighten the bolts fixing the air conditioning pipe mounting brackets to the timing side rigid engine support.1. Place the timing side power unit flexible mounting (1a) back in its housing and secure it tightening the nuts (1b) and (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	FRONT FLEXIBLE MOUNTING BLOCKS, POWER UNIT	M10	(Rigid support side) 4.5 - 5.5

	Fastening	Component	Ø	Value(daNm)
1c	Nut	FRONT FLEXIBLE MOUNTING BLOCKS, POWER UNIT	M10	(Bodyshell side) 4.1 - 5.0

2. Tighten the nut fixing the air conditioning system pipe mounting bracket to the power unit flexible mounting, timing side.

Fit the engine coolant reservoir in place and secure it using the nut and bolt.Connect the system supply line on the engine coolant reservoir side and tighten the collar.1. Connect the pipe from the expansion valve to the compressor (1b) compressor side and tighten the bolt (1b) to the recommended torque.

Replace any O-Rings for the connectors using green coloured seals only which are resistant to the R134a refrigerant fluid.Lubricate the connector threads using anti-freeze.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	EXPANSION VALVE - COMPRESSOR PIPE	M6	(Compressor side) 0.7 - 1.1

Remove the tools used for supporting the power unit safely.

	Description	Code
-	Crossmember	1.870.595.000

	Description	Code
-	Support mountings	1.870.650.000

Undo the upper bolt, loosen the lower bolts fixing the alternator and remove the bracket used for supporting the power unit.Tighten the bolts fixing the alternator to the mounting to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ALTERNATOR ASSEMBLY	M8	(Mount side) 2.3 - 2.8

Connect the connector for the engine oil vapour recovery pipe to the timing cover with drive chain and tighten the bolt.

Ensure the o-ring is present and correctly positioned.

1. Tighten the left bolt (1a) fixing the pulley support flange on the crankshaft to the recommended torque using tools (1b) and (1c) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
1a	Anticlockwise bolt	PULLEY SUPPORT FLANGE ON CRANKSHAFT	M14	(Crankshaft side) 21.9 - 24.2

	Description	Code
1b	Counter-torque	1.871.000.200

	Description	Code
1c	Support for counter-torque	1.860.831.000

1. Position the crankshaft pulley (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CRANKSHAFT PULLEY	M8	(Flange side) 2.3 - 2.8

Adjust the mobile tensioner with a wrench and fit the auxiliary drivebelt.Remove the peg from the opening in the gearbox.Remove the camshaft timing tools and tighten the plugs.

	Description	Code
-	Templates	1.870.896.900

Connect the brake servo vacuum intake pipe, vacuum unit side and tighten the band.Place the new injector seals in the housings on the single camshaft housing.1. Refit injectors (1a) with brackets (1b) into their seats.

Before refitting, replace the copper ring on the injectors.

2. Refit the tapered washer (2a) and washer (2b) in their seats.3. Tighten the nut securing the injector bracket to the specified torque.

	Fastening	Component	Ø	Value(daNm)
3	Nut	INJECTORS(DIESEL)	M8	(Cylinder head side) 1.8 - 2.2

1. Position the cam angle sensor (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CAM ANGLE SENSOR	M6	(Cylinder head side) 0.6 - 0.8

2. Place the mounting brackets (2a) complete with single fuel manifold pipe (2b) back in their housings and secure them using the bolts (2c).3. Fit new pipes from the fuel manifold to the injectors and secure with connectors without tightening.4. Tighten the connectors for the pipes from the fuel manifold to the injector side injectors to the recommended torque using an appropriate commercial wrench.

	Fastening	Component	Ø	Value(daNm)
4	Connector	PIPE FUEL MANIFOLD TO INJECTORS	M12	(Injector side) 2.3 - 2.5

5. Tighten the connectors for the pipes from the fuel manifold to the fuel manifold side injectors to the recommended torque using an appropriate commercial wrench.

	Fastening	Component	Ø	Value(daNm)
5	Connector	PIPE FUEL MANIFOLD TO INJECTORS	M14	(Fuel manifold side) 2.7 - 2.9

Clean the threaded pipe seats on the manifold and injectors with heptane.

6. Place a new pipe from the pressure pump to the single fuel manifold in its housing and secure it using the connectors without tightening them.7. Tighten the connector for the pipe from the pressure pump to the single fuel manifold, pump side, to the recommended torque using a spanner.

	Fastening	Component	Ø	Value(daNm)
7	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M12	(Pressure pump side) 2.3 - 2.5

8. Tighten the connector for the pipe from the pressure pump to the single fuel manifold, fuel manifold side, to the recommended torque using a suitable commercial wrench.

	Fastening	Component	Ø	Value(daNm)
8	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14	(Fuel manifold side) 2.7 - 2.9

9. Connect the fuel return pipe from the pressure pump, pressure pump side and tighten the band.10. Connect the injector fuel outlet pipe (10a), injector side pushing it until the clips (10b) are heard to click.

Place the duct complete with coolant return pipe to the engine coolant reservoir in position and secure it using the bolts.Connect the rapid connector for the intermediate coupling for the fuel return pipe to the reservoir.Connect the fast-on connector for the fuel return pipe to the tank, single fuel manifold pipe side, and secure.Connect the fast-on connector for the fuel supply pipe from the filter to the pressure pump, pressure pump side and secure.Connect the rapid connector for the coolant return pipe from the engine coolant reservoir, thermostat side.Proceed with the refitting Op. 1060G90 DIESEL INJECTION WIRING HARNESS - R R.Proceed with the refitting Op. 5530B52 BATTERY DRIP TRAY/SUPPORT - R.R..Proceed with the refitting Op. 5530B10 BATTERY - R+R.Proceed with the refitting Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R..Proceed with the refitting Op. 7055B66 ENGINE COMPARTMENT DUST SHIELD PROTECTION IN RIGHT FRONT WHEEL ARCH - R.R..Proceed with the refitting Op. 7055B54 UNDER-ENGINE GUARD - R R.Proceed with the refitting Op. 4450B04 RIGHT FRONT WHEEL R R.Refill the air conditioning refrigerant circuit Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE.Remove the vehicle from the lift.