1016C10 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET - Lancia - THESIS - eLearn

74677 - 1016C10 SINGLE CYLINDER HEAD - R.R. and Replace gasket

) - Position the vehicle on a lift.- Make sure that the ignition key is in the OFF position, then 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. 5040A10 Air conditioning coolant circuit - Drying and Repressurizing See in Op. 1084A16 Engine oil dip stick PIPE - R.R. 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.

- Lower the lift. See in Op. 4450B04 Right FRONT WHEEL (one) - R.R. 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. 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. 1080D24 engine oil vapour intake pipe - r + r See in Op. 1016A40 Ignition COIL COVER on cylinder head - R.R.1. 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 four fixing bolts.2. Remove the upper crossmember.

1. Undo the fixing bolt on the compressor (1a) and the bolt fixing the flange (1b) and remove the coolant return pipe (1c).

1. Disconnect the electrical connections for the engine cables/fradiator fan cables coupling.

	Description	Connector
1a	Front/radiator coupling	D009A

	Description	Connector
1b	Front/radiator coupling	D009B

1. Undo the nut (1a) and disconnect the earth lead (1b) from the bodyshell.

	Description	Connector
1b	Right front earth	C011

1. Disconnect the upper hose from the radiator (rapid connector)

1. Disconnect the electrical connection.2. Undo the four bolts fixing the fan to the radiator and extract it.

1. Disconnect the electrical connection for the rear Lambda sensor.

	Description	Connector
1	Lambda sensor on catalyzer 2	K018

2. Disconnect the electrical connection for the front Lambda sensor.

	Description	Connector
2	Lambda sensor on catalyzer	K017

1. Undo the nuts (1a) and the bolt (1b) and extract the heat shield (1c) upwards.

1. Undo the fixing bolts (1a) and remove the two half-rings (1b) between the catalytic preconverter and the turbine.

- Raise the lift.- Support the catalytic preconverter appropriately.1. Undo the nuts fixing the catalytic converter to the centre section of the exhaust pipe.2. Remove the catalytic converter mounting bracket.

1. Remove the catalytic preconverter complete with Lambda sensors.

1. Disconnect the turbocharger by-pass solenoid valve pneumatic connections.

1. Undo the fixing bolts (1a) and remove the protection (1b) for the sump oil return pipe from the turbocharger.2. Disconnect the sump oil return pipe from the turbochager.3. Undo the connector (3a) and disconnect the turbocharger oil supply pipe (3b).4. Undo the fixing bolts (4a) and nuts (4b) and remove the turbocharger mounting bracket (4c).

- Lower the lift.1. Disconnect the turbochrger air inlet hose.2. Disconnect the air oulet hose from the turbochager.3. Disconnect the coolant inlet (3a) and outlet (3b) pipes from the turbocharger.

1. Undo the nuts securing the exhaust manifold to the cylinder head.2. Remove the turbocharger (2a) complete with exhaust manifold (2b).3. Remove the exhaust manifold gasket from the studs on the cylinder head.

1. Undo the bolt (1a), release the pipes (1c) from the retaining springs (1b) and disconnect them, then remove the coolant return pipe from the turbocharger to the chamber (1d).

1. Disconnect the electrical connections for the ignition coils (1a), the injectors (1b), the injection control unit (1c), the phase transformer solenoid (1d), the throttle casing actuator (1e), the coolant temperature sensor (1f), the air temperature and pressure sensor (1g), the air conditioning compressor engagement solenoid (1h) and the timing sensor (1i).

	Description	Connector
1a	Ignition coil	A030A

	Description	Connector
1a	Ignition coil	A030B

	Description	Connector
1a	Ignition coil	A030C

	Description	Connector
1a	Ignition coil	A030D

	Description	Connector
1a	Ignition coil	A030E

	Description	Connector
1b	Injector	N070A

	Description	Connector
1b	Injector	N070B

	Description	Connector
1b	Injector	N070C

	Description	Connector
1b	Injector	N070D

	Description	Connector
1b	Injector	N070E

	Description	Connector
1c	Engine management control unit	M010A

	Description	Connector
1c	Engine management control unit	M010B

	Description	Connector
1e	Integrated throttle casing actuator	N075

	Description	Connector
1g	Integrated air temperature sensor	K043

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

	Description	Connector
1i	Timing sensor	K047

	Description	Connector
1d	Phase transformer solenoid	K098

	Description	Connector
1f	I.E. engine temperature sensor	K045

- Release the wiring from the fastening springs located on the chamber, the cylinder head and the fuel manifold and turn it over onto its side.1. Disconnect the retaining band for the throttle casing hose and release the hose.2. Disconnect the fuel supply pipe (2a) and the return pipe (2b) from the fuel manifold.

1. Disconnect the pneumatic connections for the supercharging air by-pass valve (1a), the brake servo (1b) and the evaporation control circuit (rapid connector) (1c).

- Raise the lift.1. Undo the fixing bolts (1a) and nuts (1b) and disconnect the earth lead (1c).

	Description	Connector
1c	Earth on engine	C040

- Lower the lift.2. Release the wiring from the springs and remove the chamber mounting bracket.

1. Undo the fixing bolt (1a) and nuts (1b) and remove the intake manifold (1c) complete with intake chamber and throttle casing.2. Remove the seal.

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. Raise the expansion tank and remove it.

1. Disconnect the tank return pipe on the cylinder head.2. Undo the bolts fixing the thermostat.

1. Undo the bolt (1a), loosen the bolt (1b) and rotate the reaction rod connecting rod.

- Position a hydraulic lift under the gearbox bellhousing.1. Undo the bolts fixing the engine support to the gearbox.- Gradually lower the hydraulic lift and rest the gearbox on the front crossmember.

See in Op. 1092G10 Engine components single drive BELT - R.R. See in Op. 1092A10 Crankshaft PULLEY - R.R. for versions with air conditioner1. Undo the bolt fixing the auxiliary shaft drive belt idle pulley.2. Undo the five bolts (2a) and remove the timing belt guard (2b).

1. Undo the bolts (1a) and remove the ignition coils (1b).2. Undo the bolts (2a) and remove the tappet cover (2b) complete with gasket.

1. Undo the automatic tensioner nut, in order to loosen the timing belt tension.2. Remove the timing drive belt from the pullies.

1. Undo the bolt fixing the guard behind the exhaust side timing pulley to the cylinder head.2. Undo the bolts (2a) using the spanner (2b) and remove the cylinder head (2c).- Remove the gasket underneath the cylinder head.

	Description	Code	Function
2b	Spanner	1.852.154.000	Loosen/tighten cylinder head fixing bolts

Refitting ( Removing

) - Position the cylinder head gasket on the cylinder block/crankcase.

The cylinder head gasket is the Astadur type. The material from which the gasket is made undergoes a polymerization process during the operation of the engine so that it becomes considerably harder during usage. In order for the polymerization process to take place, it is necessary to:

- Position the cylinder head on the cylinder block/crankcase taking care to ensure that the camshafts are positioned with the front cams facing outwards (valves closed).1. Tighten the bolts (1a) fixing the cylinder head to the recommended torque, in stages, using the spanner (1b) and the spanner (1c) for angular tightening.

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

	Value - daNm	Fastening	Component	Ø
1a	4 + 90° + 90° + 90°	Bolt	CYLINDER HEAD	M10

	Description	Code	Function
1b	Spanner	1.852.154.000	Loosen/tighten cylinder head fixing bolts

	Description	Code	Function
1c	Torque wrench	1.860.942.000	Cylinder head bolts angular tightening

1. Loosen the bolt (1a) for the exhaust side driven timing pulley using tools (1b) and (1c) for counter-torque.

	Description	Code	Function
1b	Support for counter-torque	1.860.831.000	Loosen/tighten driven toothed pulley bolt

	Description	Code	Function
1c	Spanner for rotating timing pullies	1.860.831.002	Loosen/tighten exhaust side camshaft drive pulley bolt

2. Loosen the bolts (2a) for the inlet side camshaft pulley using tool (2a) for counter-torque.

	Description	Code	Function
2b	Counter-torque	1.860.856.000	Loosen/tighten inlet side camshaft drive pulley bolts

- Remove the spark plug for cylinder no. 1.1. Fit the tool (1a) complete with dial gauge (1b) in the seat for the spark plug for cylinder no. 1.

	Description	Code	Function
1a	Dial gauge support	1.860.895.000	Support

- Rotate the crankshaft until the piston for cylinder no. 1 is at T.D.C. in the explosion stroke.2. With cylinder no. 1 at T.D.C., check that the reference on the crankshaft drive gear is in line with the reference on the crankshaft front cover.

- Undo the bolts and remove the inlet side camshaft third cap and the exhaust side camshaft second cap.

Mark the position of the camshaft caps removed so that they can be correctly positioned when refitting.

1. Fit the templates (1a) in place of the camshaft caps that have been removed and secure them using the bolts (1b).

Check that the camshaft cam profile and the templates are correctly aligned.

	Description	Code	Function
1a	Templates	1.870.828.000	Engine tuning

1. Fit the timing toothed drive belt in the following order: toothed drive pulley (1a), fixed tensioner (1b), exhaust side toothed driven pulley (1c), inlet side toothed driven pulley (1d), moving tensioner (1e), water pump pulley (1f).

The belt is fitted with the arrow facing the direction of rotation of the engine. There are also three reference on the belt that should coincide during the initial fitting with the references on the toothed drive pulley and the exhaust and inlet side toothed driven pullies.

1. Using a screwdriver, apply force to the tab (1a) for the automatic tensioner so that the tensioner is in the maximum tension position, then tighten the nut (1b) fixing the tensioner to the support.

	Value - daNm	Fastening	Component	Ø
1b	2.5	Nut	MOBILE TIMING TENSIONER	M8

1. Tighten the bolts (1a) for the inlet side toothed timing driven pulley using tool (1b) for counter-torque.

	Value - daNm	Fastening	Component	Ø
1a	(inlet side) 0.9	Bolt	TIMING DRIVEN PULLIES	M6

	Description	Code	Function
1b	Counter-torque	1.860.856.000	Loosen/tighten inlet side camshaft drive pulley bolts

2. Tighten the bolt (2a) for the exhaust side toothed timing driven pulley using the tools (2b) and (2c) for counter-torque.

	Value - daNm	Fastening	Component	Ø
2a	(exhaust side) 12	Bolt	TIMING DRIVEN PULLIES	M12

	Description	Code	Function
2b	Support for counter-torque	1.860.831.000	Loosen/tighten exhaust side camshaft drive pulley bolt

	Description	Code	Function
2c	Spanner for rotating timing pullies	1.860.831.002	Loosen/tighten exhaust side camshaft drive pulley bolt

- Undo the fixing botls and remove the templates.

	Description	Code	Function
.	Templates	1.870.828.000	Engine tuning

- Fit the camshaft cams removed previously and tighten the bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	1.5	Bolt	CAMSHAFT CAPS	M7

- Rotate the crankshaft throught two revolutions in the direction of rotation.- Loosen the moving timing tensioner nut.3. Using a screwdriver, rotate the moving timing tensioner until the moving tensioner reference (3a) coincoides with the fixed reference (3b).4. Tighten the nut fixing the moving timing tensioner to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.5	Nut	MOBILE TIMING TENSIONER	M8

- Remove the tool complete with dial gauge.

	Description	Code	Function
.	Dial gauge support	1.860.895.000	Support

- Fit the spark plug for cylinder no. 1 and tighten it to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.7	-	SPARK PLUGS	M14 X 1.25

- Position the timing drive belt cover and secure it using the fixing bolts.

	Value - daNm	Fastening	Component	Ø
.	0.9	Bolt	TIMING BELT PROTECTIVE COVER(S)	M6

- Tighten the bolt fixing the auxiliary shaft drive belt idle pulley.- Position the tappet cover and secure it using the fixing bolts.

	Value - daNm	Fastening	Component	Ø
.	0.9	Bolt	CAM COVER	M6

- Position the ignition coils cover and secure them using the fixing bolts.

	Value - daNm	Fastening	Component	Ø
.	0.9	Bolt	IGNITION COIL/REEL	M6

See in Op. 1092A10 Crankshaft PULLEY - R.R. for versions with air conditioner See in Op. 1092G10 Engine components single drive BELT - R.R.- Position a hydraulic lift under the gearbox bellhousing.- Raise the gearbox placing in a position that allows the engine support to be connected to the gearbox- Screw in and tighten the bolt fixing the engine support to the gearbox to the recommended torque.

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

- Connect the connecting rod to the reaction rod and secure it using the bolt.

	Value - daNm	Fastening	Component	Ø
.	(to engine support) 5	Bolt	POWER UNIT REACTION ROD	M10 X 1.25

- Fasten the thermostat and tightening the fixing bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.5	Bolt	THERMOSTAT	M8

- Connect the chamber return hose to the thermostat.- Position the expansion tank and secure it using the nut.- Connect the pipes and the electrical connection for the engine coolant level.

	Description	Connector
.	Engine coolant level sensor	K026

- Position the intake manifold complete with gasket and intake chamber.- Position the intake manifold complete with gasket and intake chamber.- Tighten the nuts and the bolt fixing the intake manifold to the cylinder head to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.5	Nut	INLET MANIFOLD	M8

	Value - daNm	Fastening	Component	Ø
.	2.5	Bolt	INLET MANIFOLD	M8

- Positin the chamber mounting bracket on the vibration damper supports and secure it using the nuts.- Raise the lift.- Tighten the bolts fixing the bracket and fasten the earth lead.

	Description	Connector
.	Earth on engine	C040

- Lower the lift.- Connect the pneumatic connections for the supercharging air by-pass valve, the brake servo and the evaporation control circuit (rapid connector).- Position the air inlet hose on the throttle casing and secure it using the retaining band.- Connect the fuel supply and return pipe to the fuel manifold.- Secure the fuel pipes to the springs.- Position the coolant return pipe on the retaining springs and tighten the fixing bolt.- Position the coolant return pipe from the turbocharger, secure it using the bolt and connect the tank side and thermostat side pipes.- Fit the new exhaust manifold gasket in the special housing on the cylinder head.- Fit the turbocharger-exhaust manifold assembly.- Tighten the nuts fixing the exhaust manifold to the cylinder head.

	Value - daNm	Fastening	Component	Ø
.	2.5	Nuts	EXHAUST MANIFOLD/S	M8

- Fit the reaction bracket for the turbocharger and tighten the fixing bolts.

	Value - daNm	Fastening	Component	Ø
.	2.5	Bolts	EXHAUST MANIFOLD RETAINING BRACKET	M8

- Connect the turbochrger air inlet hose.- Connect the air oulet hose from the turbochager.- Connect the coolant inlet and outlet pipes from the turbocharger.- Connect the turbocharger fluid supply pipe connector.- Connect the sump oil return pipe to the turbochager.- Fit the protection for the turbocharger sump oil return pipe.- Connect the turbocharger by-pass solenoid valve pneumatic connections.- Connect the lower radiator pipe.- Position the catalytic preconverter.- Position the gasket and tighten the nuts fixing the catalytic preconverter to the centre section of the exhaust pipe.

	Value - daNm	Fastening	Component	Ø
.	2.8	Nut	CATALYTIC PRE-CONVERTER	M8

- Fit the catalytic converter mounting bracket.

	Value - daNm	Fastening	Component	Ø
.	4	Nut	CATALYTIC CONVERTER MOUNT	M10

	Value - daNm	Fastening	Component	Ø
.	2.8	Bolt	STEERING SHAFT MOUNTING	M8

- Lower the lift.- Fit the half-rings securing the catalytic preconverter to the turbine and tighten the bolts.

	Value - daNm	Fastening	Component	Ø
.	2,8	Bolt	CATALYTIC PRE-CONVERTER	M8

- Position the heat shield bulkhead.- Tighten the bolt and the nuts fixing the heat shield bulkhead.- Lower the lift.- Position the radiator cooling fan and secure it using the bolts.- Connect the engine fan motor electrical connection.- Connect the electrical connections for the engine cables/radiator fan cables coupling.

	Description	Connector
.	Front/radiator coupling	D009A

	Description	Connector
.	Front/radiator coupling	D009B

- Connect the earth lead to the bodyshell.

	Description	Connector
.	Right front earth	C011

- Connect the upper hose to the radiator.- Connect the electrical connections for the ignition coils, the injectors, the injection control unit, the throttle casing actuator , the phase transformer solenoid, the coolant temperature sensor, the air temperature and pressure sensor, the air conditioning compressor engagement solenoid, the timing sensor, the front Lambda sensor and the rear Lambda sensor.

	Description	Connector
.	Ignition coil	A030A

	Description	Connector
.	Ignition coil	A030D

	Description	Connector
.	Ignition coil	A030C

	Description	Connector
.	Ignition coil	A030B

	Description	Connector
.	Ignition coil	A030E

	Description	Connector
.	Injector	N070A

	Description	Connector
.	Injector	N070C

	Description	Connector
.	Injector	N070B

	Description	Connector
.	Injector	N070D

	Description	Connector
.	Injector	N070E

	Description	Connector
.	Engine management control unit	M010A

	Description	Connector
.	Engine management control unit	M010B

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