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

849954 - 1016E10 SINGLE CYLINDER HEAD, removed - Overhaul

1. Position the camshaft housing (1a) in a vice using the tool (1b).

	Description	Code	Function
1b	Support	1.860.470.001	Locking camshaft housing in vice

1. Undo the bolt (1a) and remove the cam angle sensor (1b).

- Check that the camshaft endfloat is within the recommended values using a dial gauge.

	Subject	Value
.	Camshaft	mm
-	-	-

- If the camshaft endfloat is not within the recommended values, replace the worn components when reassembling the cylinder head.1. Remove the plugs (1a) and fit the camshaft timingn tools (1b) on the camshaft housing.

Check that the tools marked with the letter "A" are correctly inserted in the housings in the camshafts.

	Description	Code	Function
1b	Templates	1.870.896.900	Engine tuning

1. Undo the bolts fixing the camshaft gears.

- Remove the camshaft timing tools from the camshaft housing.

	Description	Code	Function
.	Templates	1.870.896.900	Camshaft timing adjustment

1. Release the camshafts (1a), as necessary and remove the camshaft gears (1b).

1. Using a suitable drift, extract the inlet side camshaft (1a) and plug (1b).2. Using a suitable drift, extract the exhaust side camshaft (2a) and oil seal (2b).- Remove the exhaust side camshaft oil seal.

1. Undo and remove the engine oil lubrication duct plugs.

- Remove the support ool complete with camshaft housing from the vice and separate them.

	Description	Code	Function
.	Support	1.860.470.001	Locking camshaft housing in vice

1. Position the cylinder head (1a) in a vice using the tool (1b).

	Description	Code	Function
1b	Support	1.860.470.001	Locking cylinder head in vice

- Remove the gasket.

1. Fit a suitable wooden stand on the cylinder head plane to support the valves and secure it using bolts.

	Description	Code	Function
1	Stand	1.860.804.001	Removing/refitting valves

1. Compress the valve spring using the tools (1a) and (1b) and remove the cotters (1c).

	Description	Code	Function
1a	Lever	1.860.644.001	Removing/refitting valves

	Description	Code	Function
1b	Chamber	1.870.890.000	Removing/refitting valves

2. Remove shim (2a) and valve spring (2b).3. Remove the valve guide seat oil seal using special pliers.

	Description	Code	Function
.	Caliper	1.870.894.000	Valve guide oil seals

- Carry out the same operations on the other valves.

- Remove the wooden stand and keep the valves.

	Description	Code	Function
.	Stand	1.860.804.001	Removing/refitting valves

- Remove the cylinder head from the support tool.

	Description	Code	Function
.	Support	1.860.470.001	Locking cylinder head in vice

- Replace the valve guides following the instructions in the description: See in Op. 1016E14 VALVE GUIDES for single cylinder head - Replace during Op. 1016E10- Clean any residues of the old gasket from the lower cylinder head plane.- Check that the planarity of the cylinder head is within the recommended limits.

	Subject	Value
.	Cylinder head	mm
-	Flatness	-

1. If the planarity of the lower cylinder head plane does not correspond to the recommended figures, regrind it without exceeding the minimum permitted height.

	Subject	Value
1	Cylinder head	mm
-	Height	-

- Check that the valves do not show signs of grooves or seizing.- Check that the diameter of the valve stems corresponds to the recommended figures; if not, replace the worn valves.

	Subject	Value
.	Cylinder head inlet valves	mm
-	Stem diameter	5,982 ÷ 6,000

	Subject	Value
.	Cylinder head exhaust valves	mm
-	Stem diameter	5,92 ÷ 5,990

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

	Subject	Value
.	Valve springs	-
-	Free length	43,1

- Using a torque wrench, check that the spring specifications correspond to the recommended figures; if not, replace the worn springs.

	Subject	Value
.	Valve springs	daN
-	Length	34 mm
-	Under a load of	21,2

	Subject	Value
.	Valve springs	daN
-	Length	24,5 mm
-	Under a load of	45

- Check that the diameter of the camshaft bearings corresponds to the recommended figures; if not, replace the worn camshaft.

	Subject	Value
.	Cyliner head inlet and exhaust shafts	mm
-	Bearing 1 diameter	43,800 ÷ 43,815

	Subject	Value
.	Cyliner head inlet and exhaust shafts	mm
-	Bearing 2 diameter	43,600 ÷ 43,615

	Subject	Value
.	Cyliner head inlet and exhaust shafts	mm
-	Bearing 5 diameter	43,000 ÷ 43,015

	Subject	Value
.	Cyliner head inlet and exhaust shafts	mm
-	Bearing 4 diameter	43,200 ÷ 43,215

	Subject	Value
.	Cyliner head inlet and exhaust shafts	mm
-	Bearing 3 diameter	43,400 ÷ 43,415

- Check that the nominal camshaft cam lift corresponds to the recommended figures; if not, replace the worn camshaft.

	Subject	Value
.	Cyliner head inlet and exhaust shafts	mm
-	Nominal inlet cam lift	8

	Subject	Value
.	Cyliner head inlet and exhaust shafts	mm
-	Nominal exhaust cam lift	8

1. Check that the diameter of the camshaft bearings corresponds to the recommended figures; if not, replace the single camshaft housing.

	Subject	Value
.	Cyliner head inlet and exhaust shafts	mm
-	Bearing 1 diameter	43,846 ÷ 43,871

	Subject	Value
.	Cyliner head inlet and exhaust shafts	mm
-	Bearing 5 diameter	43,046 ÷ 43,071

	Subject	Value
.	Cyliner head inlet and exhaust shafts	mm
-	Bearing 4 diameter	43,246 ÷ 43,271

	Subject	Value
.	Cyliner head inlet and exhaust shafts	mm
-	Bearing 3 diameter	43,446 ÷ 43,471

	Subject	Value
.	Cyliner head inlet and exhaust shafts	mm
-	Bearing 2 diameter	43,646 ÷ 43,671

- Check that the outer diameter of the valve seats corresponds to the recommended figures.

	Subject	Value
.	Cylinder head valve seats	mm
-	Inlet outer diameter	29,600 ÷ 29,611

	Subject	Value
.	Cylinder head valve seats	mm
-	Exhaust outer diameter	27,600 ÷ 27,611

1. If the values are not within the recommended limits, reface the valve seats.

	Subject	Value
.	Cylinder head valve seats	Gradi
-	Contact band angle with inlet valve	45° ± 1'

	Subject	Value
.	Cylinder head valve seats	Gradi
-	Contact band angle with exhaust valve	45° ± 0,1

- Grind the valve seats using a suitable tool.- Temporarily fit the valves.1. Check that the valve projection or recess in relation to the cylinder head plane (1a) corresponds to the recommended figures using the tool (1b) fitted with a dial gauge.

	Subject	Value
1a	Valves	mm
-	Cylinder head plane recess	-

	Description	Code	Function
1b	Dial gauge support	1.870.404.001	Valve recess in cylinder head plane measurement

- If the values measured are not within the recommended limits, reface the valve seats once again.

- Position the cylinder head in the vice using the tool.

	Description	Code	Function
.	Support	1.860.470.001	Locking cylinder head in vice

- Fit the valves in the seats, then support them using the wooden stand and secure it using suitable bolts.

	Description	Code	Function
.	Stand	1.860.804.001	Removing/refitting valves

1. Fit the fittingn tool (1a) on the valve stem, fit an oil seal (1b) and fit the oil seal in the end of travel position using a suitable drift.

	Description	Code	Function
1a	Drift	1.871.000.600	Valve guide oil seal fitting

- Carry out the same operations on the other valves.

1. Fit the valve spring in its seat.2. Fit the upper valve shim in its seat.3. Compress the valve spring using the tools (3a) and (3b) and fit the cotters (3c) in their seats.

	Description	Code	Function
3a	Lever	1.860.644.001	Removing/refitting valves

	Description	Code	Function
3b	Chamber	1.870.890.000	Removing/refitting valves

- Carry out the same operations on the other valves.

- Remove the wooden stand for supporting the valves from the cylinder head plane.

	Description	Code	Function
.	Stand	1.860.804.001	Removing/refitting valves

- Remove the cylinder head from the support tool.

	Description	Code	Function
.	Support	1.860.470.001	Locking cylinder head in vice

1. Position the camshaft housing (1a) in a vice using the tool (1b).

	Description	Code	Function
1b	Support	1.860.470.001	Locking camshaft housing in vice

- Tighten the engine oil lubrication duct plugs.- Place the camshafts in their housings.- Place the camshaft caps in their housings and secure them without tightening the bolts.1. Fit the camshaft timing tools.

Check that the tools marked with the letter "A" are correctly fitted in the housings in the camshafts.

	Description	Code	Function
1	Templates	1.870.896.900	Engine tuning

1. Tighten the camshaft gear fixing bolts to the recommended torque.

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

	Description	Code	Function
1b	Fitting tool	1.870.896.800	Fitting exhaust camshaft oil seal

- Fit the inlet side camshaft plug.1. Position the cam angle sensor (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

1. Remove the camshaft timing tools (1a) and tighten the plugs (1b).

	Description	Code	Function
1b	Templates	1.870.896.900	Engine tuning

- Remove the support ool complete with camshaft housing from the vice and separate them.

	Description	Code	Function
.	Support	1.860.470.001	Locking camshaft housing in vice