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

849943 - 1016C10 SINGLE CYLINDER HEAD - R.R. and Replace gasket

) - Position the vehicle on a lift.- Disconnect the negative battery terminal. See in Op. 7055B54 PROTECTION/GUARD under engine - R.R. See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R. 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. 1064A24 TURBOCHARGER - EXHAUST MANIFOLD - HOSE CONNECTED TO EXHAUST PIPE - R.R. 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. 1092G10 Engine components single drive BELT - R.R. See in Op. 1092G21 Engine components single belt FIXED TENSIONER - R.R. with belt removed See in Op. 1092A10 Crankshaft PULLEY - R.R. See in Op. 1032D12 Timing system protective COVER(S) - R.R.1. Loosen the nut retaining the timing belt moving tensioner.2. Release and remove the toothed timing drive belt.

1. Disconnect the electrical connection for the timing sensor.

	Description	Connector
1	Timing sensor	K047

2. Undo the fixing bolt (2a) and remove the sensor (2b) from the housing in the camshaft housing.

1. Undo the connectors (1a) and (1b) and remove the pipes from the fuel manifold to the injectors (1c).

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

1. Disconnect the electrical connections from the injectors.

	Description	Connector
1	Injector	N070A

	Description	Connector
1	Injector	N070E

	Description	Connector
1	Injector	N070D

	Description	Connector
1	Injector	N070C

	Description	Connector
1	Injector	N070B

2. Undo the fixing bolts (2a) and release the injection wiring (2b) moving it outside the work area.3. Manually push the clips (3a) and disconnect the pipe from the injectors to the fuel recovery manifold (3b), injector side, and move it sideways.

1. Undo the nuts fixing the injector brackets.2. Remove the injectors (2a) complete with brackets using the tools (2b) and (2c).

If the same injectors are being reused, mark the cylinders to which they belong so they can be correctly refitted.If new injector(s) is(are) being fitted, it is necessary to:

Start the removal beginning with the injector for cylinder no. 1 and continue with the injectors for cylinders 2, 3, 4 and 5.

	Description	Code	Function
2b	Extractor	1.870.739.000	Removing injectors

	Description	Code	Function
2b	Extractor	1.870.897.300	Removing injectors

1. Undo the fixing bolts (1a) from the fuel return manifold (1b) and move it away from the intake manifold.

1. Undo the connectors (1a), (1b) and remove the pipe from the pressure pump to the fuel manifold. (1c).

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

1. Disconnect the electrical connection from the fuel pressure sensor.

	Description	Connector
1	Fuel pressure sensor	K083

2. Undo the bolts (2a) and remove the single fuel manifold pipe (2b) complete with fuel pressure sensor (2c).

1. Disconnect the electrical wiring from the heater plugs.

	Description	Connector
1	Heater plugs	A040A

	Description	Connector
1	Heater plugs	A040E

	Description	Connector
1	Heater plugs	A040D

	Description	Connector
1	Heater plugs	A040C

	Description	Connector
1	Heater plugs	A040B

2. Disconnect the flexible sections of the vacuum pipes frm the variable geometry solenoid valve (2a) and the vacuum reservoir solenoid valve (2b).3. Undo the retaining bolts.4. Remove the rigid section of the vacuum pipe.

1. Disconnect the vacuum pipe from the vacuum unit.2. Disconnect the engine oil filler pipe from the separator.

1. Disconnect the E.G.R. electrical connection.

	Description	Connector
1	EGR solenoid valve	L030

2. Disconnect the supercharging sensor.

	Description	Connector
2	Supercharging sensor	K082

3. Disconnect the compressor electro-magnet coupling.

	Description	Connector
3	Air conditioning compressor engagement electro-magnet	L020

4. Disconnect the electrical connection for the variable geometry solenoid valve.

	Description	Connector
4	Waste gate solenoid valve	L037

5. Disconnect the coolant temperature sensor from the thermostat, release the electrical wiring from the bands and move it sideways outside the work area.

	Description	Connector
5	Engine coolant temperature sensor/sender unit	K036

1. Disconnect the heater unit coolant supply pipe from the thermostat.

1. Remove the upper coolant supply pipe from the thermostat to the radiator.

1. Undo the upper bolts fixing the vacuum reservoir and engine oil separator mounting bracket to the cylinder head.

1. Undo the fixing bolts (1a), then remove the single camshaft housing (1b).- Recover the underlying gasket.

1. Remove the hydraulic tappet assembly (1a) and rocker arms (1b).

1. Undo the bolts fixing the cylinder head to the engine block.2. Remove the cylinder head.- Keep the gasket underneath and the centering bushes.

Refitting ( Removing

) - Clean the contact areas between the engine block and the cylinder head thoroughly.

Cover the cylinder liners/bores and pistons to prevent the penetration of impurities or foreign bodies.

- Place the cylinder head centering bushes on the cylinder block.- Fit a new cylinder head gasket taking care to ensure that it is the same size as the one removed.

Position the first cylinder at T.D.C.; rotate the crankshaft a further two teeth of the toothed timing drive pulley to lower the pistons thereby preventing any interference with the valves whilst fitting the cylinder head.

- Position the cylinder head on the cylinder block/crankcase.1. Follow the order illustrated below for the tightening of the cylinder head.

1. Tighten the cylinder head bolts (1a) to the recommended torque using the angular tightening tool (1b):

	Value - daNm	Fastening	Component	Ø
1a	2 + 6.5 + 90° + 90° + 90°	Bolts	CYLINDER HEAD	M12

The figure of 2 daNm in the table below is a tightening value for all the bolts following the order illustrated in the diagram.

	Description	Code	Function
1b	Torque wrench	1.860.942.000	Tightening cylinder head bolts to cylinder block

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

- Fit the hydraulic tappet assemblies and rocker arms.- Place a new gasket on the cylinder head.1. Remove the plugs (1a) and fit the camshaft timing tools (1b) on the camshaft housing.

Check that the tools are correctly inserted in the housings in the camshafts.

	Description	Code	Function
1b	Templates	1.870.896.900	Engine tuning

- Remove the inlet side timing tool and tighten the plug.

1. Fit the camshaft housing assembly (1a) and secure it tightening the bolts (1b) to the recommended torque.2. Loosen the exhaust side camshaft pulley fixing bolt.

1. Undo the bolt fixing the crankcase front cover shown in the diagram.- Fit the timing drive belt on the drive gear, checking that the belt teeth are correctly inserted in the gear grooves.2. Fit the tool (2a) and fasten it using the calibrated screw (2b).

The crankshaft must be rotated, using small movements, to allow the locating dowel to be fitted on the timing drive pulley.

	Description	Code	Function
2a	Template	1.860.905.000	Timing belt timing

	Description	Code	Function
2b	Calibrated Screw	1.860.905.010	Timing belt timing

1. Fully fit the toothed timing drive belt.2. Use a screwdriver for leverage in the opening (2a) until the reference for the tensioner (2b) is aligned with the opening reference (2c) and, in this position, tighten the nut (2d) for the belt tensioner to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2d	2.5	Nut	MOBILE TIMING TENSIONER	M8

3. Tighten the exhaust side camshaft pulley fixing bolt to the recommended torque.

	Value - daNm	Fastening	Component	Ø
3	12	Bolt	TIMING DRIVEN PULLIES	M12

- Remove the timing tools.

	Description	Code	Function
.	Templates	1.870.896.900	Engine tuning

	Description	Code	Function
.	Template	1.860.905.000	Timing belt timing

	Description	Code	Function
.	Calibrated Screw	1.860.905.010	Timing belt timing

- Rotate the crankshaft through two revolutions.- Check that the timing is correct by refitting the timing tools.

Fit the exhaust camshaft side template only because the inlet side one is not accessible.

- Check the alignment of the references for tensioning the timing moving tensioner.- Tighten the bolt fixing the crankcase front cover removed previously.- Tighten the plug in the camshaft housing for fitting the exhaust side timing tool.- Tighten the upper bolts fixing the vacuum reservoir and engine oil separator mounting bracket to the cylinder head.- Fit the upper coolant supply pipe from the thermostat to the radiator.- Connect the heater supply pipe to the thermostat unit.- Position the engine wiring and connect the electrical connections disconnected previously.

	Description	Connector
.	Heater plugs	A040A

	Description	Connector
.	Engine coolant temperature sensor/sender unit	K036

	Description	Connector
.	Waste gate solenoid valve	L037

	Description	Connector
.	Air conditioning compressor engagement electro-magnet	L020

	Description	Connector
.	Supercharging sensor	K082

	Description	Connector
.	EGR solenoid valve	L030

	Description	Connector
.	Heater plugs	A040E

	Description	Connector
.	Heater plugs	A040D

	Description	Connector
.	Heater plugs	A040C

	Description	Connector
.	Heater plugs	A040B

- Connect the engine oil filler pipe to the separator.- Connect the vacuum pipe to the vacuum unit.- Fit the rigid section of the vacuum pipe.- Tighten the fixing bolts and connect the flexible sections of the vacuum pipes to the variable geometry solenoid valve and to the vacuum reservoir solenoid valve.- Connect the electrical wiring to the heater plugs.

	Description	Connector
.	Heater plugs	A040A

	Description	Connector
.	Heater plugs	A040E

	Description	Connector
.	Heater plugs	A040D

	Description	Connector
.	Heater plugs	A040C

	Description	Connector
.	Heater plugs	A040B

1. Fit the single fuel manifold pipe (1a) complete with fuel pressure sensor (1b) and secure it tightening the bolts (1c) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1c	2.5	Bolts	INJECTOR FUEL MANIFOLD (DIESEL)	M8

2. Connect the electrical connection to the fuel pressure sensor.

1. Fit a new pipe from the pressure pump to the single fuel manifold and secure it using the connectors without tightening them.2. Tighten the connector for the pipe from the pressure pump to the single fuel manifold, pump side, to the recommended torque using a spanner.

	Value - daNm	Fastening	Component	Ø
2	(pump side) 2.3	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14X1.5

3. Tighten the connector for the pipe from the pressure pump to the single fuel manifold, fuel manifold side, to the recommended torque using a spanner.

	Value - daNm	Fastening	Component	Ø
3	(manifold side) 2.3	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14X1.5

- Tighten the bolts fixing the fuel return manifold to the recommended torque.1. Fit the injectors (1a) in their seats complete with brackets and tighten the nuts (1b) to the recommended torque.

Start the refitting beginning with the injector for cylinder no. 5 and continue with the injectors for cylinders 4, 3, 2, and 1.

	Value - daNm	Fastening	Component	Ø
.	3	Nut	INJECTORS(DIESEL)	M8X1,25

1. Fit the new pipes from the fuel manifold to the injectors and secure them without tightening the connectors.2. Tighten the connectors for the pipes from the fuel manifold to the injector side injectors to the recommended torque using an ordinary spanner.

	Value - daNm	Fastening	Component	Ø
2	(injector side) 2	Connectors	INJECTOR FUEL MANIFOLD PIPE	M12X1.5

3. Tighten the connectors for the pipes from the fuel manifold to the fuel manifold side injectors to the recommended torque using an ordinary spanner.

	Value - daNm	Fastening	Component	Ø
3	(manifold side) 2	Connectors	PIPE FUEL MANIFOLD TO INJECTORS	M12X1.5

Clean the threaded seats for the above mentioned pipe on the manifold and on the injectors using heptane.

- Connect the pipe from the injectors to the fuel recovery manifold pushing it until the clips can be heard clicking.- Place the electrical wiring in position and tighten the cable duct fixing bolts.- Connect the electrical connections for the injectors.

	Description	Connector
.	Injector	N070A

	Description	Connector
.	Injector	N070B

	Description	Connector
.	Injector	N070D

	Description	Connector
.	Injector	N070C

	Description	Connector
.	Injector	N070E

- Fit the timing sensor and tighten the retaining bolt.- Connect the electrical connection to the timing sensor.

	Description	Connector
.	Timing sensor	K047

See in Op. 1032D12 Timing system protective COVER(S) - R.R. See in Op. 1092A10 Crankshaft PULLEY - R.R. See in Op. 1092G21 Engine components single belt FIXED TENSIONER - R.R. with belt removed See in Op. 1092G10 Engine components single drive BELT - R.R. 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. 4450B04 Right FRONT WHEEL (one) - R.R. See in Op. 1064A24 TURBOCHARGER - EXHAUST MANIFOLD - HOSE CONNECTED TO EXHAUST PIPE - R.R. 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. 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. See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R. See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.- Fill the engine cooling system as described in the operation: See in Op. 0010T20 Engine REFRIGERANT FLUID - Change- Top up or, if necessary, change the engine oil referring to operation: See in Op. 0010T10 ENGINE OIL - Change- Or: See in Op. 0010T11 ENGINE OIL - Check level and top up if necessary- Remove the vehicle from the lift.