1016D20 LEFT CYLINDER HEAD - R.R. AND REPLACE GASKET - Lancia - THESIS - eLearn

184738 - 1016D20 LEFT 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 disconnect the negative battery lead. See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R. See in Op. 1088B10 Engine coolant SUPPLY RESERVOIR - R.R. See in Op. 1048A28 vacuum air circuit resonator pipe - r+r See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R. See in Op. 1048A23 Cold AIR INTAKE for air filter - R.R. See in Op. 1048A11 COMPLETE AIR FILTER -R.R. See in Op. 1008C10 Power unit REACTION ROD - Replace See in Op. 1016A42 LEFT CYLINDER HEAD IGNITION COIL COVER - R.R. See in Op. 1088E10 Radiator cooling FAN - R.R.- Position a suitable container for collecting the coolant.- Raise the vehicle See in Op. 4450B04 Right FRONT WHEEL (one) - 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. 1092G10 Engine components single drive BELT - R.R. See in Op. 7055B54 PROTECTION/GUARD under engine - R.R. See in Op. 1076B82 EXHAUST PIPE BETWEEN RIGHT PRECONVERTER AND CATALYTIC CONVERTER - R.R. See in Op. 1080B38 LEFT CATALYTIC PRECONVERTER - R.R. or Replace Gasket1. Release the retainers (1a) and disconnect the gearbox bowden cable (1b).

1. Disconnect the connectors (1a) for the gearbox wiring.

	Description	Connector
1	Automatic transmission solenoid valves	L050A

	Description	Connector
1	Automatic transmission solenoid valves	L050B

	Description	Connector
1	Automatic transmission solenoid valves	L050C

1. Open the protective flap (1a) and undo the nut (1b) fixing the starter motor supply lead (1c) to the junction node and move the lead between the junction node and the motor aside.

	Description	Connector
1b	Contact board	A005A

	Description	Connector
1b	Contact board	A005B

1. Position a hydraulic jack under the gearbox casing and undo the two nuts (1a) fixing the gearbox side engine support (1b) to the bracket (1c), then lower the jack until the gearbox casing is resting on the suspension frame.

1. Open the band (1a) retaining the power assisted steering pipes (1b) and move them aside.2. Undo the upper bolts (2a) fixing the timing belt upper cover (2b) and remove it.

1. Undo the two bolts (1a) fixing the power assisted steering pipe band mounting bracket (1b) and move it aside.

- Raise the vehicle See in Op. 1092A10 Crankshaft PULLEY - R.R. for versions with air conditioner See in Op. 1088C24 Water pump PULLEY - R.R. with timing belt removed-1. Undo the six fixing bolts (1a) and remove the two lower timing belt guards (1b).

1. Disconnect the rapid connector (1a) for the fuel pipe (1b) from the tank, undo the bolt (1c) fixing the pipe retaining duct (1d), then open the duct and release the pipe.

1. Undo the two fixing bolts (1a) and remove the left head fuel manifold (1b) complete with injectors.

1. Undo the bolt (1a) and remove the upper timing belt moving tensioner (1b).- Release the timing drive belt from the driven pullies.

1. Tighten the fixing bolt (1b) using the tool (1a) and remove the upper timing drive belt fixed tensioner (1c).

	Description	Code	Function
1a	Spanner for fixed tensioner	1.870.749.000	Loosen/tighten timing lower fixed tensioner fixing bolt

1. Undo the bolts (1a) for the left head driven toothed pullies using the tool (1b) for counter-torque.

	Description	Code	Function
1b	Support for counter-torque	1.860.831.000	Loosen/tighten exhaust side camshaft drive pulley bolt

1. Remove the left head toothed driven pullies (1a) using the tool (1b).

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

1. Undo the four fixing bolts (1a) and remove the left rear guard (1b) for the timing belt.

1. Undo the fixing bolts (1a) and remove the left head intake manifold (1b).

1. Undo the two gearbox side bolts (1a) fixing the power assisted steering pump (1b).

1. Undo the timing belt side bolt (1a) fixing the power assisted steering pump (1b) and move the latter to the side leaving it connected to the pipes.

1. Undo the nuts (1a) and remove the left cylinder head (1b).

Two mechanics are needed for this stage

- Remove the left head gasket

Refitting ( Removing

) - Fit a new left cylinder head gasket.

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: - keep the gasket sealed in its container until it is fitted; - do not lubricate the gasket or contact surfaces or get oil on them.

Two mechanics are needed for this stage

- Position the cylinder head on the cylinder block/crankcase.1. Tighten the nuts (1a) fixing the cylinder head to the recommended torque, in stages, using the angular tightening tool (1b).

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

	Value - daNm	Fastening	Component	Ø
1a	2,5 + 230°	Nut	CYLINDER HEAD FASTENERS	M12

	Description	Code	Function
1b	Torque wrench	1.860.942.000	Cylinder head nuts angular tightening.

- Position the power assisted steering pump and then tighten the fixing bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.2	Bolt	POWER STEERING PUMP SUPPORT/BRACKET	M8

- Position the intake manifold and gasket and tighten the fixing bolts.- Position the timing belt left rear guard and tighten the fixing bolts.- Fit the left head toothed driven pullies and secure them without tightening the bolts.- Fit the upper fixed timing tensioner and secure it by tightening the bolt to the recommended torque.

	Value - daNm	Fastening	Component	Ø
	2.1	Bolt	FIXED TENSIONER	M8

- Fit the moving timing belt tensioner and secure it without tightening the bolts. See in Op. 1072B50 Air CHAMBER - R.R. See in Op. 5510C18 Right cylinder head IGNITION COILS - R.R. See in Op. 1016A34 Right TAPPET COVER - R.R. and Replace gasket- Using the tool consisting of the USAG 279 MG bush and extension USAG 236 3/8 125 or an equivalent tool, undo and remove the spark plug for the right head timing side cylinder.1. Fit the tool (1a), complete with dial gauge (1b), in the housing for the spark plug removed previously.

	Description	Code	Function
1a	Extension	1.870.896.500	Engine tuning

- Rotate the crankshaft through small rotations (in both directions) until the piston for the right head timing side cylinder no. 1 is at T.D.C. in the explosion stroke.

Take care that the last rotation of the crankshaft is in the direction of operation.

2. Remove the camshaft caps marked with the letters "B" and "G" for the right head and, in their place, fit the templates (2a) and (2b) with the writing "1.860.820.001 /DX A 1 CIL" and "1.870.896.600 / DX S 1 CIL", respectively.

	Description	Code	Function
2a	Templates	1.860.820.000	Engine tuning

	Description	Code	Function
2b	Templates	1.860.820.000	Engine tuning

1. Remove the camshaft caps marked with the numbers "7" and "4" for the left cylinder head and, in their place, fit the templates (1a) and (1b) with the writing "1.870.896.600 / SX S 4CIL" and "1.860.820.002 /SX A 6CIL".

	Description	Code	Function
1a	Templates	1.860.820.000	Engine tuning

	Description	Code	Function
1b	Templates	1.860.820.000	Engine tuning

- Loosen the bolts for the camshaft drive pullies using the special tool for counter-torque.

	Description	Code	Function
.	Counter-torque	1.870.896.300	Lock the rotation of the driven toothed pulley

- Fit the timing drive belt starting from the drive pulley and continuing in an anti-clockwise direction making sure that the drive branches are properly taut.1. Fit the tool (1a) and secure it using bolt (1b) for the alternator and bolt (1c) for the water pump.

The tooth (1d) for the tool should engage with the moving part of the timing belt tensioner.

	Description	Code	Function
1a	Belt tensioner	1.860.950.000	Timing belt tensioning

2. Act on the belt tensioner tool nut (2a) until the moving reference on the belt tensioner (2b) is under the fixed reference.

1. Tighten the bolts (1a) for the camshaft drive pullies to the recommended torque using tools (1b) and (1c).

The tightening torque figure in the table is a nominal one; therefore the correct value must be calculated according to the length of the spanner extension.

	Value - daNm	Fastening	Component	Ø
1a	6.8 - 8.4	Bolt	TIMING DRIVEN PULLIES	M10

	Description	Code	Function
1b	Counter-torque	1.870.896.300	Lock the rotation of the driven toothed pulley

	Description	Code	Function
1c	Extension for torque wrench	1.870.896.400	Tightening camshaft drive pulley bolts

- Remove the timing templates.

	Description	Code	Function
	Templates	1.860.820.000	Engine tuning

- Fit the camshaft caps removed in place of the templates removed and secure them by tightening the bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	(Cylinder head side) 1.8 -2.0	Bolt	CAMSHAFT CAPS	M8

- Rotate the crankshaft through two revolutions in its direction of rotation to allow the timing belt to bed in.1. Check that the moving reference for the timing belt tensioner coincides with the fixed reference.2. If the references are not aligned, gently release the tensioner tension acting on the nut for the tensioning tool until the reference coincide.3. Tighten the bolts for the timing belt tensioner to the recommended torque.

	Value - daNm	Fastening	Component	Ø
3	(Cylinder head side) 1.7 -2.1	Bolt	MOBILE TIMING TENSIONER	M8

- Remove the belt tensioner tool.

	Description	Code	Function
.	Belt tensioner	1.860.950.000	Timing belt tensioning

- Remove the dial gauge and the extension from the housing for the spark plug for the right head timing side cylinder no. 1.

	Description	Code	Function
	Extension	1.870.896.500	Engine tuning

- Fit the spark plug for the right head timing side cylinder no. 1 tightening it to the recommended torque using the tool consisting of the USAGE 279 MG bush and the USAG 236 3/8 125 extension or an equivalent tool.

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

See in Op. 1016A34 Right TAPPET COVER - R.R. and Replace gasket See in Op. 5510C18 Right cylinder head IGNITION COILS - R.R. See in Op. 1072B50 Air CHAMBER - R.R.- Position the left head fuel manifold complete with injectors and tighten the fixing bolts to the recommended torque.

Check that the injectors are correctly positioned in their seats.

	Value - daNm	Fastening	Component	Ø
.	0.9	Bolt	COMPLETE FUEL PIPE	M6

- Connect the rapid connector for the fuel pipe from the tank, then position the pipe and tighten the fixing bolt for the pipe retaining duct.- Position the two lower timing belt guards and tighten the six fixing bolts to the recommended torque.

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

See in Op. 1088C24 Water pump PULLEY - R.R. with timing belt removed See in Op. 1092A10 Crankshaft PULLEY - R.R. for versions with air conditioner- Lower the vehicle.- Correctly position the power assisted steering pipe band mounting bracket and tighten the two fixing bolts.- Position the timing belt upper cover (2b) and tighten the fixing bolts to the recommended torque.

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

- Position the power assisted steering pipes and close the retaining band.- Raise the jack positioned under the gearbox casing and tighten the two nuts fixing the gearbox side engine support to the bracket to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	5	Nut	POWER UNIT GEAR BOX END RIGID MOUNT	M10 X 1.25

- Connect the lead between the junction node and the starter motor to the actual node and tighten the fixing nut, then close the protective flap.

	Value - daNm	Fastening	Component	Ø
.	0.5	Nut	TERMINAL/MOTOR LEAD	M8

- Connect the connectors for the gearbox wiring.

	Description	Connector
.	Automatic transmission solenoid valves	L050A

	Description	Connector
.	Automatic transmission solenoid valves	L050B

	Description	Connector
.	Automatic transmission solenoid valves	L050C

- Position the gearbox bowden cable and secure the retainers. See in Op. 1080B38 LEFT CATALYTIC PRECONVERTER - R.R. or Replace Gasket See in Op. 1076B82 EXHAUST PIPE BETWEEN RIGHT PRECONVERTER AND CATALYTIC CONVERTER - R.R. See in Op. 7055B54 PROTECTION/GUARD under engine - R.R. See in Op. 1092G10 Engine components single drive BELT - 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. 4450B04 Right FRONT WHEEL (one) - R.R.- < R1 > Lower the vehicle See in Op. 1088E10 Radiator cooling FAN - R.R. See in Op. 1016A42 LEFT CYLINDER HEAD IGNITION COIL COVER - R.R. See in Op. 1008C10 Power unit REACTION ROD - Replace See in Op. 1048A11 COMPLETE AIR FILTER -R.R. See in Op. 1048A23 Cold AIR INTAKE for air filter - R.R. See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R. See in Op. 1048A28 vacuum air circuit resonator pipe - r+r See in Op. 1088B10 Engine coolant SUPPLY RESERVOIR - R.R. See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.- Connect the negative battery lead, then close the boot.- Remove the vehicle from the lift. See in Op. 0010T21 ENGINE COOLANT - Check density and top up if necessary-