1016E22 RIGHT CYLINDER HEAD - OVERHAUL - DISMANTLING - Lancia - THESIS - eLearn

753249 - 1016E22 Right CYLINDER HEAD - Overhaul - Dismantling

) 1. Place the tool A in the vice.

	Description	Code	Function
1	Support	1.860.783.000	-

2. Fit the tool (2a) A complete with the tool (2b) A.

	Description	Code	Function
2a	Support	1.860.784.000	-

	Description	Code	Function
2b	Bearings	1.860.952.000	-

3. Position the cylinder head (3a) on the support tools and fasten it using the nuts (3b).

1. Undo the bolts (1a) and remove the intake manifolds (1b).2. Undo the bolts (2a) and remove the fuel distribution manifold (2b) with injectors (2c).3. Remove the air intake manifold (3a) complete with gasket (3b).

1. Undo the bolts (1a) and remove the timing drive belt automatic belt tensioner (1b).2. Undo the bolt (2a) and remove the timing drive belt fixed belt tensioner (2b).

1. Loosen the bolts (1a) for the camshaft drive pullies using the tools (1b) A for counter-torque.

	Description	Code	Function
1b	Support for counter-torque	1.860.831.000	Support

1. Remove the camshaft drive pullies (1a) using the tool (1b) A.

	Description	Code	Function
1b	Extractor	1.860.954.000	-

1. Undo the bolts (1a) and remove the timing belt guard (1b).2. Undo the nuts (2a) and remove the reaction rod support (2b).

1. Undo the bolt (1a) and remove the coolant outlet connector (1b) from the right cylinder head.2. Undo the bolt (2a) and remove the cam angle sensor (2b) complete with O-Ring (2c).

- Check that the camshaft endfloat M is within the recommended values using a dial gauge on a mangetic base.

	Subject	Value
.	Camshafts	-
-	End float	0.060 - 0.201

- If the camshaft endfloat does not correspond to the recommended figures, replace the worn components when reassembling.1. Undo the bolts (1a) and remove the camshaft caps (1b).2. Remove the camshafts.3. Remove the camshaft front oil seals.4. Remove the hydraulic tappets.5. Remove the spark plug seat seals.

1. 1. Remove the cotters (1a) using the tools (1b), (1c), (1d), (1e) and (1f) A.

	Description	Code	Function
1b	Valve support	1.860.786.000	-

	Description	Code	Function
1c	Special nut	1.860.787.000	-

	Description	Code	Function
1d	Support	1.860.788.000	Removing/refitting valves

	Description	Code	Function
1e	Chamber	1.860.840.000	-

	Description	Code	Function
1f	Lever	1.860.790.000	-

2. Remove the valve upper shim.3. Remove the valve springs.- Remove the tools used for dismantling the valves.4. Remove the valve.- Carry out the same operations for removing the remaining valves.

1. Remove the valve guide oil seal (1a) using the tool (1b) A.

	Description	Code	Function
1b	Extractor	1.860.835.000	-

2. Remove the spring lower seal (2a) and the valve lower shim (2b).

- Remove the cylinder head from the support tools and place it on a special workbench.1. Thread the special extraction tool (b) into the valve seat (1a).- Turn the cylinder head upsidedown on the workbench.- Remove the valve seat using the extraction tool.

1. Remove the valve guides (1a) using the tool (1b) A.

	Description	Code	Function
1b	Extractor	1.860.395.000	-

Refitting ( Removing

) - Clean any residues of the old gasket from the lower cylinder head plane.1. Check that the planarity of the lower cylinder head plane M corresponds to the recommended values.

	Subject	Value
1	Cylinder head	-
-	Lower plane planarity	0.05

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 M.

	Subject	Value
1	Cylinder head	-
-	Minimum permitted height after refacing	134.85 - 135.15

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

	Subject	Value
.	Valves	-
-	Stem diameter	6.965 - 6.980

- Check that the outer diameter of the hydraulic tappets M corresponds to the recommended figures; if not, replace the worn hydraulic tappets.

	Subject	Value
.	Hydraulic tappets	-
-	Outer diameter	32.959 - 32.975

- Check that the diameter of the hydraulic tappet housings M corresponds to the recommended figures; if not, replace the cylinder head.

	Subject	Value
.	Cylinder head	-
-	Hydraulic tappet housing diameter	33.000 - 33.025

- Check that the length of the valve springs M released corresponds to the recommended figures.

	Subject	Value
.	Valve springs	-
-	-	Free length
-	Outer	45
-	Inner	42

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

	Subject	Value
.	Valve springs	-
-	Length with load	22.4 - 23.6
-	Outer	32.5

	Subject	Value
.	Valve springs	-
-	Length with load	45.9 - 43.9
-	Outer	23

	Subject	Value
.	Valve springs	-
-	Length with load	12.6 - 13.4
-	Inner	30.5

	Subject	Value
.	Valve springs	-
-	Length with load	23.5 - 26.5
-	Inner	21

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

	Subject	Value
.	Camshafts	-
-	Journal diameter	26.959 - 26.980

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

	Subject	Value
.	Camshafts	-
-	Nominal cam lift	9.30

1. Fit the camshaft caps on the right cylinder head following the order illustrated in the diagram.

1. Tighten the camshaft cap bolts to torque C.

	Value - daNm	Fastening	Component	Ø
.	1.8 - 2.5	Bolt	CAMSHAFT CAPS	M8

2. Check that the diameter of the camshaft supports M corresponds to the recommended figures; if not, replace the cylinder head.

	Subject	Value
2	Cylinder head	-
-	Diameter of camshaft supports	27.010 - 27.036

- Check that the outer diameter of the valve guides M to be fitted corresponds to the recommended figures.

	Subject	Value
.	Valve guides	-
-	-	Outer diameter
-	Inlet	12.040 - 12.051
-	Exhaust	12.050 - 12.068

	Subject	Value
.	Cylinder head valve guides	mm
-	Valve guide oversize	0.20
-	Spares (*)	12.053 - 12.064

	Subject	Value
.	Cylinder head valve guides	mm
-	Valve guide oversize	0.20
-	Spares (**)	12.064 - 12.082

1. Fit the valve guides (1a) using the tool (1b) A.

	Description	Code	Function
.	Fitting tool	1.860.947.000	-

- Ream the valve guide inner diameter M to the recommended figure.

	Description	Code	Function
.	Reamer	1.890.313.000	Ream

	Subject	Value
.	Valve guides	-
-	Inner diameter (reaming)	7.000 - 7.015

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

	Subject	Value
.	Valve seats	-
-	-	Outer diameter
-	Inlet	35.500 - 35.900
-	Exhaust	31.000 - 31.200

	Subject	Value
.	Cylinder head valve seats (all)	mm
-	Oversize	0.3

	Subject	Value
.	Cylinder head valve seats (all)	mm
-	Oversize	0.3

1. Heat the cylinder head to 100-120°C, then fit the valve seats (1a) using a suitable tool (1b).

	Description	Code	Function
1b	Fitting tool	1.860.395.000	Fit

1. Regrind the valve seats to the recommended size M.

	Subject	Value
1	Valve seats	-
-	Contact band taper with valve	90° ± 20'

- Grind the valve seats using a suitable tool.

- Fit the cylinder head on the support tools and fasten it using the nuts.- Fit the lower valve shim and the lower valve seal.1. Fit the valve guide oil seal (1a) using the tool (1b) A.

	Description	Code	Function
1b	Fitting tool	1.860.454.000	-

1. Fit the valves (1a) for the cylinder in question and support them using the tools (1b) and (1c) A.

	Description	Code	Function
1b	Valve support	1.860.786.000	-

	Description	Code	Function
1c	Special nut	1.860.787.000	-

2. Fit the valve springs.3. Fit the upper valve shims.4. Fit the cotters (4a) using the tools (4b), (4c), and (4d) A.

	Description	Code	Function
4b	Support	1.860.788.000	Removing/refitting valves

	Description	Code	Function
4c	Chamber	1.860.840.000	-

	Description	Code	Function
4d	Lever	1.860.790.000	-

- Carry out the same operations to refit the remaining valves.- Remove the tools used for fitting the valves.

1. Fit the spark plug seat seals.2. Fit the hydraulic tappets.3. Fit the camshafts.

1. Fit the camshaft caps on the right cylinder head following the order illustrated in the diagram.

- Tighten the camshaft cap bolts to torque C.

	Value - daNm	Fastening	Component	Ø
.	1.8 - 2.5	Bolt	CAMSHAFT CAPS	M8

1. Fit the camshaft front oil seals (1a) using the tool (1b) A.

	Description	Code	Function
1b	Fitting tool	1.860.948.000	Camshaft front oil seal

- Fit the cam angle sensor complete with O-Ring and fasten it using the bolt.

	Value - daNm	Fastening	Component	Ø
.	0.7 - 1.0	Bolt	CAM ANGLE SENSOR

- Fit the right cylinder head coolant outlet connector and fasten it using the bolt.- Fit the reaction rod support and secure it using the nuts.

	Value - daNm	Fastening	Component	Ø
.	2.3 - 3.3	Nuts	POWER UNIT REACTION ROD	-

- Fit the timing belt guard and secure it using the bolts.

	Value - daNm	Fastening	Component	Ø
.	0.8 - 1.2	Bolts	TIMING BELT PROTECTIVE COVER(S)	-

1. Fit the camshaft drive pullies.2. Tighten the camshaft drive pulley bolts (2a) using the tools (2b) A to torque C.

	Description	Code	Function
2b	Support for counter-torque	1.860.831.000	Support

	Value - daNm	Fastening	Component	Ø
2a	7.3 - 10.6	-	CAMSHAFT DRIVE PULLIES	M10

- Fit the timing drive belt fixed belt tensioner and fasten it using the bolt.- Fit the timing drive belt automatic belt tensioner and secure it without tightening the bolts.- Fit the intake manifold complete with gasket.- Fit the fuel distribution manifold complete with injectors and secure it using the fixing bolts.- Fit the intake manifolds and secure them using the bolts.- Remove the cylinder head from the support tools.- Remove the cylinder head support tools from the vice and put them down.