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

753249 - 1016E22 Right CYLINDER HEAD - Overhaul - Dismantling

) 1. Position the cylinder head (1a) in the vice using the tools (1b), (1c) and (1d).

	Description	Code	Function
1b	Adjustable mount	1.820.012.000	Supporting cylinder head in vice

	Description	Code	Function
1d	Studs	1.860.952.000	Supporting cylinder head in vice

	Description	Code	Function
1c	Fork	1.820.050.000	Supporting cylinder head in vice

1. Undo the bolts (1a) and remove the fuel manifold pipe (1b) with injectors (1c).2. Undo the nuts (2a) and remove the reaction rod support (2b).

1. Undo the bolts (1a) and remove the intake manifold (1b).2. Remove the seal.

1. Undo the bolts (1a) and remove the mobile timing belt tensioner (1b).2. Undo the nuts (2a) and remove the bracket (2b).

- Check that the camshaft endfloat corresponds to the recommended values using a dial gauge on a magnetic base.

	Subject	Value
.	Cyliner head inlet and exhaust shafts	mm
-	Camshaft 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.

1. Remove the spark plug seat seals. 2. Remove the spark plugs.

1. Remove the cylinder half-cones (1a) using the tools (1b), (1c), (1d), (1e) and (1f).

	Description	Code	Function
1b	Valve support	1.820.011.000	Removing/refitting valves

	Description	Code	Function
1f	Lever	1.821.058.000	Removing/refitting valves

	Description	Code	Function
1e	Chamber	1.821.205.000	Removing/refitting valves

	Description	Code	Function
1d	Support	1.821.124.000	Removing/refitting valves

	Description	Code	Function
1c	Connector	1.820.049.000	Removing/refitting valves

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

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

	Description	Code	Function
1b	Extractor	1.821.208.000	Removing valve guide oil seals

2. Remove the spring lower sealing rings (2a) and the valve lower shims (2b).

- Remove the cylinder head from the support tools and place it on a special workbench.1. Remove the valve guides (1a) using the tool (1b).

	Description	Code	Function
1b	Extractor	1.821.176.000	Extracting valve guides

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 surface corresponds to the recommended values.

If grinding is necessary, adjust the flatness of both cylinder heads.

	Subject	Value
1	Engine cylinder heads	mm
-	Cylinder head lower surface flatness	< 0.1

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.

The minimum permitted cylinder head height must never be exceeded, otherwise the cylinder head must be replaced.

	Subject	Value
1	Engine cylinder heads	mm
-	Minimum permitted cylinder head height	134.85 ÷ 135.15

- Remove valve deposits, checking the rod for scoring or signs of binding.- Check that the diameter of the valve stems corresponds to the recommended figures; if not, replace the worn valves.

	Subject	Value
.	Cylinder head valves (all)	mm
-	Valve stem diameter	6.965 ÷ 6.980

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

	Subject	Value
.	Hydraulic tappet casings	mm
-	External hydraulic tappet diameter	32.959 ÷ 32.97

- Check that the diameter of the main journal seats is within specified limits.

	Subject	Value
.	Engine cylinder heads	mm
-	Hydraulic tappet housing diameter	33.000 ÷ 33.025

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

	Subject	Value
.	Cylinder head valve springs (all)	mm
-	-	Valve spring free length
-	Outer	45.0
-	Inner	42.0

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

	Subject	Value
.	Cylinder head valve springs (all)	mm
-	External valve spring height	32.5
-	Test load	21.9 ÷ 23.1

	Subject	Value
.	Cylinder head valve springs (all)	mm
-	External valve spring height	23,0
-	Test load	43.1 ÷ 45.0

	Subject	Value
.	Cylinder head valve springs (all)	mm
-	Internal valve spring height	30,5
-	Test load	12.4 ÷ 13.1

	Subject	Value
.	Cylinder head valve springs (all)	mm
-	Internal valve spring height	21,0
-	Test load,	24.0 ÷ 26.0

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

The camshaft journal surfaces must not show signs of wear, scoring or binding, otherwise replace the shafts.

	Subject	Value
.	Cyliner head inlet and exhaust shafts	mm
-	Camshaft journal diameter	26.959 ÷ 26.980

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

The camshaft cam surfaces must not show signs of wear, scoring or binding, otherwise replace the shafts.

	Subject	Value
.	Cyliner head inlet and exhaust shafts	mm
-	Nominal camshaft cam lift	9.30

- Refit the camshaft caps on the right cylinder head following the order illustrated in the diagram.

1. Tighten the camshaft cap bolts to the recommended torque.

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

2. Check that the diameter of the camshaft mounts is as specified.

	Subject	Value
.	Engine cylinder heads	mm
-	Diameter of camshaft mounts	27.010 ÷ 27.036

- Check that the outer diameter of the valve guides is as specified.

	Subject	Value
.	Cylinder head valve guides	mm
-	-	Valve guide outer diameter
-	Inlet	12.040 ÷ 12.051

	Subject	Value
.	Cylinder head valve guides	mm
-	-	Valve guide outer diameter oversize
-	Inlet	0.20

Parts supplies intake valve guides with outer diameter of 12.053 ÷ 12.064 mm

	Subject	Value
.	Cylinder head valve guides	mm
-	-	Valve guide outer diameter
-	Exhaust	12.050 ÷ 12.068

	Subject	Value
.	Cylinder head valve guides	mm
-	-	Valve guide outer diameter oversize
-	Exhaust	0.20

Parts supplies exhaust valve guides with outer diameter of 12.064 ÷ 12.082 mm

- Check that the valve guide seat diamters is within specified values. If not, ream the seats according to the valve guide oversize.

	Subject	Value
.	Engine cylinder heads	mm
-	Valve guide seat diameter	12.000 ÷ 12.018

1. Refit the valve guides (1a) in their seats using installing tool (1b).

The use of the above tool ensures correct valve guide protrusion.

	Description	Code	Function
1b	Fitting tool	1.821.207.000	Fitting valve guides

1. Ream the new valve guides using an appropriate tool to calibrate the holes to the specified diameter.

	Subject	Value
1	Cylinder head valve guides	mm
-	Inner valve guide diameter (reaming)	7.000 ÷ 7.015

1. Regrind the valve seats to the recommended size.

	Subject	Value
1	Cylinder head valve seats (all)
-	Contact band angle with valves	90° ± 20'

- Grind the valve seats using a suitable tool.

Use SIPAL Arexons abrasive or a simlar product to grind the valve seats.

- Position the cylinder head in a vice using the tools.

	Description	Code	Function
.	Adjustable mount	1.820.012.000	Supporting cylinder head in vice

	Description	Code	Function
.	Fork	1.820.050.000	Supporting cylinder head in vice

	Description	Code	Function
.	Studs	1.860.952.000	Supporting cylinder head in vice

- Refit the lower valve shims and the lower spring contact rings in their seats.1. Remove the valve guide oil seals (1a) using the tool (1b).

	Description	Code	Function
1b	Fitting tool	1.821.206.000	Fitting valve guide oil seals

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

	Description	Code	Function
1b	Valve support	1.820.011.000	Removing/refitting valves

	Description	Code	Function
1c	Connector	1.820.049.000	Removing/refitting valves

2. Place the valve springs in their housings.3. Refit the upper valve shims in their housings.4. Place the cylinder valve half-cones (4a) in their housings using the tools (4b), (4c) and (4d).

	Description	Code	Function
4b	Support	1.821.124.000	Removing/refitting valves

	Description	Code	Function
4c	Chamber	1.821.205.000	Removing/refitting valves

	Description	Code	Function
4d	Lever	1.821.058.000	Removing/refitting valves

- Remove the tools used for fitting the valves.- Carry out the same operations to refit the remaining valves.1. Fit the spark plugs and tighten them to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1	(Cylinder head side) 2.4 - 3.0	-	SPARK PLUGS	M14

1. Test the valve seal using tools (1a) and (1b).

	Description	Code	Function
1a	Lever	1.860.490.000	Valve leakage test

	Description	Code	Function
1b	Pressurising device	1.895.868.000	Valve leakage test

1. Refit the spark plug socket seals.2. Place the hydraulic tappets in their housings.3. Place the camshafts in their housings.

- Refit the camshaft caps on the right cylinder head following the order illustrated in the diagram.

- Tighten the bolts fixing the camshaft caps to the recommended torque.

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

1. Remove the camshaft oil seals (1a) using the tool (1b).

	Description	Code	Function
1b	Fitting tool	1.860.948.000	Fitting camshaft front oil seals

- Refit the bracket and secure with the bolt.- Reposition the moving timing system tensioner in its housing and secure it without tightening the nut.1. Refit the intake manifold (1a) complete with gasket (1b) back in its housing and secure it tightening the bolts (1c) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1c	(Cylinder head side) 1.9 - 2.3	Bolt	INLET MANIFOLD	M8

1. Refit the reaction rod bracket (1a) in its seat and secure it by tightening the nuts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Cylinder head side) 4.5 - 5.5	Nut	REACTION LINK BRACKET ON ENGINE	M10

- Place the fuel manifold pipe complete with injectors in its housing and secure it using the bolts.- Remove the cylinder head from the support tools.