1016D14 CYLINDER HEADS - R.R. AND REPLACE GASKETS WITH ENGINE REMOVED - Lancia - THESIS - eLearn

866778 - 1016D14 CYLINDER HEADS - R.R. and Replace gaskets with engine removed

) See in Op. 1004D40 ENGINE - Position on stand and Remove- Proceed with the removal1. Open the electrical connection holder case.2. Disconnect the electrical connection for the timing side knock sensor.

	Description	Connector
2	Detonation sensor - 2	K050

1. Loosen the bands securing the intake manifolds to the air chamber.2. Loosen the band securing the engine idle oil vapour recovery pipe, air capacity chamber side.3. Disconnect the electrical connection from the throttle casing with D.V.L.

	Description	Connector
3	Integrated throttle casing actuator	N075

1. Unscrew retaining bolt (1a) and disconnect earth lead (1b) from the air capacity chamber.

	Description	Connector
1b	Earth on engine	C040

2. Unscrew the bolt securing the stiffening rod to the reaction link mount on the engine.3. Undo bolts (3a) and remove air capacity chamber (3b).

1. Undo the bolts (1a) and remove the intake ducts (1b) complete with sleeves (1c).2. Remove the seals.

1. Disconnect the electrical connections from the right cylinder head injectors.

	Description	Connector
1	Injector	N070A

	Description	Connector
1	Injector	N070B

	Description	Connector
1	Injector	N070D

	Description	Connector
1	Injector	N070C

	Description	Connector
1	Injector	N070E

	Description	Connector
.	Injector	N070F

2. Disconnect the electrical connections from the right cylinder head ignition coils.

	Description	Connector
2	Ignition coil	A030A

	Description	Connector
2	Ignition coil	A030B

	Description	Connector
2	Ignition coil	A030F

	Description	Connector
2	Ignition coil	A030E

	Description	Connector
2	Ignition coil	A030D

	Description	Connector
2	Ignition coil	A030C

3. Undo bolts (3a) and move electrical wiring duct (3b) aside.

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

Take care not to damage the cam angle sensor.

1. Undo the bolts (1a) and remove the ignition coils (1b) from the right cylinder head.

1. Disconnect the electrical connection for the coolant temperature sensor.

	Description	Connector
1	Engine coolant temperature sensor/sender unit	K036

2. Open the electrical connection holder case.3. Release the electrical connections and wiring from the connection holder case.

1. Undo the bolts (1a) and remove the thermostat (1b) complete with connection holder case (1c).2. Remove the fitting

1. Disconnect the electrical connection for the flywheel side knock sensor.

	Description	Connector
1	Detonation sensor - 2	K051

2. Disconnect the electrical connection for the rpm sensor.

	Description	Connector
2	Rpm sensor	K046

1. Undo the nut (1a) and disconnect the earth lead (1b) from the left cylinder head.

	Description	Connector
1b	Earth on engine	C040

1. Undo the bolts (1a) and remove the ignition coil cover on the left cylinder head (1b).

1. Disconnect the electrical connections from the left cylinder head injectors.

	Description	Connector
1	Injector	N070A

	Description	Connector
1	Injector	N070B

	Description	Connector
1	Injector	N070F

	Description	Connector
1	Injector	N070E

	Description	Connector
1	Injector	N070D

	Description	Connector
1	Injector	N070C

2. Disconnect the electrical connections from the left cylinder head ignition coils.

	Description	Connector
2	Ignition coil	A030A

	Description	Connector
2	Ignition coil	A030B

	Description	Connector
2	Ignition coil	A030F

	Description	Connector
2	Ignition coil	A030E

	Description	Connector
2	Ignition coil	A030D

	Description	Connector
2	Ignition coil	A030C

3. Undo bolts (3a) and move electrical wiring duct (3b) aside.4. Remove the engine wiring.

1. Undo the bolts (1a) and remove the ignition coils (1b) from the left cylinder head.

1. Disconnect the rapid connector from the fuel manifold pipes.

1. Undo the fixing bolts (1a) and remove the upper protective timing cover (1b).

1. Undo the fixing bolts (1a) and remove the lower protective timing cover (1b).

1. Loosen the bolts retaining the timing belt moving tensioner.2. Prise off the timing drive belt from the toothed driven pullies.

1. Unscrew the bolt securing the left rear cove protecting the right cylinder head timing drivebelt.

1. Undo the bolts (1a) and bolt (1b) remove bracket (1c).

1. Unscrew the power steering pump bolt

1. Undo the bolts (1a) and remove the left cylinder head cam cover (1b) complete with gasket.

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

	Description	Code	Function
1b	Counter-torque	1.822.146.000	Loosen/tighten driven toothed pulley bolts

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

	Description	Code	Function
1b	Extractor	1.860.954.001	Extracting toothed driven pullies

1. Undo the bolts (1a) and remove the fixed timing belt tensioner (1b).2. Undo the fixing bolts (2a) and remove the left rear protective timing cover (2b).

1. Undo nuts (1a) securing the left cylinder head using tool (1b).

	Description	Code	Function
1b	Spanner	1.822.121.000	Loosen/tighten cylinder head fixing bolts

- Remove the left cylinder head and gasket.

1. Undo the fixing bolts (1a) and remove the right rear protective timing cover (1b).

1. Undo the bolts (1a) and remove the right cylinder head cam cover (1b) complete with gasket.

1. Undo the bolts (1a) and remove the alternator bracket (1b).

1. Undo nuts (1a) securing the right cylinder head using tool (1b).

	Description	Code	Function
1b	Spanner	1.822.121.000	Loosen/tighten cylinder head fixing bolts

- Remove the right cylinder head and gasket.

1. Fit the cylinder liner retaining tools.

	Description	Code	Function
1	Cylinder bore lock	1.820.279.000	Keep the cylinder liners/bores in their seats

Refitting ( Removing

) - Carry out a preliminary camshaft timing adjustment: apply a wrench into seat (1a) in the centre of the camshafts and turn to align reference marks (b) on the shafts with the upper cylinder head surface.

The reference marks must face the middle of each cylinder head.

1. Remove caps 4 to 7 from the left cylinder head.2. Remove caps B and G from the right cylinder head.

1. Repalce the removed camshaft caps with the timing templates.

	Description	Code	Function
1	Templates	1.870.849.000	Engine tuning

- Remove the liner/bore locks.

	Description	Code	Function
.	Cylinder bore lock	1.820.279.000	Keep the cylinder liners/bores in their seats

- Place the cylinder head centering bushes on the cylinder block.1. Position the new cylinder head gaskets (1a) taking care to inser the sealing rings in the lubrication ducts (1b) (two for each cylinder head).

The material from which these gaskets are 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:

- Set the 1st cylinder to TDC before fitting the cylinder heads on the engine block.- Position the cylinder heads on the cylinder block/crankcase.1. Tighten nuts (1a) securing the cylinder heads to the specified torque using tools (1b) and (1c) for angular tightening.

Lubricate threads, nuts and washers with engine oil.

Follow the order shown in the figure for each tightening sequence.The right cylinder head is illustrated; the tightening order for the left cylinder head is symmetrical.

	Value - daNm	Fastening	Component	Ø
1a	(Engine crankcase) 2.4 ÷ 2.6 + 228° ÷ 232°	Nut	CYLINDER HEAD	M12

	Description	Code	Function
1c	Spanner	1.822.121.000	Tightening cylinder head nuts

- Place the alternator bracket in its housing and secure it using the bolts.- Fit the rear timing belt covers and secure them using the bolts.1. Place the fixed timing tensioners (1a) in their housings and secure them tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Cylinder head side) 4.5 - 5.5	Bolt	FIXED TENSIONER	M10

2. Refit toothed driven pulleys (2a) and secure by screwing in bolts (2b) without tightening.

- Tighten the bolt securing the left rear cover protecting the right cylinder head timing drivebelt.1. Fit the tool (1a) complete with dial gauge (1b) in the seat for the spark plug for cylinder no. 1.

	Description	Code	Function
1a	Extension	1.821.225.000	T.D.C. check

- 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 combustion stroke.

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

1. 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 bracket 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	Toothed timing drive belt tensioner

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 bolts (1a) for the right head toothed driven pullies to the specified torque using the tool (1b) for counter-torque.

	Value - daNm	Fastening	Component	Ø
1a	(camshaft side) 7.2 - 8.8	bolt	TIMING DRIVEN PULLIES	M12

	Description	Code	Function
1b	Counter-torque	1.822.146.000	Loosen/tighten driven toothed pulley bolts

- Remove the tools for timing the camshafts.

	Description	Code	Function
.	Templates	1.870.849.000	Engine tuning

- Place the camshaft caps in their housings to replace the removed tools and secure them 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 toothed 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 nut fixing the moving timing tensioner to the recommended torque.

	Value - daNm	Fastening	Component	Ø
3	(Cylinder head side) 1.9 - 2.3	Bolt	FIXED TENSIONER	M8

- Remove the belt tensioner tool.

	Description	Code	Function
.	Belt tensioner	1.860.950.000	Toothed timing drive belt tensioner

1. - Place the cylinder head cam covers (1a) in their housings with gaskets and secure them tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Cylinder head side) 1.4 - 1.7	Bolt	TAPPET COVERS	M7

1. Tighten the bolt securing the power steering pump to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1	(Mount side) 2.3 - 2.8	Bolt	POWER STEERING PUMP	M8

2. Refit bracket (2a) and secure with bolt (2b) and bolts (2c).

- Fit the lower timing belt covers and secure them using the bolts.- Fit the upper timing belt covers and secure them using the bolts.- Connect the rapid connector for the fuel manifold pipes.1. Replace the left cylinder head ignition coils (1a) in their housings with gaskets and secure them tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Cam cover side) 0.8 ÷ 1.0	Bolt	IGNITION COIL/REEL	M6

- Refit the engine wiring- Refit the electrical wiring channel and secure with bolts.-- Connect the electrical connections to the left cylinder head ignition coils.- Connect the electrical connections to the left cylinder head injectors.- Place the ignition coil cover on the left cylinder head back in its housing and secure it using the bolts.- Connect the earth lead to the left cylinder head and secure it using the nut.- Connect the electrical connection for the flywheel side knock sensor.- Connect the electrical connection for the rpm sensor.1. Place the connector back in its housing.2. Place the thermostat (2a) in its housing and secure it by tightening the bolts (2b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2b	(Cylinder head side) 0.8 - 1.0	Bolt	THERMOSTAT	M6

- Refit the wiring and connections in the eletrical connection holder case, then close the cover.- Connect the coolant temperature sensor electrical connection.1. Replace the right cylinder head ignition coils (1a) in their housings with gaskets and secure them tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	(Cam cover side) 0.8 ÷ 1.0	Bolt	IGNITION COIL/REEL	M6

1. Place the cam angle sensor (1a) back in its housing and secure it tightening the bolt (1b) to torque.

	Value - daNm	Fastening	Component	Ø
1b	(Cylinder head side) 0.7 - 0.8	Bolt	CAM ANGLE SENSOR (MPI)	M6

- Refit the electrical wiring channel and secure with bolts.-- Connect the electrical connections to the right cylinder head ignition coils.- Connect the electrical connections to the right cylinder head injectors.1. Refit the intake ducts (1a) wiht sleeves (1b) and gaskets (1c) and tighten bolts (1d) to the specified torque.

	Value - daNm	Fastening	Component	Ø
1d	(Intake manifold side) 0.6 ÷ 0.9	Bolt	INTAKE AIR DUCT SHROUD	M6

- Fit the air capacity chamber and secure it using the bolts.- Tighten the bolt securing the stiffening rod to the reaction link mount on the engine.- Connect the earth lead to the air capacity chamber and secure with the bolt.- Connect the electrical connection to the throttle casing with D.V.L.- Tighten the band securing the engine idle oil vapour recovery pipe, air capacity chamber side.- Tighten the bands securing the intake manifolds to the air chamber.- Connect the electrical connection for the timing side knock sensor.- Close the electrical connection holder casing. See in Op. 1004D40 ENGINE - Position on stand and Remove- Proceed with the refitting.