1016D24 RIGHT CYLINDER HEAD - REMOVING-REFITTING AND REPLACING GASKET - Lancia - THESIS - eLearn

184741 - 1016D24 RIGHT CYLINDER HEAD - REMOVING-REFITTING AND REPLACING GASKET

) - Position the vehicle on a lift.- Open the boot, remove the cover on the left hand side and disconnect the negative battery lead. See in Op. 4450B04 Right FRONT WHEEL (one) - R.R.- Raise the vehicle on the lift. See in Op. 7055B54 PROTECTION/GUARD under engine - 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.- Lower the lift. 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. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R. See in Op. 1048A28 vacuum air circuit resonator pipe - 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. 1048A11 COMPLETE AIR FILTER -R.R. See in Op. 1032B10 TOOTHED timing BELT - R.R. for timing adjustment or replacement 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- Position a container for collecting the coolant.- Raise the vehicle1. Open the rapid attachment band (1a) and disconnect the lower pipe (1b) from the radiator.

- Lower the vehicle.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 (1) and remove the right head fuel manifold (1b) complete with injectors.

1. Undo the six fixing bolts (1a) and remove the intake manifold (1b) complete with gasket underneath.

1. Open the bands and disconnect the water supply pipe (1a) from the thermostat to the radiator, the water supply pipe (1b) to the heater, the water return pipe (1c) from the heater, the breather pipe (1d) and the fluid feeder pipe (1e) from the pump.2. Disconnect the engine coolant temperature sensor electrical connection.

	Description	Connector
2	I.E. engine temperature sensor	K045

1. Undo the fixing bolts (1a) and remove the thermostat unit (1b).

See in Op. 1008C14 BRACKET ON ENGINE FOR REACTION ROD See in Op. 1032C18 Timing belt MOVING TENSIONER - R.R.- Raise the vehicle.1. Undo the nuts (1a) fixing the flanges for the front section of the exhaust manifold (1b) to the pre-catalyzer and remove the section of pipe.

1. Remove the front Lambda sensor (1a) from the right head exhaust manifolds (1b).

	Description	Connector
1a	Lambda sensor on pre-catalyzer	K015

2. Undo the nuts fixing the right head exhaust manifolds and move the manifolds aside towards the engine compartment bulkhead.

1. Undo the bolt (1a) fixing the timing sensor (1b) and move it aside.

	Description	Connector
1b	Timing sensor	K047

1. Undo the bolt (1a) fixing the alternator mounting bracket (1b) to the head

1. Undo the nuts (1a) fixing the right head to the cylinder block/crankcase then, with the help of a second mechanic, remove the head (1b) and the gasket underneath.

1. Position the liner/bore locks (1a) fastening them to the studs (1b).

Refitting ( Removing

) - Remove the liner/bore locks.- Position the cylinder head gasket on the cylinder block/crankcase.

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; - 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 studs.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 timing sensor on the right head and tighten the fixing bolt.- Raise the vehicle- Tighten the bolt fixing the alternator mounting bracket.

	Value - daNm	Fastening	Component	Ø
.	0.6	Bolt	ALTERNATOR BRACKETS	M6

- Working in the lower part of the vehicle, position the preconverter complete with heat shield bulkhead and gaskets between the head and manifolds.- Lower the vehicle- Tighten the nuts fixing the exhaust manifolds to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.8	Nut	CATALYTIC PRE-CONVERTER	M8

- Position the Lambda sensor and tighten it to the recommended torque.

	Description	Connector
	Lambda sensor on pre-catalyzer	K015

	Value - daNm	Fastening	Component	Ø
.	5.8	Connector	LAMBDA PROBE (ONE)	M18 X 1.5

- Raise the vehicle- Position the pipe between the right pre-converter and the converter complete with gaskets, then tighten the nuts fixing the pipe flanges to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.8	Nut	EXHAUST PIPE MOUNTS/FASTENERS	M8

- Lower the vehicle See in Op. 1008C14 BRACKET ON ENGINE FOR REACTION ROD See in Op. 1032C18 Timing belt MOVING TENSIONER - R.R.- Fit the thermostat unit and secure it tightening the bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	0.9	Bolt	THERMOSTAT MOUNT	M6

- Connect the engine coolant temperature sensor electrical connection.

	Description	Connector
	I.E. engine temperature sensor	K045

- Connect the water supply pipe from the thermostat to the radiator, the water supply pipe to the heater, the water return pipe from the heater, the breather pipe and the fluid feeder pipe from the pump and close the bands.- Position the intake manifold and tighten the fixing bolts to the recommended torque.- 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 "1860082001 / DX A 1 CIL" and "1.870.896.600 /DX S 1 CIL".

	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 "1870896600 /SX S 4CIL" and "1860820002 /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
.	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. See in Op. 1032B10 TOOTHED timing BELT - R.R. for timing adjustment or replacement See in Op. 1048A11 COMPLETE AIR FILTER -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. 1048A28 vacuum air circuit resonator pipe - r+r See in Op. 1048A21 AIR INLET HOSE FROM INTAKE TO FILTER - R.R. See in Op. 1088B10 Engine coolant SUPPLY RESERVOIR - R.R. See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.- Raise the lift. 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. 7055B54 PROTECTION/GUARD under engine - R.R. See in Op. 4450B04 Right FRONT WHEEL (one) - R.R.- Connect the negative battery lead, then close the boot.- Remove the vehicle from the lift.- [0010T21]