1016C10 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET - Lancia - THESIS - eLearn

74677 - 1016C10 SINGLE CYLINDER HEAD - R.R. and Replace gasket

) - Position the vehicle on a lift.- Open the boot, remove the cover on the left hand side and disconnect the negative battery lead.- Raise the vehicle on the lift. See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.- Position a suitable container for collecting the engine coolant.- Raise the lift.1. Disconnect the lower radiator pipe.

See in Op. 4450B04 Right FRONT WHEEL (one) - 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. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - 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. 1016A40 Ignition COIL COVER on cylinder head - R.R.1. Disconnect the coolant pipe retaining band on the cylinder head.2. Undo the nut fixing the expansion tank (this nut also fastens the windscreen washer fluid reservoir).3. Disconnect the electrical connection for the engine coolant level.

	Description	Connector
3	Engine coolant level sensor	K026

4. Disconnect the pipe (4a) and lift up the expansion tank (4b) and remove it.

1. Undo the fixing nuts (1a) and remove the bonnet lock (1b) from the housing in the crossmember.2. Undo the lower bolt (2a) and remove the lock reinforcement bracket (2b).

1. Undo the fixing nuts2. Remove the front crossmember.

See in Op. 1072C44 Exhaust manifold heat shield on BULKHEAD - R.R.1. Disconnect the retaining band for the throttle casing hose.2. Disconnect the pipe on the tappet cover connected to the hose on the throttle casing.3. Release the electrical connector (3a) and remove the hose (3b).

1. Disconnect the engine cooling system pipes on the thermostat.2. Disconnect the electrical connection for the coolant temperature sensor.

	Description	Connector
2	I.E. engine temperature sensor	K045

3. Disconnect the heater return pipe on the cylinder head.

1. Disconnect the electrical connections (1a) for the injection control unit, then undo the bolt (1b) fixing the injection control unit mounting bracket.

	Description	Connector
1a	Engine management control unit	M010A

	Description	Connector
1a	Engine management control unit	M010B

2. Disconnect the earth lead (2a) and the electrical connector (2b) for the throttle casing actuator.

	Description	Connector
2b	Integrated throttle casing actuator	N075

	Description	Connector
2a	Earth on engine	C040

3. Undo the four fixing bolts and remove the throttle casing complete with injection control unit and mounting bracket.

1. Disconnect the electrical connections for the ignition coils (1a), the injectors (1b) and the phase transformer solenoid (1c); release the wiring from the retaining bands.

	Description	Connector
1a	Ignition coil	A030A

	Description	Connector
1b	Injector	N070A

	Description	Connector
1a	Ignition coil	A030B

	Description	Connector
1a	Ignition coil	A030C

	Description	Connector
1a	Ignition coil	A030D

	Description	Connector
1a	Ignition coil	A030E

	Description	Connector
1b	Injector	N070B

	Description	Connector
	Injector	N070C

	Description	Connector
	Injector	N070D

	Description	Connector
	Injector	N070E

2. Disconnect the connectors for the front Lambda sensor (2a), the rear Lambda sensor (2b) and the air conditioning compressor coupling.

	Description	Connector
2a	Lambda sensor on catalyzer	K017

	Description	Connector
2b	Lambda sensor on catalyzer 2	K018

3. Disconnect the earth lead, then release the engine wiring from the retaining bands on the intake chamber and place it to the side.

- Discharge the fuel pressure with the tool connected to the valve on the single fuel manifold pipe.

	Description	Code	Function
.	Rapid attachment connector	1.870.684.000	Single fuel manifold pipe complete with injectors

1. Disconnect the fuel supply pipe from the manifold.2. Disconnect the oil vapour recovery pipe from the tappet cover.3. Disconnect the fuel vapour recovery pipe.

1. Disconnect the electrical connection (1a) on the intake chamber for the left detonation sensor and the electrical connection (1b) for the rpm sensor, then undo the bolts fixing the connector; release the wiring from the retaining bands.

	Description	Connector
1a	Detonation sensor - 2	K050

	Description	Connector
1b	Rpm sensor	K046

1. Disconnect the electrical connection (1a) for the timing sensor and the connector (1b) for the right detonation sensor on the intake chamber, then undo the bolts fixing the connectors.

	Description	Connector
1a	Timing sensor	K047

	Description	Connector
1b	Detonation sensor - 2	K051

2. Undo the bolt fixing the engine oil dipstick pipe.

1. Undo the bolt (1a), loosen the bolt (1b) and rotate the reaction rod connecting rod.

1. Undo the bolt (1a), open the retaining brackets (1b) and remove the engine coolant recovery pipe (1c).

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

- Raise the vehicle.1. Undo the nut fixing the intake chamber to the mounting bracket.- Release the wiring from the mounting bracket.

- Lower the vehicle on the lift.1. Undo the bolt fixing the intake chamber to the manifold.

1. Disconnect the bands joining the intake chamber to the hoses connected to the intake manifold, then release the chamber from the hoses.

1. Undo the fixing nuts (1a) and the bolt (1b) and remove the intake manifold complete with hoses connected to the intake chamber.

1. Disconnect the electrical connections for the V.I.S.control actuator solenoid valve (1a) and the fuel vapour recovery solenoid valve (1b), then remove the intake chamber (1c).

	Description	Connector
1a	Variable geometry solenoid valve	L015

	Description	Connector
1b	Fuel vapour recovery solenoid valve	L010

1. Remove the rigid coolant pipe (1a), acting on the fixing nut (1b).2. Disconnect the two pipes (2a) from the connector (2b) on the coolant pump.

1. Undo the nuts securing the exhaust manifold to the cylinder head.2. Extract the exhaust manifold from the studs on the head; keep the gasket which is underneath.

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

- Position a hydraulic lift under the gearbox bellhousing.1. Undo the bolts fixing the engine support to the gearbox.- Gradually lower the hydraulic lift and rest the gearbox on the front crossmember.

See in Op. 1092G10 Engine components single drive BELT - R.R. See in Op. 1092A10 Crankshaft PULLEY - R.R. for versions with air conditioner1. Undo the bolt fixing the auxiliary shaft drive belt idle pulley.2. Undo the five bolts (2a) and remove the timing belt guard (2b).

1. Undo the bolts (1a) and remove the ignition coils (1b).2. Undo the bolts (2a) and remove the tappet cover (2b) complete with gasket.

1. Undo the automatic tensioner nut, in order to loosen the timing belt tension.2. Remove the timing drive belt from the pullies.

1. Undo the bolt fixing the guard behind the exhaust side timing pulley to the cylinder head.2. Undo the bolts (2a) using the spanner (2b) and remove the cylinder head (2c).- Remove the gasket underneath the cylinder head.

	Description	Code	Function
2b	Spanner	1.852.154.000	Loosen/tighten cylinder head fixing bolts

Refitting ( Removing

) - 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. 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.

- Position the cylinder head on the cylinder block/crankcase taking care to ensure that the camshafts are positioned with the front cams facing outwards (valves closed).1. Tighten the bolts (1a) fixing the cylinder head to the recommended torque, in stages, using the spanner (1b) and the spanner (1c) for angular tightening.

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

	Value - daNm	Fastening	Component	Ø
1a	4 + 90° + 90° + 90°	Bolt	CYLINDER HEAD	M10

	Description	Code	Function
1b	Spanner	1.852.154.000	Loosen/tighten cylinder head fixing bolts

	Description	Code	Function
1c	Torque wrench	1.860.942.000	Cylinder head bolts angular tightening

- Position the intake chamber in the vehicle, then connect the electrical connection for the V.I.S. control actuator solenoid valve and the electrical connection for the fuel vapour recovery solenoid valve.- Insert the threaded pin which is in the rear part of the chamber into the opening in the mounting bracket.- Position the intake manifold complete with gasket underneath and hoses connected to the intake chamber.- Tighten the nuts and the bolt fixing the intake manifold to the cylinder head to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.5	Nut	INLET MANIFOLD	M8

	Value - daNm	Fastening	Component	Ø
.	2.5	Bolt	INLET MANIFOLD	M8

- Fit the intake chamber ducts on the hoses connected to the intake manifold and secure them using the retaining bands.- Tighten the bolt fixing the intake chamber to the manifold.- Raise the vehicle on the lift.- Tighten the nut fixing the intake chamber to the mounting bracket.- Lower the vehicle on the lift.- Position the fuel manifold complete with injectors and secure it using the fixing bolts.- Position the thermostat and fasten it tightening the fixing bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.5	Bolt	THERMOSTAT	M8

1. Loosen the bolt (1a) for the exhaust side driven timing pulley using tools (1b) and (1c) for counter-torque.

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

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

2. Loosen the bolts (2a) for the inlet side camshaft pulley using tool (2a) for counter-torque.

	Description	Code	Function
2b	Counter-torque	1.860.856.000	Loosen/tighten inlet side camshaft drive pulley bolts

- Remove the spark plug for cylinder no. 1.1. Fit the tool (1a) complete with dial gauge (1b) in the seat for the spark plug for cylinder no. 1.

	Description	Code	Function
1a	Dial gauge support	1.860.895.000	Support

- Rotate the crankshaft until the piston for cylinder no. 1 is at T.D.C. in the explosion stroke.2. With cylinder no. 1 at T.D.C., check that the reference on the crankshaft drive gear is in line with the reference on the crankshaft front cover.

- Undo the bolts and remove the inlet side camshaft third cap and the exhaust side camshaft second cap.

Mark the position of the camshaft caps removed so that they can be correctly positioned when refitting.

1. Fit the templates (1a) in place of the camshaft caps that have been removed and secure them using the bolts (1b).

Check that the camshaft cam profile and the templates are correctly aligned.

	Description	Code	Function
1a	Templates	1.870.828.000	Engine tuning

1. Fit the timing toothed drive belt in the following order:1. - toothed drive pulley (1a)1. - moving tensioner (1e)1. - exhaust side toothed driven pulley (1c)1. - fixed tensioner (1b)1. - inlet side toothed driven pulley (1d)1. - water pump pulley (1f).

The belt is fitted with the arrow facing the direction of rotation of the engine. There are also three reference on the belt that should coincide during the initial fitting with the references on the toothed drive pulley and the exhaust and inlet side toothed driven pullies.

1. Using a screwdriver, apply force to the tab (1a) for the automatic tensioner so that the tensioner is in the maximum tension position, then tighten the nut (1b) fixing the tensioner to the support.

	Value - daNm	Fastening	Component	Ø
1b	2.5	Nut	MOBILE TIMING TENSIONER	M8

1. Tighten the bolts (1a) for the inlet side toothed timing driven pulley using tool (1b) for counter-torque.

	Value - daNm	Fastening	Component	Ø
1a	(inlet side) 0.9	Bolt	TIMING DRIVEN PULLIES	M6

	Description	Code	Function
1b	Counter-torque	1.860.856.000	Loosen/tighten inlet side camshaft drive pulley bolts

2. Tighten the bolt (2a) for the exhaust side toothed timing driven pulley using the tools (2b) and (2c) for counter-torque.

	Value - daNm	Fastening	Component	Ø
2a	(exhaust side) 12	Bolt	TIMING DRIVEN PULLIES	M12

	Description	Code	Function
2b	Support for counter-torque	1.860.831.000	Loosen/tighten exhaust side camshaft drive pulley bolt

	Description	Code	Function
2c	Spanner for rotating timing pullies	1.860.831.002	Loosen/tighten exhaust side camshaft drive pulley bolt

- Undo the fixing botls and remove the templates.

	Description	Code	Function
.	Templates	1.870.828.000	Engine tuning

- Fit the camshaft cams removed previously and tighten the bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	1.5	Bolt	CAMSHAFT CAPS	M7

- Rotate the crankshaft throught two revolutions in the direction of rotation.- Loosen the moving timing tensioner nut.3. Using a screwdriver, rotate the moving timing tensioner until the moving tensioner reference (3a) coincoides with the fixed reference (3b).4. Tighten the nut fixing the moving timing tensioner to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.5	Nut	MOBILE TIMING TENSIONER	M8

- Remove the tool complete with dial gauge.

	Description	Code	Function
.	Dial gauge support	1.860.895.000	T.D.C. check

- Fit the spark plug for cylinder no. 1 and tighten it to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.7	-	SPARK PLUGS	M10 X 1.25

- Position the timing drive belt cover and secure it using the fixing bolts.

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

- Tighten the bolt fixing the auxiliary shaft drive belt idle pulley. See in Op. 1092A10 Crankshaft PULLEY - R.R. for versions with air conditioner See in Op. 1092G10 Engine components single drive BELT - R.R.- Position a hydraulic lift under the gearbox bellhousing.- Screw in and tighten the bolt fixing the engine support to the gearbox to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	(on gearbox) 5	Bolt	POWER UNIT GEAR BOX END RIGID MOUNT	M10 X 1.25

- Position the exhaust manifold on the cylinder head studs and tighten the fixing nuts to torque.

	Value - daNm	Fastening	Component	Ø
.	2.5	Nut	EXHAUST MANIFOLD/S	M8

- Position the rigid coolant pipe and secure it using the bolt.- Connect the two engine coolant pipes to the water pump connector. See in Op. 1072C44 Exhaust manifold heat shield on BULKHEAD - R.R.- Fit the upper front crossmember.- Fit the bonnet lock on the crossmember complete with reinforcement bracket.- Connect the engine cooling system pipes and the heater pipes to the thermostat.- Connect the connecting rod to the reaction rod and secure it using the bolts.

	Value - daNm	Fastening	Component	Ø
.	(to bracket on bodyshell) 5	Bolt	POWER UNIT REACTION ROD	M10 X 1.25

	Value - daNm	Fastening	Component	Ø
.	(to engine support) 5	Bolt	POWER UNIT REACTION ROD	M10 X 1.25

- Tighten the bolt fixing the engine oil dipstick pipe.- Position the tappet cover and secure it using the fixing bolts.

	Value - daNm	Fastening	Component	Ø
.	0.9	Bolt	CAM COVER	M6

- Position the ignition coils cover and secure them using the fixing bolts.

	Value - daNm	Fastening	Component	Ø
.	0.9	Bolt	IGNITION COIL/REEL	M6

- Position the injection control unit mounting bracket together with the throttle casing and fasten the assembly to the intake chamber.- Connect the earth lead and the electrical connector for the throttle casing actuator.

	Description	Connector
.	Integrated throttle casing actuator	N075

- Connect the electrical connections on the injection control unit, then tighten the bolt fixing the engine mounting bracket to the intake manifold.

	Description	Connector
.	Engine management control unit	M010A

	Description	Connector
.	Engine management control unit	M010B

- Connect the electrical connections for the injectors

	Description	Connector
.	Injector	N070A

	Description	Connector
.	Injector	N070B

	Description	Connector
.	Injector	N070C

	Description	Connector
.	Injector	N070D

	Description	Connector
.	Injector	N070E

- Connect the electrical connection for the phase transformer solenoid- Connect the electrical connections for the ignition coils.

	Description	Connector
.	Ignition coil	A030A

	Description	Connector
.	Ignition coil	A030B

	Description	Connector
.	Ignition coil	A030C

	Description	Connector
.	Ignition coil	A030D

	Description	Connector
.	Ignition coil	A030E

- Connect the electrical connections for the front Lambda sensor, the rear Lambda sensor and the air conditioning compressor coupling.

	Description	Connector
.	Lambda sensor on catalyzer	K017

	Description	Connector
.	Lambda sensor on catalyzer 2	K018

- Connect the electrical connections for the engine coolant temperature sensor.- Connect the earth lead on the cylinder head.- Secure the engine wiring to the retaining bands on the intake chamber.- Connect the fuel supply pipe to the manifold.- Connect the fuel vapour recovery pipe.- Connect the oil vapour recovery pipe to the tappet cover.- Connect the electrical connection for the left detonation sensor and the electrical connection for the rpm sensor to the intake chamber; secure the wiring to the retaining bands.

	Description	Connector
.	Detonation sensor - 2	K050

	Description	Connector
.	Rpm sensor	K046

- Connect the electrical connection for the timing sensor and the electrical connector for the right detonation sensor to the intake chamber.

	Description	Connector
.	Detonation sensor - 2	K051

	Description	Connector
.	Timing sensor	K047

- Position the rigid coolant recovery pipe and secure it using the bolt and the retaining brackets.- Position the expansion tank and secure it using the nut.- Connect the pipes and the electrical connection for the engine coolant level.- Position the hose on the throttle casing and secure it using the retaining band.- Connect the oil vapour recovery pipe to the tappet cover. 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. 1016A40 Ignition COIL COVER on cylinder head - 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.- Connect the lower radiator pipe. See in Op. 4450B04 Right FRONT WHEEL (one) - R.R.- Connect the negative battery lead, then close the boot. See in Op. 0010T20 Engine REFRIGERANT FLUID - Change See in Op. 7055B54 PROTECTION/GUARD under engine - R.R. See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.- Remove the vehicle from the lift.