3237654 - 1016C10 cylinder head - r + r and replace gasket

 - 1092E10  counter-rotating shaft drive toothed belt - r + r .  - 1092E10  counter-rotating shaft drive toothed belt - r + r . Removing ( Refitting ) Position the vehicle on the ramp.PROCEED WITH DRAINING THE HIGH PRESSURE FUEL SYSTEM FOLLOWING THE INSTRUCTIONS GIVEN BELOW.Start the engineKeep the engine idling for 2 minutes.Detach the fuel pump relay.Wait until the engine cuts out.Try and start the engine: if the engine starts within 10 seconds, wait until it cuts out, then try and start it up again; if the engine does not start within 10 seconds, continue for another 5 seconds.Wait until the engine cools down.Ensure that the ignition key is in OFF position, then disconnect the negative battery terminal.

	Name	Connector
-	Battery	A1B

Drain the air conditioner coolant circuit  - 5040A10  Air conditioning refrigerant CIRCUIT - Draining and Refilling . Proceed with removal  - 4450B04  right front wheel r r . Proceed with removal  - 7055B54  under-engine guard - r r . Proceed with removal  - 1016A40  ignition coil cover on cylinder head- r+r . Proceed with removal  - 5040A20  air conditioner compressor - r+r - includes fluid level check and top up if necessary . Proceed with removal  - 5040A26  compressor mount - r r . Proceed with removal  - 1076A48  catalytic converter heat shield - r r . Proceed with removal  - 1080B62  catalytic converter - r + r . 1. Undo bolts (1a) and remove protection (1b).2. Fit the flywheel lock.

	Name	Country
2	Counter-torque	1.860.898.000

1. Undo the bolts (1a) and remove the crankshaft pulley (1b). 1. Remove the cap (1a), undo the bolt (1b) and remove the single belt fixed tensioner (1c). 1. Undo the bolts (1a) and remove the upper protective timing cover (1b). 1. Undo the bolts (1a) and remove the right side protective timing cover (1b).2. Undo the bolts (2a) and remove the left side protective timing cover (2b). 1. Undo the bolts (1a) and remove the lower protective timing cover (1b). 1. Loosen the nut for the counter-balance shaft toothed drive belt tensioner.2. Remove the counter-balance shaft drive belt. 1. Undo the bolts (1a) and remove the counter-balance shaft drive belt drive pulley (1b). Remove the flywheel lock.

	Name	Country
-	Counter-torque	1.860.898.000

1. Disconnect the electrical connections from the ignition coils.

	Name	Connector
1	Ignition coil	A30

2. Undo the bolts (2a) and remove the ignition coils (2b). Remove the spark plug for cylinder no. 1.1. Fit the tool (1a), complete with dial gauge (1b), in the housing of the spark plug for cylinder no. 1.

	Name	Country
1a	Extension	1.860.895.001

Adjust the bolt securing the timing drive sprocket and turn the crankshaft clockwise, timing gear side, until the piston of cylinder no.1 is at T.D.C. in the explosion stroke.

If TDC is exceeded, do not turn backwards, but proceed by rotating the crankshaft through a further two revolutions in the same direction until the piston for cylinder no. 1 is at TDC.

Remove the tool with dial gauge from the first cylinder spark plug socket.

	Name	Country
-	Extension	1.860.895.001

1. Slacken the nut on the timing belt moving tensioner.2. Prise off and remove the timing belt. 1. Undo the bolt fixing the rigid pipe support collar for the exhaust pipe between the catalytic converter and the silencer to the bracket.2. Undo the bolts (2a) and remove the rigid pipe for the exhaust pipe between the catalytic converter and the silencer (2b).3. Remove the gasket. 1. Undo bolts (1a) (1b) and remove the modular inlet manifold mounting bracket (1c) after releasing the wiring from the bands on the bracket. 1. Disconnect the electrical connection for the knock sensor.

	Name	Connector
1	Detonation sensor - 1	K50

2. Disconnect the electrical connection for the insufficient engine oil pressure sensor.

	Name	Connector
2	Engine oil pressure sensor	K30

1. Disconnect the electrical connection for the rpm sensor.

	Name	Connector
1	Rpm sensor	K46

2. Disconnect the earth lead from the starter motor.

	Name	Connector
2	Starter' motor	A20

3. Disconnect the earth lead from the alternator

	Name	Connector
3	Alternator	A10

Proceed with removal  - 5530B10  battery - r+r . 1. Loosen the band and disconnect the oil vapour recirculation pipe from the cam cover.2. Loosen the band and disconnect the vacuum pipe from the corrugated sleeve. 1. Loosen bands (1a) and remove the rigid pipe (1b) with corrugated air intake sleeve (1c) from the air filter to the throttle body. 1. Withdraw and remove the guide tube with the engine oil dipstick. 1. Disconnect the lower coolant outlet hose from the radiator and drain the engine coolant.

Manually press the springs and remove the rapid attachment for the hose.

Recover the coolant using a suitable container.

1. Loosen band and disconnect the upper coolant inlet hose to the radiator thermostat side.2. Loosen the band and disconnect the coolant outlet pipe from the climate control heater, water pump rigid inlet pipe side. 3. Loosen the band and disconnect the lower radiator coolant outlet hose from the radiator, water pump rigid inlet pipe end.4. Loosen the band securing the coolant outlet pipe from the engine oil heat exchanger on the water pump rigid inlet pipe side.5. Loosen the band and disconnect the coolant return pipe to the climate control heater, thermostat side.6. Loosen the band and disconnect the engine oil heat exchanger flexible coolant supply pipe, rigid pipe side. 1. Loosen the band and disconnect the engine coolant supplyj sleeve, water pump rigid inlet pipe side. 1. Loosen the band and disconnect the flexible section from the rigid section of the coolant return pipe from the engine coolant supply reservoir. 1. Undo the bolt (1a) and disconnect the earth lead (1b) from the cam cover.

	Name	Connector
1b	Earth on engine	C40

2. Undo the bolts (2a) and move the wiring channel (2b) aside. 1. Disconnect the vacuum intake pipe from the modular inlet manifold.2. Connect electrical connections (2a) and (2b) from the engine wiring.

	Name	Connector
2a	Front/engine connection	D4A

	Name	Connector
2b	Front/engine connection	D4B

1. Disconnect the rapid attachment for the fuel supply pipe.2. Disconnect the rapid attachment coupling for the fuel vapour recover pipe. 1. Disconnect the electrical connection from the enablement solenoid of the changeover device actuator.

	Name	Connector
1	Variable geometry control solenoid	L15

2. Disconnect the vacuum intake pipe from the air flow switching device actuator and release it from the fastening.3. Disconnect the linkage for the air flow switching cotrol actuator.4. Undo the bolts (4a) and remove the air flow switching control actuator (4b). 1. Undo the bolts (1a) and move the power assisted steering fluid reservoir (1b) aside. 1. Undo the bolts (1a) and remove the bracket (1b) after releasing the electrical wiring from the band. 1. Loosen the band and disconnect the oil vapour recirculation pipe from the modular intake manifold. 1. Release the fuel vapour supply pipe to the high-pressure fuel pump (1a) from the band on the tappet cover. 1. Undo the bolts (1a) and remove the tappet cover (1b), complete with seal. 1. Undo the bolts (1a) and remove the cylinder head (1b).

To undo/tighten the cylinder head bolts, use the ordinary spanner USAG 233 1/2 S.

2. Remove the cylinder head gasket. Refitting ( Removing ) Make sure that the bushes for locating the cylinder head on the cylinder block are present.Place the cylinder head gasket back in its housing.Position the cylinder head on the cylinder block taking care to ensure that the valves for cylinder no. 1 are closed.1. Tighten the bolts (1a) fixing the cylinder head to the recommended torque using the angular tightening tool (1b).

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

To undo/tighten the cylinder head bolts, use the ordinary spanner USAG 233 1/2 S.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	CYLINDER HEAD	M10	(Engine crankcase side) 2.0 + 2.0 + 90° + 90° + 90 °

	Name	Country
1b	Protractor	1.860.942.000

1. Fit the tool (1a), complete with dial gauge (1b), in the housing of the spark plug for cylinder no. 1.

	Name	Country
1a	Extension	1.860.895.001

Rotate the crankshaft in a clockwise direction until the piston for cylinder no. 1 is at T.D.C. in the explosion stroke.

If T.D.C. is exceeded, do not turn backwards, but proceed by rotating the crankshaft through a further two revolutions in the same direction until the piston for cylinder no. 1 is at T.D.C.

1. Undo the bolts (1a) of the timing driven pulley, inlet side, using the tool (1b) for counter-torque.

	Name	Country
1b	Counter-torque	1.860.856.001

2. Loosen the bolt (2a) for the exhaust -side driven toothed pulley, using tool (2b) for counter-torque.

	Name	Country
2b	Spanner for camshaft pulley rotation	1.860.831.002

Undo the bolts and remove the 4th cap on the inlet side camshaft and the 2nd cap on the exhaust side camshaft.1. Fit the tool (1a) in place of the camshaft caps removed and fix it tightening the bolts (1b) to the recommended torque.

Check that the camshaft cam profile matches the tool correctly.

	Name	Country
1a	Gauge	1.870.859.000

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	ENGINE TIMING ADJUSTMENT TEMPLATES	M7	(Cylinder head side) 1.0

1. Fit the timing belt, following the order indicated in the diagram.toothed drive pulley (1a)fixed tensioner (1b)exhaust side toothed driven pulley (1c)

Before fitting the belt on the exhaust side driven pulley, rotate it in a clockwise direction (see diagram) until the end of travel position.

inlet side toothed driven pulley (1d).

Before fitting the belt on the inlet side driven pulley, rotate it in a clockwise direction (see diagram) until the end of travel position.

mobile tensioner (1e)coolant pump pulley (1f).

When fitting, ensure that the arrow stamped on the belt is facing in the direction of engine rotation (clockwise - timing side).

1. Using the tool, rotate the timing moving tensioner until the maximum tension is applied to the timing belt.

	Name	Country
1	Key	1.822.149.000

2. Tighten the nut for the moving tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Nut	MOBILE TIMING TENSIONER	M8	2.3 ÷ 2.8

1. Tighten the bolts (1a) for the camshaft driven pulley, inlet side, to the recommended torque using the tool (1b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	TIMING GEAR DRIVEN PULLEYS	M6	(Inlet camshaft side) 0.8 ÷ 1.0

	Name	Country
1b	Counter-torque	1.860.856.001

2. Tighten the bolt (2a) securing the exhaust side timing driven pulley to the recommended torque, using the tool (2b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	TIMING GEAR DRIVEN PULLEYS	M12	(Exhaust camshaft side) 10.8÷13.2

	Name	Country
2b	Spanner for camshaft pulley rotation	1.860.831.002

Remove the tool for timing the camshafts.

	Name	Country
-	Gauge	1.870.859.000

Place the previously removed camshaft caps back in their housings and secure them tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAMSHAFT SUPPORTS	M7	(Cylinder head side) 1.4 ÷ 1.7

Rotate the crankshaft through two revolutions in its direction of rotation (clockwise - timing side) and ensure that the piston for cylinder no. 1 is at TDC.1. Fit the tool (1a) for keeping the moving timing tensioner still and loosen the tensioner nut (1b).

	Name	Country
1a	Key	1.822.149.000

2. Rotate the tool (2a) in an anti-clockwise direction (timing side) until the tensioner moving reference (2b) coincides with the reference opening (2c).

	Name	Country
2a	Key	1.822.149.000

3. Tighten the nut for the moving tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3	Nut	MOBILE TIMING TENSIONER	M8	2.3 ÷ 2.8

Rotate the crankshaft through two revolutions in its direction of rotation (clockwise - timing side) until cyllinder no. 1 is at TDC in the explosion stroke and check that the engine timing is correct using the tool.

	Name	Country
-	Gauge	1.870.859.000

Remove the tool to check T.D.C. from the cylinder 1 spark plug socket.

	Name	Country
-	Extension	1.860.895.001

Place the spark plug for cylinder no. 1 back in its housing and tighten it to the recommended torque.

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

1. Fit the counter-balancer shaft drive belt drive pulley (1a) tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	COUNTER-ROTATING SHAFT DRIVE PULLEY	M6	(Timing drive pulley side.) 0.8÷1.0

1. Rotate the counter-balance shafts so that the references (1a) on the pullies are aligned with the ribs (1b).2. Temporarily fit the lower timing cover and the crankshaft pulley and check the alignment of the references. 1. Fit the counter-balance shaft toothed drive belt.2. Tension the counter-balance shaft drive belt using the tool (2a) so that the reference opening (2b) in the belt tensioner is at the centre of the rotation sector.

	Name	Country
2a	Key	1.822.154.000

3. Tighten the nut fixing the counter-balance shaft drive belt tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3	Nut	COUNTER-ROTATING SHAFT BELT TENSIONER	M6	(.Left. counter balance shaft front) cover side 0.8÷1.0

1. Place the tappet cover (1a), complete with gasket, back in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CAM COVER	M6	(Cylinder head side) 0.8 ÷ 1.0

Secure the fuel supply pipe to the high-pressure pump to the band on the tappet cover.Connect the oil vapour recirculation pipe to the modular inlet manifold and tighten the band.Refit the bracket back in its housing and secure it using the bolts, then secure the electrical wiring to the band.Refit in its seating the power steering fluid reservoir and secure it with its bolts.Fit the air flow switching device actuator in its seating and secure it using the bolts.Connect the linkag for the air flow switching control actuator.Connect the air flow switching control actuator vacuum intake pipe and fasten it to the device with a band.Connect the electrical connection from the enablement solenoid of the changeover device actuator.Connect the rapid attachment for the fuel vapour recovery pipe.Connect the rapid attachment for the fuel supply pipe.Connect the engine wiring electrical connections.Connect the vacuum intake pipe to the modular inlet manifold.1. Place the ignition coils (1a) back in their housings and secure them by tightening bolts (1b) to the recommended torque.

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

Refit the wiring duct and secure with bolts.Connect the earth lead to the tappet cover and secure it with its bolt.Connect the electrical connections to the ignition coils.Connect the flexible section to the rigid section of the coolant return pipe to the coolant reservoir and do up the band.Connect the engine coolant supply sleeve, water pump rigid inlet pipe side, to the water pump and tighten the band.Connect the coolant supply pipe to the engine oil heat exchanger, thermostat side, and tighten the band.Connect the engine coolant return pipe from the climate control system heater, thermostat side, and tighten the band.Connect the coolant outlet pipe from the engine oil heat exchanger to the water pump rigid inlet pipe and tighten the band.Connect the lower radiator coolant outlet hose to the water pump rigid inlet pipe and tighten the band.Connect the coolant return hose from the climate control heater on the side of the rigid inlet pipe to the water pump and do up the band.Connect the upper coolant inlet hose to the radiator, thermostat side, and tighten the band.Connect the rapid attachment for the bottom coolant outlet hose from the radiator.Refit the guide tube and engine oil dipstick.Place the rigid air supply pipe with corrugated air intake sleeve from the filter to the throttle body back in its housing and secure it using the bands.Connect the vacuum pipe to the corrugated hose and tighten the band.Connect the oil vapour recirculation pipe to the tappet cover and secure with a band. Proceed with refitting  - 5530B10  battery - r+r . Connect the earth lead to the starter motor.Connect the earth lead to the alternator.Connect the electrical connection to the engine oil pressure warning sensor.Connect the electrical connection for the knock sensor.Connect the electrical connection for the rpm sensor.Place the modular intake manifold mounting bracket back in its housing and secure it using the bolts. Then secure the electrical wiring to the bands.1. Place the rigid pipe for the exhaust pipe between the catalytic converter and the silencer (1a), complete with gasket (1b), back in its housing and secure it to the front exhaust silencer tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	RIGID EXHAUST PIPE	M10	(Front silencer side) 5.9 ÷ 7.2

2. Tighten the bolt fixing the rigid pipe support collar for the exhaust pipe between the catalytic converter and the silencer to the bracket. Fit the lower protective timing cover and secure using the bolts.Place the protective timing side covers back in their housings and secure them using the bolts.Fit the upper protective timing gear cover and fix it using the bolts.1. Place the engine components single drive belt fixed tensioner (1a) back in its housing and fix it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FIXED SINGLE SERVICE BELT TENSIONER	M8	2.2 ÷ 2.8

2. Place the engine components single drive belt fixed tensioner plug back in its seating. Fit the flywheel lock.

	Name	Country
-	Counter-torque	1.860.898.000

1. Place the crankshaft pulley (1a) back in its seating and secure it tightening the bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CRANKSHAFT PULLEY	M8	2.3 ÷ 2.8

Remove the flywheel lock.

	Name	Country
-	Counter-torque	1.860.898.000

Place the protection back in its housing and secure it using the bolt. Proceed with refitting  - 1080B62  catalytic converter - r + r . Proceed with refitting  - 1076A48  catalytic converter heat shield - r r . Proceed with refitting  - 5040A26  compressor mount - r r . Proceed with refitting  - 5040A20  air conditioner compressor - r+r - includes fluid level check and top up if necessary . Proceed with refitting  - 1016A40  ignition coil cover on cylinder head- r+r . Proceed with refitting  - 7055B54  under-engine guard - r r . Proceed with refitting  - 4450B04  right front wheel r r . Fill the air conditioner coolant circuit  - 5040A10  Air conditioning refrigerant CIRCUIT - Draining and Refilling . Connect the negative (-) battery terminal. Refill the engine cooling system with coolant  - 0010T20  coolant change . Remove the car from the ramps.