1016D14 CYLINDER HEADS - R + R AND REPLACE GASKETS WITH ENGINE REMOVED - Alfa - 156 - eLearn

3239065 - 1016D14 cylinder heads - r + r and replace gaskets with engine removed

) Proceed with the removal - 1004D40 engine - position on stand and remove . 1. Disconnect the earth cable from the left cylinder head tappet cover.2. Disconnect the electrical connection of the motorized throttle body actuator.

	Name	Connector
2	Throttle body actuator	N75

1. Disconnect the oil vapour recovery pipe.2. Disconnect the condensation oil return pipe from the separator.

Slacken the bolts on the clips securing the air intake ducts to the intake chamber.1. Undo the bolts (1a) and remove the complete intake duct (1b).

1. Disconnect the electrical connection for the cam angle sensor (light blue).

	Name	Connector
1	Timing sensor	K47

2. Disconnect the electrical connection for the engine rpm and timng sensor (black).

	Name	Connector
2	Rpm sensor	K46

3. Disconnect the electrical connection for the rear detonation sensor (black).

	Name	Connector
3	Detonation sensor - 1	K50

4. Disconnect the electrical connection from the combined sender unit for the engine coolant temperature gauge and warning light.

	Name	Connector
4	Coolant temperature sender unit	K35

5. Disconnect the electrical connection from the engine coolant temperature sensor.

	Name	Connector
5	Engine temperature sensor	K45

6. Disconnect the earth cable from the left cylinder head tappet cover.

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

1. Disconnect the electrical connection for the air conditioning compressor.

	Name	Connector
1	Air conditioning compressor "on" electromagnet	L20

1. Disconnect the electrical connection for the front detonation sensor.

	Name	Connector
1	Knock sensor - 2	K51

2. Undo the bolts (2a) and remove the electrical wiring securing brackets (2b).3. Disconnect the electrical connections from the injectors.

	Name	Connector
3	Injector	N70

4. Disconnect the electrical connections from the ignition coils.

	Name	Connector
4	Ignition coil	A30

5. Remove the electrical wiring after releasing it from the securing bands.

1. Loosen the engine components drive belt tension by adjusting the belt tensioner.2. Lock the belt tensioner with the belt slack inserting a suitable peg.3. Remove the engine components single drive belt.

1. Undo the bolts (1a) and remove the timing belt guards (1b).2. Undo the bolt joining the timing belt rear guards.

1. Slacken the timing belt tensioner bolts.2. Remove the timing belt from the camshaft pulleys.

1. Disconnect the flexible pipe from the fuel distribution manifold rigid pipe.2. Undo the bolts (2a) and remove the bracket (2b) securing the timing belt guard.

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

1. Disconnect, from the thermostat, the coolant supply pipe to the water/oil heat exchanger.2. Undo the bolts (2a) and remove the thermostat (2b).

1. Undo the upper bolt (1a), the lower nut (1b) and remove the engine oil dipstick (1c).2. Undo the nuts (2a) and remove the protection (2b) for the left cylinder head exhaust manifold.3. Undo the nuts (3a) and remove the exhaust manifolds (3b) from the cylinder heads.

1. Undo the bolt securing the alternator bracket to the right cylinder head.2. Remove the bolt securing the power steering pump to the left cylinder head.3. Undo the bolts (3a) and remove the tappet covers (3b).4. Undo the bolts (4a) and remove the cylinder heads (4b).5. Remove the cylinder head gaskets.

1. Fit the cylinder/bore locks.

	Name	Country
1	Liner/bore holder	1.820.279.000

Refitting ( Removing

) Rotate the crankshaft until the piston of cylinder no. 1 is at T.D.C.1. Before fitting the cylinder head, rotate the camshafts using the tool (1a) until the reference marks (1b) on the shafts line up with the cylinder head top surface.

	Name	Country
1a	Counter-torque	1.822.146.000

Remove the bore/liner locks.

	Name	Country
-	Liner/bore holder	1.820.279.000

Make sure that the bushes centering the cylinder head on the cylinder block are fitted.Fit the new cylinder head gaskets.

The cylinder head gaskets are of the Astadur type.The material from which these gaskets are made undergoes a polymerization process during the operation of the engine so that they become considerably harder during usage.In order for the polymerization process to take place it is necessary to:keep the gasket in its sealed container until fittingnot lubricate or get oil on the gasket and the contact surfaces.

Position the cylinder heads on the engine block.1. Tighten the nuts for the cylinder heads (1a) to the recommended torque using the angular tightening tool (1b).

Follow the order shown in the diagram for each tightening sequence.The diagram shows the right cylinder head; the tightening order to the left cylinder head is symmetrical.

	Fastening	Component	Ø	Value(daNm)
1a	Nut	CYLINDER HEAD	M12	Engine crankcase side 2.4 ÷ 2.6 ÷ 240?

	Name	Country
1b	Protractor	1.860.942.000

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

1. Fit the tool in place of the removed camshaft caps.

	Name	Country
1	Gauge	1.825.040.000

Slacken the bolts on the camshaft drive pullies using the tool as counter-torque.

	Name	Country
-	Counter-torque	1.822.146.000

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	1.825.013.000

Rotate the crankshaft, using small movements (in both directions), until the piston for cylinder no. 1 is at T.D.C. at the power stroke.

Make sure that the last crankshaft rotation is in the direction of operation.

1. Fit the timing belt starting from the drive pulley and continuing in an anti-clockwise direction, making sure that the drive sections are firmly taut.

1. Fit the tool (1a) and secure it with the alternator bolt (1b) and the bolt (1c) to the water pump.

The tool lug (1d) must press against the moving part of the timing belt tensioner.

	Name	Country
1a	Belt tensioner	1.860.950.000

2. Adjust the nut (2a) of the belt tensioner tool until the moving reference on the belt tensioner (2b) is under the fixed reference.

1. Tighten the bolts (1a) for the camshaft pullies to torque using the tool (1b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	TIMING GEAR DRIVEN PULLEYS	M10	6.8 ÷ 8.4

	Name	Country
1b	Counter-torque	1.822.146.000

Remove the tool.

	Name	Country
-	Gauge	1.825.040.000

Fit the camshaft caps in place of the removed tool and tighten the bolts to torque.

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

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 on the timing belt tensioner lines up with the fixed reference.2. If the references do not line up, slightly discharge the tensioner acting on the tensioning tool nut and make sure that the references are aligned. 3. Tighten the timing belt tensioner bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	MOBILE TIMING TENSIONER	M8	1.7 ÷ 2.1

Remove the tool.

	Name	Country
-	Belt tensioner	1.860.950.000

Fit the tappet covers and fix them with their bolts.Fit the exhaust manifolds and fix them using the nuts.Fit the left exhaust manifold shield and fix it using the nuts.Fit the oil level dipstick and fix it using the bottom nut and top bolt.Fit the thermostat and fix it using the bolts.Connect, to the thermostat, the coolant supply pipe to the water-oil heat exchanger.Fit the ignition coils and fix them using the bolts.Fit the bracket securing the timing cover and fix it using the bolts.Connect the flexible pipe to the fuel distribution manifold rigid pipe.Tighten the bolt joining the timing belt rear covers.Fit the timing belt covers and fix them using the bolts.Fit the single drive belt.Push the single belt tensioner with a spanner to remove the belt tensioner retaining pin.Place the electrical wiring back in its housing and fix it to the bands.Connect the electrical connections to the ignition coils.Connect the electrical connections to the injectors.Fit the electrical wiring securing brackets to the rocker covers and fix them using the bolts.Connect the electrical connection for the front knock sensor.Connect the electrical connection for the air conditioning compressor.Fit the left cylinder head ignition coils cover and fix it using the bolts.Connect the earth lead to the left cylinder head tappet cover.Connect the electrical connection to the engine coolant temperature sensor.Connect the electrical connection to the combined sender unit for the coolant temperature gauge and overheating warning light.Connect the electrical connection for the rear knock sensor (black).Connect the electrical connection for the rpm and timing sensor (black).Connect the electrical connection for the cam angle sensor (light blue).Fit the complete intake chamber and fix it using the bolts.Tighten the bands fixing the air intake ducts to the intake chamber.Connect the condensation oil return pipe to the separator.Connect the oil vapour recovery pipe.Connect the electrical connection to the motorized throttle body actuator.Connect the earth lead on the left cylinder head rocker cover. Proceed with the refitting - 1004D40 engine - position on stand and remove .