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. Open the cover of the electrical connection box. 2. Disconnect the electrical connection for the knock sensor timing side.

	Name	Connector
2	Detonation sensor - 1	K50

1. Loosen the bands fixing the inlet ducts to the air chamber.2. Loosen the band securing the engine oil vapour recovery pipe to the air chamber.3. Disconnect the electrical connection from the throttle casing integrated with the D.V.L.

	Name	Connector
3	Throttle body actuator	N75

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

	Name	Connector
1b	Earth on engine	C40

2. Undo the bolt fixing the reinforcement strut to the support on the engine for the reaction rod.3. Undo the bolts (3a) and remove the air chamber (3b).

1. Undo the bolts (1a) and remove the intake pipes (1b) complete with hoses (1c).2. Remove the gaskets.

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

	Name	Connector
1	Injector	N70

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

	Name	Connector
2	Ignition coil	A30

3. Undo the bolts (3a) and move the duct electrical wiring (3b) to the side.

1. Undo the bolt (1a) and release the cam angle sensor (1b) from its housing.

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 from the coolant temperature sensor.

	Name	Connector
1	Engine temperature sender unit	K36

2. Open the cover of the electrical connection box. 3. Release the electrical connections and the wiring from the connector box.

1. Undo the bolts (1a) and remove the thermostat (1b) complete with connector box (1c).2. Remove the adaptor.

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

	Name	Connector
1	Knock sensor - 2	K51

2. Disconnect the electrical connection for the rpm sensor.

	Name	Connector
2	Rpm sensor	K46

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

	Name	Connector
1b	Earth on engine	C40

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

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

	Name	Connector
1	Injector	N70

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

	Name	Connector
2	Ignition coil	A30

3. Undo the bolts (3a) and move the duct electrical wiring (3b) to the side.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 for the fuel manifold pipes.

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

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

1. Loosen the bolts fixing the moving timing belt tensioner.2. Release the timing drive belt from the driven pullies.

1. Undo the bolts fixing the left rear timing belt protective cover to the right cylinder head.

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

1. Undo the bolt fixing the power assisted steering pump.

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

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

	Name	Country
1b	Counter-torque	1.822.146.000

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

	Name	Country
1b	Extractor	1.860.954.001

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

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

	Name	Country
1b	Spanner	1.822.121.000

Remove the left cylinder head and gasket.

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

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

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

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

	Name	Country
1b	Spanner	1.822.121.000

Remove the right cylinder head and gasket.

1. Fit the cylinder/bore locks.

	Name	Country
1	Liner/bore holder	1.820.279.000

Refitting ( Removing

) 1. Carry out a preliminary timing check on the camshafts: fit a spanner in the special housing (1a) in the centre of the camshafts and rotate it until the reference markts (1b) on the actual shafts coincides with the cylinder head upper plane.

The reference marks should be facing the centre of each cylinder head.

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 timing templates in place of the camshaft caps removed.

	Name	Country
1	Gauge	1.870.849.000

Remove the bore/liner locks.

	Name	Country
-	Liner/bore holder	1.820.279.000

Position the cylinder head centering bushes on the cylinder block/crankcase.1. Position the new cylinder head gaskets (1a), taking care to fit the lubrication duct seals (1b) (two for each cylinder head).

The material from which the cylinder head 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 of the gasket to take place it is necessary to:

keep the gasket in its sealed container until fitting
not lubricate or get oil on the gasket and the contact surfaces.

Position cylinder no. 1 at T.D.C. before fitting the cylinder heads on the cylinder block/crankcase.Position the cylinder heads on the cylinder block/crankcase.1. Tighten the nuts (1a) fixing the cylinder heads to the recommended torque using the angular tightening tools (1b) and (1c).

Lubricate the threads, nuts and washers with engine oil.

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 + 228? ÷ 232?

	Name	Country
1b	Protractor	1.860.942.000

	Name	Country
1c	Spanner	1.822.121.000

Refit the alternator bracket in its seating and fix it using the bolts.Place the rear protective timing covers back in their housings and secure them using the bolts.1. Place the timing belt fixed tensioners (1a) back in their housings and secure them tightening the bolts (1b) to the recommended torque.

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

2. Place the driven toothed pullies (2a) back in their housings and secure them without tightening the bolts (2b).

Tighten the bolt fixing the left rear timing belt protective cover to the right cylinder head.1. Fit the tool (1a), complete with dial gauge (1b), in the housing of the spark plug for cylinder no. 1.

	Name	Country
1a	Fitting tool	1.821.225.000

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 toothed timing drive belt starting from the toothed 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 bolt (1b) to the alternator bracket and with bolt (1c) to the water pump.

The tool tooth should press on the moving part of the timing belt tensioner.

	Name	Country
1a	Belt tensioner	1.860.950.000

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

1. Tighten the bolts (1a) fixing the toothed driven pullies using the tool (1b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	TIMING GEAR DRIVEN PULLEYS	M12	(Camshaft side) 7.2 ÷ 8.8

	Name	Country
1b	Counter-torque	1.822.146.000

Remove the tools for timing the camshafts.

	Name	Country
-	Gauge	1.870.849.000

Place the camshaft caps back in their housings in place of the tools removed and tighten the bolts to the recommended 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 moving 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 bolts for the moving tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	MOBILE TIMING TENSIONER	M8	(Cylinder head side) 1.9 ÷ 2.3

Remove the belt tensioner tool.

	Name	Country
-	Belt tensioner	1.860.950.000

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

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

1. Tighten the power steering pump bolt to the specified torque.

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

2. Place the bracket (2a) back in its housing and secure it using the bolt (2b) and the bolts (2c).

Place the lower protective timing covers back in their housings and secure them using the bolts.Fit the upper protective timing gear cover and fix it using the bolts.Connect the rapid connector for the fuel manifold pipes.1. Place the ignition coils (1a) back in their housings on the left cylinder head and secure them tightening the bolts (1b) to the recommended torque.

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

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

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

Place the wiring and the connections in the connection box, then close the cover.Connect the electrical connection to the water temperature sensor.1. Place the ignition coils (1a) back in their housing on the right cylinder head and secure them tightening the bolts (1b) to the recommended torque.

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

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

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

Place the electrical wiring duct back in its housing and secure it using the bolts. Connect the electrical connections to the right cylinder head ignition coils.Connect the electrical connections to the right cylinder head injectors.1. Place the intake manifolds (1a), complete with hoses (1b) and gaskets (1c) back in their housings and tighten the bolts (1d) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1d	Bolt	INLET MANIFOLD	M6	(Intake manifold side) 0.6 ÷ 0.9

Place the air chamber back in its housing and secure it using the bolts.Tighten the bolt fixing the reinforcement strut to the support on the engine for the reaction rod.Connect the earth lead to the air chamber and secure it using the bolt.Connect the electrical connection to the throttle body integrated with the D.V.L.Tighten the band securing the engine oil vapour recovery pipe to the air chamber.Tighten the bands fixing the inlet ducts to the air chamber.Connect the electrical connection for the knock sensor timing side.Close the electrical connection box cover. Proceed with the refitting - 1004D40 engine - position on stand and remove .