1016C10 CYLINDER HEAD - R + R AND REPLACE GASKET - Alfa - 156 - eLearn

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

) - 4450B10 Front WHEEL (one) - R.R. . - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. . - 1092G10 single engine belt r r . - 1092A10 Crankshaft services PULLEY - R.R. . - 1032D12 timing system protective cover(s) - r + r . - 1008C10 power unit upper reaction link r r . - 1016A10 sound-proofing cover - r + r . - 1008C14 engine link bracket - r r . - 1032B14 toothed timing belt - r + r for timing adjustment or replacement versions with air conditioner . - 5530B10 battery - r+r . 1. Undo nuts (1a) and move fuel filter assembly (1b) away from the intake manifold.2. Undo nuts (2a) and move oil vapour separator (2b) away from the intake manifold.3. Undo the bolts (3a) and move the fuel return manifold pipe (3b) aside.4. Push the springs (4a) manually and disconnect the fuel return pipe for lubricating the injectors (4b) from the injectors.5. Undo the bolts (5a) and remove the coolant supply pipe (5b) to the engine coolant reservoir.6. Disconnect the electrical connections from the heater plugs.

	Name	Connector
6	Heater plug	A40

7. Disconnect the electrical connections from the injectors and move the electrical wiring aside.

	Name	Connector
7	Injector	N70

1. Disconnect the electrical connection from the fuel pressure sensor.

	Name	Connector
1	Fuel pressure sensor	K83

2. Loosen the manifold side connector for the supply pipe from the pressure pump to the manifold using a suitable spanner.3. Disconnect the pressure pump side connector from the pipe leading from the pressure pump using a suitable spanner.4. Remove the fuel supply pipe from the pressure pump to the fuel manifold.

Fit a new high pressure pipe from the pressure pump to the fuel manifold upon reassembly.

Raise the car.1. Disconnect the lower coolant outlet hose from the radiator and drain the engine coolant.

Recover the coolant using a suitable container.

Lower the vehicle.2. Disconnect the lower radiator coolant outlet hose from the pump rigid coolant inlet pipe and remove it.

1. Disconnect the system supply pipe from the water pump rigid inlet pipe.2. Disconnect the coolant outlet pipe from the water-oil heat exchanger from the water pump rigid inlet pipe.3. Undo the bolts (3a) and remove the left side protection (3b) for the timing belt.

1. Disconnect the vacuum intake pipe from the EGR valve.2. Disconnect the coolant return pipe from the climate control system heater from the water pump rigid inlet pipe.

1. Disconnect the coolant supply hose to the radiator from the thermostat.2. Disconnect the coolant supply pipe to the water-oil heat exchanger from the thermostat.3. Disconnect the electrical connection from the engine temperature sensor.

	Name	Connector
3	Engine temperature sensor	K45

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, from the thermostat, the coolant supply pipe to the climate control system heater.

1. Disconnect the air supply hose from the heat exchanger from the inlet manifold.2. Disconnect the vacuum intake pipe from the vacuum pump.

1. Undo the three bolts indicated securing the exhaust manifold to the turbocharger.2. Unscrew the turbocharger bracket nuts.

Raise the car.Undo the remaining bolt securing the exhaust manifold to the turbocharger.1. Undo the bolt (1a) and remove the turbocharger mounting bracket.Undo the bolt securing the rigid mounting to the front exhaust pipe collar.2. Loosen the nuts for the reinforcement bracket.

Lower the vehicle.1. Undo the bolts (1a) and remove the tappet cover (1b).2. Undo the bolts securing the pressure pump mounting to the inlet manifold.3. Undo the bolts (3a) and remove the complete cylinder head (3b).4. Remove the cylinder head gasket.

Refitting ( Removing

) Fit a new cylinder head gasket on the cylinder block/crankcase, taking care that it is the same size as the one removed.

The cylinder head gasket is of the Astadur type.These gaskets are made from a special material designed to undergo polymerization during the use of the engine. This means that they harden considerably during use.In order for the polymerization process to take place it is necessary to:- keep the gasket in its sealed nylon container until fitting- not to take out of its container until ready to fit- not lubricate or get oil on the gasket.

Position the cylinder head on the crankcase. 1. Tighten the bolts securing the cylinder head to the cylinder block/crankcase to the recommended torque following the order shown in the diagram and using the angular tightening tool.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	CYLINDER HEAD	M10	2.0+4.5+90°+90°+90°

	Name	Country
1	Protractor	1.860.942.000

Tighten the bolts securing the pressure pump mounting to the inlet manifold to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	INJECTION PRESSURE PUMP SUPPORT	M8	Intake manifold side 2.1 - 2.6

Fit the tappet cover and fix it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAM COVER	M6	0.8 ÷ 1.0

Tighten the nuts for the reinforcement bracket.Tighten the bolt securing the rigid mounting to the front exhaust pipe collar.Fit the turbocharger bracket and secure it to the crankcase using the bolts.Tighten the bolt securing the exhaust manifold to the turbocharger to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	TURBOCHARGER	M8	(Exhaust manifold side) 2.1 - 2.6

Lower the vehicle.Tighten the nuts securing the bracket to the turbocharger.Tighten the remaining bolts securing the exhaust manifold to the turbocharger to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	TURBOCHARGER	M8	(Exhaust manifold side) 2.1 - 2.6

Connect the vacuum intake pipe to the vacuum pump.Conect the air supply hose from the heat exchanger to the inlet manifold.Connect the coolant supply pipe to the climate control system heater to the thermostat.Connect the electrical connection to the combined sender unit for the coolant temperature gauge and overheating warning light.Connect the electrical connection to the engine temperature senor.Connect the coolant supply hose to the water-oil heat exchanger to the thermostat.Connect the coolant supply hose to the radiator to the thermostat.Connect the coolant return pipe from the climate control system heater to the water pump rigid inlet pipe.Connect the vacuum intake pipe to the E.G.R. valve.Fit the left side protection for the timing belt and fix it using the bolts.Connect the coolant outlet pipe from the water-oil heat exchanger to the water pump rigid inlet pipe.Conect the system supply pipe to the water pump rigid inlet pipe.Fit the coolant lower outlet hose from the radiator and connect to the water pump rigid inlet pipe.Raise the car.Connect the lower coolant outlet hose to the radiator.Lower the vehicle.1. Place the pipe from the pressure pump to the single fuel manifold back in its housing and fix it using the connectors without tightening them.2. Tighten the connector for the pipe from the pressure pump to the fuel manifold, pump side, to the recommended torque using a suitable spanner.

	Fastening	Component	Ø	Value(daNm)
2a	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M12	(Pressure pump side) 2.2

3. Tighten the connector for the pipe from the pressure pump to the fuel manifold, fuel manifold side, to the recommended torque using a suitable spanner.

	Fastening	Component	Ø	Value(daNm)
2a	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14	(Fuel manifold side) 2.2

4. Connect the electrical connection to the fuel pressure sensor.

Place the electrical wiring back in its housing and connect the electrical connections to the injectors.Connect the electrical connections to the heater plugs.Place the coolant supply pipe to the engine cooling system reservoir back in its housing and fix it using the bolts.Position the connectors for the fuel return pipe for lubricating the injectors in the corresponding housings of the injectors and fully insert them until the click of the spring is heard. Place the fuel return manifold pipe back in its housign and secure it using the bolts.Place the oil vapour separator back in its housing and fix it to the inlet manifold using the nuts.Place the fuel filter back in its housing and fix it to the inlet manifold using the nuts. - 5530B10 battery - r+r . - 1032B14 toothed timing belt - r + r for timing adjustment or replacement versions with air conditioner . - 1008C14 engine link bracket - r r . - 1016A10 sound-proofing cover - r + r . - 1008C10 power unit upper reaction link r r . - 1032D12 timing system protective cover(s) - r + r . - 1092A10 Crankshaft services PULLEY - R.R. . - 1092G10 single engine belt r r . - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. . - 4450B10 Front WHEEL (one) - R.R. .