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.Ensure that the ignition key is in the OFF position, then disconnect the negative battery terminal (-).

	Name	Connector
-	Battery	A1B

Proceed with removal  - 1016A10  sound-proofing cover - r + r . Proceed with removal  - 1008C10  power unit upper reaction link r r . Proceed with removal  - 1060G80  ds electric injection control unit - r r . Proceed with removal  - 4450B04  right front wheel r r . Proceed with removal  - 7055B54  under-engine guard - r r . Proceed with removal - 7055B91 Right front WHEEL ARCH LINER - R.R. . Proceed with removal  - 1092G10  single engine belt r r . Proceed with removal  - 1092A10  Crankshaft services PULLEY - R.R. . Proceed with removal  - 1092G20  engine component single belt fixed tensioner - one - r + r . Proceed with removal  - 1032D12  timing system protective cover(s) - r + r . 1. Undo the bolts (1a) and (1b), then remove the bracket on the engine for the reaction rod (1c). 1. Loosen the nut securing the timing belt mobile tensioner.2. Prise off and remove the timing belt. 1. Loosen the band and disconnect the lower radiator coolant outlet hose from the radiator, water pump rigid inlet pipe end.

Collect the coolant which comes out in a suitable container.

1. Disconnect the electrical connections from the injectors.

	Name	Connector
1	Injector	N70

2. Disconnect the electrical connection from the cam angle sensor.

	Name	Connector
2	Timing sensor	K47

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

	Name	Connector
3	Air conditioning compressor "on" electromagnet	L20

Release the electrical wiring from the band on the timing cover. 4. Undo the bolts fastening the cable duct and move the electrical wiring aside. 1. Push clips (1a) by hand and disconnect the pipe from the injectors to the fuel recovery manifold (1b), injectors side and move it aside. 2. Undo the connectors (2a), (2b) and remove the pipe from the fuel manifold to the injectors (2c).

Use new pipes from from fuel manifold to injectors upon reassembly.

1. Undo the nuts fixing the injector brackets.2. Remove the injectors (2a) complete with bracket using the tool (2b).

If the same injectors are being reused, mark the cylinder to which they belong so that they can be correctly refitted. If new fuel injectors are fitted: determine the identification code stamped on the top; check that the new injectors(s) is (are) recognized by the engine management control unit using the Examiner.

Start the removal beginning with the injector for cylinder no. 1 and continuing with the injectors for cylinders 2, 3 and 4.

	Name	Country
2b	Extractor	1.870.897.300

1. Undo the connectors (1a), (1b) and remove the pipe from the pressure pump to the fuel manifold (1c).

When refitting, fit a new pipe from the pressure pump to the fuel manifold.

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

	Name	Connector
1	Fuel pressure sensor	K83

2. Undo the bolts (2a) and remove the single fuel manifold pipe (2b) complete with fuel pressure sensor (2c). Proceed with removal  - 5530B10  battery - r+r . 1. Disconnect the hose from the rigid vacuum pipe leading to the turbocharger vane actuator solenoid. 2. Undo the bolts (2a) and move the rigid vacuum pipe leading to the turbocharger vane actuator solenoid (2b) to one side. 3. Loosen the band and disconnect the vacuum pipe from the brake servo. 4. Loosen the band and disconnect the engine oil vapour recovery pipe from the engine oil filler. 1. Disconnect the electrical connection from the engine coolant temperature sensor.

	Name	Connector
1	Engine temperature sender unit	K36

1. Undo the bolts (1a) and remove the engine oil filler (1b). 2. Remove the gasket. 1. Undo bolts (1a) and remove vacuum unit (1b).2. Remove the gasket. 1. Undo the bolts (1a), (1b), and remove the camshaft housing assembly (1c). 2. Remove the gasket. 1. Remove the valve rocker arms.2. Remove the hydraulic tappets. 1. Disconnect the electrical connections from the heater plugs.

	Name	Connector
1	Heater plug	A40

2. Undo and remove the heater plugs. 1. Disconnect the electrical connection from the air flow meter.

	Name	Connector
1	Air flow meter	K41

1. Disconnect the electrical connection from the E.G.R. valve.

	Name	Connector
1	EGR solenoid	L30

2. Disconnect the electrical connection from the excess pressure sensor.

	Name	Connector
2	Turbocharging sensor	K82

Release the wiring from the bands near the thermostat. 1. Loosen the band and disconnect the coolant return pipe from the engine coolant reservoir, thermostat side. 2. Loosen the band and disconnect the coolant outlet pipe from the cylinder head, engine coolant return pipe to the coolant reservoir side. 3. Loosen the band and disconnect the flexible coolant return pipe from the rigid coolant return pipe to the engine coolant reservoir. 4. Undo the bolts (4a) and remove hose (4b) carrying coolant to the coolant supply reservoir. 1. Loosen the band and disconnect the air intake hose from the connector on the throttle casing. 1. Undo the bolts (1a) and remove the connector on the throttle body (1b) complete with gasket (1c). 1. Disconnect the vacuum pipe from the pneumatic valve on the throttle body.2. Undo the bolts (2a) and remove the electropneumatically controlled throttle body (2b) complete with gasket (2c). Disconnect the vacuum pipe from the three-way connector on the brake servo vacuum intake pipe.Disconnect the intermediate coupling for the vacuum pipe for the turbocharger vane position control actuator solenoid valve.1. Loosen the band and disconnect the upper coolant inlet hose to the radiator, thermostat side. 2. Loosen the band and disconnect the coolant return pipe to the climate control heater, thermostat side. 3. Loosen the band and disconnect the coolant supply pipe to the water/exhaust gas heat exchanger for the E.G.R. system, thermostat side. 4. Loosen the band and disconnect the coolant outlet pipe from the water/exhaust gas heat exchanger for the E.G.R. system, heat exchanger side. 1. Undo the bolts (1a) and remove the thermostat (1b) complete with O-Ring (1c). 1. Loosen the collar fastening the E.G.R. system water/exhaust gas heat exchanger, exhaust gas inlet pipe side. 2. Undo the bolts fixing the exhaust gas outlet pipe to the water/exhaust gas heat exchanger for the E.G.R. system, E.G.R. system solenoid valve side.3. Undo the bolts (3a) and remove the E.G.R. system water/exhaust gas heat exchanger (3b) complete with exhaust gas pipe (3c). 1. Undo the nuts (1a) and move the oil vapour recovery pipe mounting bracket (1b) aside.2. Undo the bolts (2a) and remove the E.G.R. system solenoid valve (2b).3. Remove the gasket. 1. Disconnect the rapid attachment for the fuel return pipe from the fuel filter, return manifold pipe side. 2. Disconnect the rapid attachment for the fuel return pipe to the tank, return manifold pipe side. 3. Loosen the band and disconnect the fuel return pipe from the pressure pump, fuel return manifold pipe side. 1. Undo the bolts (1a) and remove the fuel return manifold pipe (1b) complete with the pipe from the injectors to the fuel recovery manifold (1c). 1. Undo the bolt fixing the guide pipe for the engine oil dipstick to the pressure pump mounting. 2. Disconnect the electrical connection from the fuel pressure regulator.

	Name	Connector
2	Fuel pressure regulator	N77

Release the electrical wiring from the band and move it to the side. 1. Loosen the band and disconnect the condensation oil recovery pipe from the crankcase sump. 1. Loosen the band and disconnect the oil vapour recovery pipe from the separator.2. Loosen the band and disconnect the oil vapour recirculation pipe from separator. Disconnect the electrical connection from the solenoid on the vacuum tank.

	Name	Connector
-	Butterfly casing solenoid valve	L62

1. Undo the bolts (1a) and remove the mounting bracket (1b) complete with oil vapour separator (1c) and vacuum reservoir (1d). 1. Stop the pressure pump pulley from rotating using two bolts. 2. Undo the pressure pump pulley nut.Undo the two bolts fitted previously to stop the rotation of the pressure pump pulley. 1. Remove the pressure pump pulley (1a) using the tool (1b).

	Name	Country
1b	Extractor	1.860.854.001

1. Undo nuts (1a) and remove pressure pump (1b) from its mount. 1. Disconnect the electrical connection from the engine oil pressure warning light switch.

	Name	Connector
1	Engine oil pressure sensor	K30

2. Disconnect the electrical connection for the engine oil level sensor.

	Name	Connector
2	Engine oil level sensor	K32

3. Disconnect the electrical connection for the rpm sensor.

	Name	Connector
3	Rpm sensor	K46

1. Disconnect the earth lead from the alternator.

	Name	Connector
1	Alternator	A10

2. Disconnect the earth lead from the starter motor.

	Name	Connector
2	Starter' motor	A20

1. Disconnect the electrical connection from the pre-heating control unit.

	Name	Connector
1	Plug preheating control unit	M15

1. Undo the bolts (1a) and remove the power steering pump drive pulley (1b). 1. Undo the bolts securing the power steering pump to its mounting. Remove the guide tube complete with engine oil dipstick. 1. Undo the bolts (1a) and remove the pressure pump mounting (1b). 1. Undo the nuts (1a) and remove the air chamber assembly (1b) complete with gasket (1c). 1. Loosen the band and disconnect the system supply pipe from the water pump rigid inlet pipe. 2. Loosen the band and disconnect the coolant outlet pipe from the climate control heater, water pump rigid inlet pipe side. 3. Undo the bolts (3a) and remove the coolant inlet rigid pipe to the water pump (3b).Remove the gasket. 1. Undo the bolts (1a) and remove the exhaust manifold heat shield (1b). 1. Undo the nuts (1a) and remove the upper exhaust manifold heat shield (1b). 1. Undo the nuts fixing the front section of the exhaust pipe to the catalytic pre-converter. 2. Undo the nuts fixing the front section of the exhaust pipe to the catalytic converter. 3. Remove the front exhaust pipe section complete with seals. 1. Disconnect the vacuum pipe from the turbocharger variable geometry control actuator. 2. Loosen the band and disconnect the air supply hose between the turbocharger and the heat exchanger, turbocharger side. 3. Loosen the band and disconnect the corrugated air intake sleeve to the turbocharger, turbocharger side. 1. Undo the bolts (1a) and the nuts (1b) fixing the catalytic preconverter mounting bracket. 2. Undo the bolts securing the engine oil return pipe from the turbocharger, engine crankcase side. 1. Undo the connector (1a) and disconnect engine oil supply pipe to the turbocharger (1b), crankcase side. 1. Loosen the collar (1a) and remove the catalytic preconverter (1b).2. Keep the catalytic preconverter mounting bracket. 1. Undo the nuts (1a) and remove the exhaust manifold (1b) complete with turbocharger (1c). 2. Remove the exhaust manifold gasket. 1. Undo the bolts (1a) and remove the lower cylinder head assembly (1b). 2. Remove the cylinder head gasket.3. Remove the locating bushes. Refitting ( Removing ) Position the cylinder head centring bushes on the cylinder block/crankcase.Fit a new cylinder head gasket, taking care that it is the same thickness as the old one.

Position cylinder no. 1 at T.D.C.; rotate the crankshaft through two further teeth on the toothed drive pulley in order to lower the pistons preventing any interference with the valves when fitting the cylinder head.

Position the cylinder head on the crankcase.1. Tighten the cylinder head bolts (1a) to the recommended torque using the angular tightening tool (1b).

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	CYLINDER HEAD	M12	(Engine block side) 2.0 + 4.5 + 90° + 90° + 90°

	Name	Country
1b	Protractor	1.860.942.000

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

1. Place an exhaust manifold gasket in the housing.2. Place the exhaust manifold (2a) complete with turbocharger (2b), back in its housing and fix it tightening the nuts (2c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2c	Nut	EXHAUST MANIFOLD/S	M8	(Cylinder head side) 2.3 ÷ 2.8

Place the catalytic preconverter complete with mounting back in its housing and fasten it to the turbocharger using the collar. 1. Connect the engine oil delivery pipe to the turbocharger (1a), crankcase side, and tighten the connector (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Connector	OIL DELIVERY PIPE TO TURBO	M10	(Engine crankcase side) 1.4 ÷ 1.7

Tighten the bolt fixing the enigne oil return pipe from the turbocharger, engine crankcase side.Tighten the bolts and the nuts fixing the catalytic preconverter mounting bracket. Connect the corrugated air intake sleeve to the turbocharger, turbocharger side, and tighten the band.Connect the air supply hose between the turbocharger and the heat exchanger, turbocharger side, and secure with a band. Connect the vacuum pipe from the turbocharger variable geometry control actuator. 1. Place the front section of the exhaust pipe with gaskets back in its housing. 2. Tighten the nuts securing the exhaust pipe front section to the catalytic converter to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2	Nut	PRE-CAT CONVERTOR/CAT CONVERTOR PIPE	M8	(Catalytic converter side) 2.3 ÷ 2.8

3. Tighten the nuts fixing the front section of the exhaust pipe to the catalytic preconverter to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3	Nut	PRE-CAT CONVERTOR/CAT CONVERTOR PIPE	M8	(Catalyitic preconverter side) 2.3 ÷ 2.8

Place the upper exhaust manifold heat shield back in its housing and fix it using the nuts. Place the lower exhaust manifold heat shield back in its housing and fix it using the bolts. Place the water pump rigid inlet pipe, complete with gasket, back in its housing and secure it with the bolts. 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 system supply pipe to the water pump rigid inlet pipe and tighten the band. 1. Refit air chamber (1a) complete with gasket (1b) and secure it by tightening nuts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	INLET MANIFOLD	M8	Cylinder head side) 2.3 ÷ 2.8

1. Place the pressure pump support (1a) back in its housing and secure it tightening the bolts (1b).

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	INJECTION PRESSURE PUMP MOUNT	M8	(Engine crankcase side) 2.3 ÷ 2.8

Refit the guide tube and engine oil dipstick.1. Place the power assisted steering pump back in its housing and fix it tightening the bolts to the recommended torque.

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

1. Place the power assisted steering pump pulley (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER STEERING PUMP DRIVE PULLEY	M8	(Power assisted steering pump side 23 28

Connect the electrical connection to the pre-heating control unit.Connect the earth lead to the starter motor.Connect the earth lead to the alternator.Connect the electrical connection for the rpm sensor.Connect the electrical connection for the engine oil level sensor. Connect the electrical connection to the engine oil pressure warning light switch.1. Fit the clutch pump (1a) back in its housing and tighten the nuts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	PRESSURE PUMP	M8	(Support side) 2.3 ÷ 2.8

1. Replace the pressure pump pulley in its housing.2. Stop the pressure pump pulley from rotating using two bolts. 3. Tighten the pressure pump pulley nut to torque.

	Fastening	Component	Ø	Value(daNm)
3	Nut	PRESSURE PUMP CONTROL PULLEY	M14	4.5 ÷ 5.5

Undo the two bolts fitted previously to stop the rotation of the pressure pump pulley. Place the mounting bracket complete with oil vapour separator and vacuum reservoir back in its housing and secure it using the bolts.Connect the electrical connection to the solenoid on the vacuum tank.Connect the oil vapour recirculation pipe to the separator and tighten the band.Connect the oil vapour recovery pipe to the separator and tighten the band.Connect the condensation oil recovery pipe to the crankcase sump and tighten the band. Place the electrical wiring back in its housing and fix it to the band.Connect the electrical connection to the fuel pressure regulator. Tighten the bolt fixing the engine oil dipstick guide pipe to the pressure pump mounting.Place the fuel return manifold pipe complete with the pipe from the injectors to the fuel recovery manifold back in its housing and secure it using the bolts.Connect the fuel return pipe to the pressure pump, fuel return manifold pipe side and tighten the band.Connect the rapid attachment for the fuel return pipe to the tank, fuel return manifold pipe side.Connect the rapid attachment for the fuel return pipe from the fuel filter, return manifold pipe side. 1. Place the E.G.R. system solenoid valve (1a) complete with gasket (1b) back in its housing and fasten it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	-	-	-	-

2. Place the oil vapour recovery pipe mounting bracket (2a) back in its housing and secure it using the nuts (2b). 1. Place the water/exhaust gas heat exchanger for the E.G.R. system (1a), complete with exhaust gas outlet pipe (1b) back in its housing. 2. Tighten the bolts fixing the exhaust gas outlet pipe to the water/exhaust gas heat exchanger for the E.G.R. system, E.G.R. system solenoid valve side to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	WATER/GAS HEAT EXCHANGER FOR EGR SYSTEM	M8	(E.G.R.) solenoid valve side 2.3 ÷ 2.8

3. Tighten the collar fixing the water/exhaust gas heat exchanger for the E.G.R. system. 1. Refit thermostat (1a), complete with O-ring (1b) and secure by tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	-	-	-	-

Connect the coolant outlet pipe from the E.G.R. water/exhaust gas heat exchanger, heat exchanger side, and tighten the band. Connect the engine coolant supply pipe to the EGR system water/exhaust gas 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 upper coolant inlet hose to the radiator, thermostat side, and tighten the band. Connect the intermediate coupling for the vacuum pipe for the turbocharger vane position control actuator solenoid valve. Connect the vacuum pipe to the three-way connector on the brake servo vacuum intake pipe.1. Replace the pneumatically-controlled throttle body (1a), complete with gasket (1b), back in its housing and secure by tightening bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	-	-	-	-

2. Connect the vacuum pipe to the pneumatic valve on the throttle body. 1. Replace the connector on the throttle body (1a), complete with gasket (1b), back in its housing and secure by tightening bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	-	-	-	-

Connect the air inlet hose to the connector on the throttle casing and tighten the band. Place the coolant return pipe to the engine cooling system reservoir back in its housing and fix it using the bolts. Connect the flexible pipe to the coolant return pipe to the engine coolant reservoir and tighten the band. Connect the coolant oulet pipe from the cylinder head, engine coolant return pipe to the supply reservoir side and tighten the band. Connect the engine coolant return pipe to the supply reservoir, thermostat side and tighten the band. Fasten the electrical wiring to the bands near the thermostat. Connect the electrical connection to the excess pressure sensor. Connect the electrical connection to the EGR solenoid.Connect the electrical connection to the air flow meter.Connect the electrical connection to the turbocharger vane actuator solenoid. 1. Place the heater plugs back in their housings and tighten them to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	-	GLOW PLUGS	M9	(Cylinder head side) 0.7 ÷ 0.9

2. Connect the electrical connections to the heater plugs. Place the hydraulic tappets in their housings.Place the valve rocker arms back in their housings.Place the upper cylinder head gasket back in its housing.1. Remove the plugs (1a) and fit the camshaft timing tools (1b) in the upper cylinder head.

Check that the tools are correctly inserted in the housings in the camshafts.

	Name	Country
1b	Gauge	1.870.986.900

Remove the inlet side camshaft timing tool and tighten the plug. 1. Place the complete upper cylinder head (1a) back in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CYLINDER HEAD EXTENSION	M8	(Cylinder head side 23 28

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	INJECTION PRESSURE PUMP MOUNT	M8	(Cylinder head side) 2.3 ÷ 2.8

2. Loosen the exhaust side camshaft toothed drive pulley fixing bolt. 1. Undo the bolt for the crankcase front cover shown in the diagram. Temporarily fit the timing drive belt on the drive pulley. 2. Fit the tool (2a) and secure it using the calibrated screw (2b)

To allow the engagement of the locating dowel on the timing drive belt drive pulley in the opening in the tool, rotate the crankshaft using small movements.

	Name	Country
2a	Template	1.860.905.000

	Name	Country
2b	Calibrated screw	1.860.905.010

1. Completely fit the timing belt.2. Use a screwdriver to lever in the hole (2a) until the reference on the tensioner (2b) lines up with the reference hole (2c) and, in this position, tighten the tensioner nut (2d) to torque.

	Fastening	Component	Ø	Value(daNm)
2d	Nut	MOBILE TIMING TENSIONER	M10	4.2 ÷ 5.2

3. Tighten the exhaust side camshaft toothed drive pulley fixing bolt to the recommended torque.

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

Remove the timing tools.

	Name	Country
-	Gauge	1.870.986.900

Remove the exhaust camshaft template, as the inlet camshaft has already been removed.

	Name	Country
-	Template	1.860.905.000

	Name	Country
-	Calibrated screw	1.860.905.010

Rotate the crankshaft through two revolutions.Check once again that the timing is correct by refitting the timing tools.

Only fit the exhaust camshaft side template because the inlet side one is not accessible.

Check that the tensioning references on the timing belt tensioner are aligned. Tighten the bolt for the crankcase front cover previously removed. Tighten the plug in the camshaft housing for fitting the exhaust side timing tool. 1. Place the vacuum unit (1a), complete with gasket (1b), back in its housing and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	BRAKE SERVO VACUUM PUMP	M6	(Cylinder head side 05 06 50

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

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	OIL FILTER FITTING	M6	(Cylinder head side 08 10

Connect the electrical connection to the engine coolant temperature sensor. Connect the oil vapour recovery pipe to the engine oil filler and tighten the band. Connect the vacuum pipe to the brake servo and tighten the band.Fit the rigid pipe leading to the turbocharger vane actuator solenoid back in its housing and secure with the nuts. Connect the hose to the rigid vacuum pipe leading to the turbocharger vane actuator solenoid. Proceed with refitting  - 5530B10  battery - r+r . 1. Place the single fuel manifold pipe (1a), complete with fuel pressure sensor (1b), back in its housing and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	INJECTOR FUEL MANIFOLD (DIESEL)	M8	(Camshaft housing side 23 28

2. Connect the electrical connection to the fuel pressure sensor. 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 single fuel manifold, pump side, to the recommended torque using a suitable spanner.

	Fastening	Component	Ø	Value(daNm)
2	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14	(Pressure pump side 22 24

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

	Fastening	Component	Ø	Value(daNm)
3	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14	(Fuel manifold side 22 24

1. Refit the injectors (1a) complete with brackets and secure by tightening the nuts (1b) to the specified torque.

Start the refitting beginning with the injector for cylinder no. 4 and continuing with the injectors for cylinders 3, 2 and 1.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	INJECTORS(DIESEL)	M8	(Camshaft housing side 23 28

1. Fit the new pipes from the fuel manifold to the injectors and secure them using the connectors without tightening them. 2. Tighten the connectors for the pipes from the fuel manifold to the injectors, injector side, to the recommended torque using a suitable spanner.

	Fastening	Component	Ø	Value(daNm)
2	Connector	FUEL MANIFOLD LINE TO INJECTORS	M12	(Injector side 22 24

3. Tighten the connectors for the pipes between the fuel manifold and the injectors, fuel manifold side, to the recommended torque using a suitable spanner.

	Fastening	Component	Ø	Value(daNm)
3	Connector	FUEL MANIFOLD LINE TO INJECTORS	M12	Fuel manifold side 22 24

Clean the threaded seats for the above-mentioned pipe on the manifold and the injectors using heptane.

4. Connect the pipe from the injectors to the fuel recovery manifold (4a) to the injectors pushing it until the clips (4b) can be heard clicking into place. Place the electrical wiring back in its housing and tighten the cable duct fixing bolts. Fasten the electrical wiring using the band on the timing cover. Connect the electrical connection to the air conditioner compressor. Connect the electrical connection to the cam angle sensorConnect the electrical connections to the injectors.1. Fit the bracket on the engine for the reaction rod (1a) and fix it tightening the bolts (1b) and (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	REACTION LINK BRACKET ON ENGINE	M10	(Cylinder head side), 4.5 ÷ 5.5

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	REACTION LINK BRACKET ON ENGINE	M10	(Power assisted steering pump mounting side), 4.5 ÷ 5.5

Proceed with refitting  - 1032D12  timing system protective cover(s) - r + r . Proceed with refitting  - 1092G20  engine component single belt fixed tensioner - one - r + r . Proceed with refitting  - 1092A10  Crankshaft services PULLEY - R.R. . Proceed with refitting  - 1092G10  single engine belt r r . Proceed with refitting - 7055B91 Right front WHEEL ARCH LINER - R.R. . Proceed with refitting  - 7055B54  under-engine guard - r r . Proceed with refitting  - 4450B04  right front wheel r r . Proceed with refitting  - 1060G80  ds electric injection control unit - r r . Proceed with refitting  - 1008C10  power unit upper reaction link r r . Refill the engine cooling system with coolant  - 0010T20  coolant change . Proceed with refitting  - 1016A10  sound-proofing cover - r + r . Connect the negative (-) battery terminal.Remove the car from the ramps.