3237855 - 1016B10 single cylinder head extension - change gasket
Removing
(
Refitting
)
Position the vehicle on the ramp.
Proceed with removal
- 1016A10 sound-proofing cover
- r + r
.
Ensure that the ignition key is in the
OFF position, then disconnect the negative battery terminal (-).
| Name | Connector |
|---|
| - | Battery | A1B |
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
.
Proceed with removal
- 1032B10 toothed timing belt -
r + r for timing adjustment or replacement
.
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 brackets 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 removal beginning with the
fuel injector of 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.
Refitting
(
Removing
)
1. Place the upper cylinder head gasket back in its housing.2. Place the camshaft housing assembly (2a) back in its housing
and secure it tightening the bolts (2b) to the recommended torque. 
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2b | Bolt | CYLINDER HEAD EXTENSION | M8 | (Cylinder head side 23 28 |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2b | Bolt | INJECTION PRESSURE PUMP MOUNT | M8 | (Cylinder head side) 2.3 ÷ 2.8 |
Proceed with refitting
- 1032B10 toothed timing belt -
r + r for timing adjustment or replacement
.
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 sensor.Connect the electrical connections to the
injectors.
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
.
Connect the negative (-) battery terminal.
Proceed with refitting
- 1016A10 sound-proofing cover
- r + r
.
Remove the car from the ramps.
