1036C10 CAMSHAFTS IN CYLINDER HEAD EXTENSION - R R - INCLUDES CYLINDER HEAD EXTENSION REPLACEMENT IF NECESSARY - Alfa - 156 - eLearn

3237858 - 1036C10 camshafts in cylinder head extension - r r - includes cylinder head extension replacement if necessary

) Position the vehicle on the ramp Proceed with removal - 1016A10 sound-proofing cover - r + rEnsure 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 + r1. 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 tensioner2. Prise off and remove the timing belt.

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+r1. 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. Position the upper cylinder head (1a) in the vice using the tool (1b).

	Name	Country
1b	Mount	1.860.470.001

1. Undo the bolts (1a) and remove the cam angle sensor (1b).

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	1.870.896.900

1. Undo the camshaft sprocket fixing bolts.

1. Undo the bolt (1a) and remove the exhaust side camshaft toothed drive pulley (1b).

Remove the camshaft timing tools from the camshaft housing.

	Name	Country
-	Gauge	1.870.896.900

1. Release the camshafts (1a) as necessary and remove the camshaft sprockets (1b).

1. Using a suitable drift, extract the inlet side camshaft (1a) and the plug (1b). 2. Using a suitable drift, extract the exhaust side camshaft (2a) and the oil seal (2b). Remove the exhaust side camshaft oil seal.

Refitting ( Removing

) Place the camshafts back in their housings.Place the camshaft gears back in their housings and secure them without tightening the bolts. 1. Fit the camshaft timing tools.

	Name	Country
1	Gauge	1.870.896.900

1. Tighten the camshaft sprocket fixing bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	IDLER GEAR ON CAMSHAFTS	M12	(Camshaft side 108 132

1. Fit the front camshaft oil seal, exhaust side (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.870.896.800

Fit the inlet side camshaft plug.Fit the exhaust side timing drive pulley and fix it with the bolt without tightening it. 1. Place 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 08 10

Remove the support tool, complete with upper cylinder head from the vice and separate them. Remove the inlet side camshaft timing tool and tighten the nut.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

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+r1. 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	-	GLOW PLUGS	M8	(Cylinder head side) 0.9 ÷ 1.0

	Fastening	Component	Ø	Value(daNm)
1c	Nut	EXHAUST MANIFOLD/S	M8	(Cylinder head side) 2.1 ÷ 2.5

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 rConnect the negative (-) battery terminal Proceed with refitting - 1016A10 sound-proofing cover - r + rRemove the car from the ramps.