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. Proceed with removal  - 1016A10  sound-proofing cover - r + r . Proceed with removal  - 5530B10  battery - r+r . Proceed with removal  - 5530B52  Battery DRIP TRAY/SUPPORT - 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 - 7055B66 Engine compartment DUST SHIELD protection in right front wheel arch - R.R. . Proceed with removal  - 1092G10  single engine belt r r . Proceed with removal  - 1092A10  Crankshaft services PULLEY - R.R. . Proceed with removal  - 1092G21  engine component single belt fixed tensioner - r rwith belt removed . Proceed with removal  - 1008C10  power unit upper reaction link 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 . Proceed with removal  - 1048A50  air inlet pipe to turbo charger - r + r . Proceed with removal  - 1076B70  exhaust pipe between pre-catalytic converter and catalytic converter - r r . Proceed with removal  - 1080B40  catalytic pre-converter - r r . Proceed with removal  - 1064A24  variable geometry turbocharger exhaust manifold assembly sleeveleading to exhaust pipe r r . 1. Disconnect the electrical connection from the cam angle sensor.

	Name	Connector
1	Timing sensor	K47

2. Undo the bolt (2a) and remove the cam angle sensor (2b). 1. Undo the connectors (1a) and (1b) and remove the pipes from the fuel manifold to the injectors (1c).

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

1. Disconnect the electrical connections from the injectors.

	Name	Connector
1	Injector	N70

2. Undo the bolts (2a) and move the electrical wiring (2b) aside.3. Manually push the springs (3a) and disconnect the pipe from the injectors to the fuel recovery manifold (3b), injectors side and move aside. 1. Undo the nuts fixing the injector brackets.2. Remove the injectors (2a) complete with brackets using the tools (2b) and (2c).

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, 4 and 5.

	Name	Country
2b	Extractor	1.870.739.000

	Name	Country
2c	Extractor	1.870.897.300

1. Undo the bolts (1a) and move aside the fuel return manifold pipe (1b).2. Loosen the band and disconnect the flexible coolant return pipe from the rigid coolant return pipe to the engine coolant reservoir. 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). 1. Disconnect the intermediate quick-release fitting on the vacuum pipe for the brake servo.2. Disconnect the engine oil vapour recovery pipe, engine oil filler fitting side.3. Undo the fastenings and move the pipe/wiring bracket to the side.4. Disconnect the vacuum pipe from the pneumatic valve on the throttle body.5. Loosen the band and disconnect the air supply duct from heat exchanger to inlet manifold, manifold side. 1. Disconnect the electrical connections from the heater plugs.

	Name	Connector
1	Heater plug	A40

2. Disconnect the hose from the rigid vacuum pipe leading to the turbocharger vane actuator solenoid. 3. Undo the bolts (3a) and remove the rigid vacuum pipe leading to the turbocharger vane actuator solenoid (3b). 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

3. Disconnect the electrical connection from the air conditioning compressor engagement electromagnet.

	Name	Connector
3	Air conditioning compressor "on" electromagnet	L20

4. Disconnect the electrical connection from the engine coolant temperature sensor.

	Name	Connector
4	Engine temperature sender unit	K36

5. Release the electrical wiring from the securing band and move aside. 1. Undo the bolts (1a) and remove the single cylinder head extension (1b).Remove the cylinder head extension gasket. 1. Remove the hydraulic tappets (1a) and the rockers (1b). 1. Loosen the band and disconnect the coolant return pipe to the climate control heater, thermostat side.

Collect the coolant which comes out in a suitable container.

1. Remove the upper coolant inlet hose to the radiator. 1. Undo the upper bolts fixing the vacuum reservoir and engine oil vapour separator reservoir bracket to the cylinder head. 1. Undo the bolts (1a) and remove the cylinder head (1b).Remove the cylinder head gasket.Remove the locating bushes. Refitting ( Removing ) Clean the contact surfaces between the engine block and cylinder head thoroughly.

Cover the cylinder liners and pistons to prevent impurities or foreign bodies from entering.

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.

Place the cylinder head in its seat on the engine block.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 crankcase side) 2.0 + 6.5 + 90° + 90° + 90 °,

The value of 2 daNm in the table below is a figure which must be adhered to for all the bolts following the tightening order illustrated in the diagram.

	Name	Country
1b	Protractor	1.860.942.000

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

Place the rockers and hydraulic tappets in their housings.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

Remove the inlet side camshaft timing tool and tighten the plug. Fit a new cylinder head extension gasket.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	-	-	-	-

Proceed with refitting  - 1032B10  toothed timing belt - r + r for timing adjustment or replacement . Tighten the upper bolts securing the vacuum reservoir and engine oil vapour separator reservoir bracket to the cylinder head.Refit the upper radiator coolant inlet sleeve to the radiator.Connect the engine coolant return pipe from the climate control system heater, thermostat side, and tighten the band. Place the electrical wiring back in its seating and fix it to the bands.Connect the electrical connection to the engine coolant temperature sensor. Connect the electrical connection to the air conditioner compressor electromagnet.Connect the electrical connection to the excess pressure sensor. Connect the electrical connection to the EGR solenoid.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. Conect the air supply hose from the heat exchanger to the inlet manifold, inlet manifold side, and tighten the band.Connect the vacuum pipe to the pneumatic valve on the throttle body. Place the piping/wiring mounting bracket back in its seating and secure.Connect the oil vapour recovery pipe, oil filler fitting side.Connect the intermediate quick-release fitting on the brake servo vacuum pipe.Connect the electrical connections to the heater plugs.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) 2.5

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) 2.3

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) 2.3

Connect the flexible pipe to the coolant return pipe to the engine coolant reservoir and tighten the band. Place the fuel return manifold pipe back in its housing and secure it using the bolts. 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. 5 and continuing with the injectors for cylinders 4, 3, 2 and 1.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	INJECTORS(DIESEL)	M8	(Camshaft housing side) 3.0

Place the pipe from the injectors to the fuel recovery manifold back in its housing and connect it to the injectors pushing it until the clips can be heard clicking into place.Place the electrical wiring back in its seating and fix it using the bolts.Connect the electrical connections to the injectors.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) 2.0

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) 2.0

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

Place the cam angle sensor back in its housing and fix it using the bolt.Connect the electrical connection to the cam angle sensor Proceed with refitting  - 1064A24  variable geometry turbocharger exhaust manifold assembly sleeveleading to exhaust pipe r r . Proceed with refitting  - 1080B40  catalytic pre-converter - r r . Proceed with refitting  - 1076B70  exhaust pipe between pre-catalytic converter and catalytic converter - r r . Proceed with refitting  - 1048A50  air inlet pipe to turbo charger - r + r . Proceed with refitting  - 1032D12  timing system protective cover(s) - r + r . Proceed with refitting  - 1008C10  power unit upper reaction link r r . Proceed with refitting  - 1092G21  engine component single belt fixed tensioner - r rwith belt removed . Proceed with refitting  - 1092A10  Crankshaft services PULLEY - R.R. . Proceed with refitting  - 1092G10  single engine belt r r . Proceed with refitting - 7055B66 Engine compartment DUST SHIELD protection in right front wheel arch - 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  - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. . Proceed with refitting  - 5530B10  battery - r+r . Proceed with refitting  - 1016A10  sound-proofing cover - r + r . Refill the engine cooling system with coolant  - 0010T20  coolant change . Remove the car from the ramps.