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 . Proceed with removal  - 5530B10  battery - 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 . 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 remove it. 1. Undo the nuts fixing the injector brackets.2. Remove the injectors (2a) complete with bracket using 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 injector(s) is(are) being fitted, it is necessary to: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, 4 and 4.

	Name	Country
2b	Extractor	1.870.739.000

	Name	Country
2c	Extractor	1.870.897.300

1. Undo the bolts securing the fuel return manifold pipe. 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) with. 1. Release the fuel vapour recovery pipe (1a) from the band (1b).2. Disconnect the intermediate quick-release connector on the vacuum pipe for the brake servo.3. Loosen the engine oil vapour recovery pipe, engine oil filler fitting side.4. Loosen the band and disconnect the air supply duct from heat exchanger to inlet manifold, manifold side. 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. 1. Undo the bolts (1a) and remove the single cylinder head (1b).Remove the cylinder head extension gasket. Refitting ( Removing ) 1. Remove the plugs (1a) and fit the camshaft timing tools (1b) in the camshaft housing.

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

	Name	Country
1b	Gauge	1.870.896.900

Remove the timing tools, intake camshaft side, and tighten the plug. Place a new cylinder head extension gasket back in its housing.1. Place the camshaft housing assembly (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 . 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 oil vapour recovery pipe to the engine oil filler.Connect the intermediate quick-release fitting on the vacuum intake pipe for the brake servo.Fasten the engine oil vapour recirculation pipe using the band.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

Tighten the bolts securing the fuel return manifold pipe.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  - 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  - 5530B10  battery - r+r . Proceed with refitting  - 1016A10  sound-proofing cover - r + r . Remove the car from the ramps.