2400065 - 1016B12 single cylinder head extension - r r with timing belt removed - replace

Removing ( Refitting ) Proceed with removal  - 5530B10  battery - r+r Proceed with removal  - 5530B52  Battery DRIP TRAY/SUPPORT - R.R.1. Loosen the collar and disconnect the engine oil vapour intake pipe from the tappet cover.2. Disconnect the engine oil vapour inlet pipe from the intake manifold.3. Loosen the band, disconnect the hose from the air filter to the intake manifold, intake manifold side and remove it.4. Loosen band and disconnect the upper coolant inlet hose to the radiator, thermostat side.
Recover the coolant which comes out in a suitable container.
1. Loosen the band and disconnect the lower radiator coolant outlet hose from the radiator, radiator side.
1. Disconnect the electrical connection from the cam angle sensor.

NameConnector
1Timing sensor.  K47 
1. Disconnect the electrical connection for the front Lambda sensor for the catalytic converter.

NameConnector
1Lambda sensor on catalyzer  K17 
2. Disconnect the electrical connection for the rear Lambda sensor for the catalytic converter.

NameConnector
2Lambda sensor on catalyzer  K17 
1. Disconnect the electrical connection from the engine coolant temperature sensor.

NameConnector
1Engine temperature sender unit  K36 
2. Disconnect the electrical connection from the throtle body integrated with the M.D.S.

NameConnector
2Integrated throttle body actuator  N75 
1. Disconnect the electrical connections (1a) and (1b) from the injection/ignition system control unit.

NameConnector
1aEngine management control unit  M10A 

NameConnector
1bEngine management control unit  M10B 
2. Release the electrical wiring (2a) from the band (2b).3. Undo the nut (3a) and disconnect the earth lead (3b) from the injection-ignition system.4. Disconnect the electrical connection from the fuel vapour solenoid valve.

NameConnector
4Fuel vapour recovery solenoid  L10 
1. Undo the nut (1a) and disconnect the earth lead (1b) from the air conditioner compressor. 2. Disconnect electrical connection (2a) from the intake air pressure/temperature sensor and release the electrical wiring from band (2b).

NameConnector
2aIntegrated air temperature sensor  K43 
3. Disconnect the rapid connector for the fuel vapour recirculation pipe from the air chamber.
1. Disconnect the electrical connection for the rpm sensor.

NameConnector
1Rpm sensor  K46 
2. Disconnect the electrical connection from the engine oil pressure warning light switch.

NameConnector
2Engine oil pressure sensor (switch)  K30 
1. Open the cover (1a), undo the nuts (1b) and disconnect the electrical connections (1c) for the alternator.

NameConnector
1cStarter' motor  A20 
2. Undo nut (2a) and disconnect earth lead (2b).3. Disconnect the electrical connection for the knock sensor.

NameConnector
3Detonation sensor  K50 
4. Disconnect the electrical connection from the air conditioning compressor engagement electromagnet.

NameConnector
4Air conditioning compressor engagement electro-magnet  L20 
5. Release engine electrical wiring (5a) from bands (5b) on the air capacity chamber, then move aside.
1. Disconnect the brake servo single-acting valve from the brake servo.2. Release the vacuum pipe for the brake servo (2a) from the retaining band (2b).
1. Loosen the band and disconnect the coolant return pipe to the climate control heater, thermostat side.2. Release the electrical wiring (2a) from the band (2b).
1. Undo the lower bolts (1a) and upper central bolt (1b) securing the air chamber to the cylinder head.
1. Undo the remaining upper side bolts (1a) and remove the air chamber (1b) assembly.
Proceed with removal  - 1072C44  exhaust manifold heat shield on bulkhead - r+r Proceed with removal  - 1072C16  exhaust manifold with catalytic converter - r rUndo the bolt fixing the engine oil dipstick tube.1. Undo protective caps (1a), then undo cylinder head extension bolts (1b).2. Slightly raise the cylinder head extension and insert the tool.

NameCountry
2Tappet retaining tool1.860.988.000
Remove the single cylinder head extension.Remove the gasket. Refitting ( Removing ) Refit a new right cylinder head extension gasket.Refit the single cylinder head extension.1. Remove the tool.

NameCountry
1Tappet retaining tool1.860.988.000
2. Tighten the bolts securing the single cylinder head extension to torque.

FasteningComponentØValue(daNm)
2BoltCYLINDER HEAD EXTENSIONM81.4 ÷ 1.7
3. Tighten the protective caps to the specified torque.

FasteningComponentØValue(daNm)
3PlugCYLINDER HEAD EXT FASTENERSM161.4 ÷ 1.7
Tighten the bolt fixing the engine oil dipstick pipe. Proceed with removal  - 1072C16  exhaust manifold with catalytic converter - r r . Proceed with removal  - 1072C44  exhaust manifold heat shield on bulkhead - r+r . Refit in its seating the air capacity chamber assembly, and tighten the bolts to the specified torque.

FasteningComponentØValue(daNm)
-BoltINLET AIR DUCTM60.6 ÷ 0.8
Secure the engine electrical wiring with the bands.Connect the engine coolant return pipe from the climate control system heater, thermostat side, and tighten the band.Secure the vacuum pipe for the brake servo using the band.Connect the brake servo one-way valve to the brake servo.Place the engine electrical wiring back in its housing and fasten to the air chamber using the bands.Connect the electrical connection to the air conditioner compressor electromagnet.Connect the electrical connection for the knock sensor.Connect the earth lead and fix it using the nut.Connect the electrical connection to the starter motor, secure it with the nut and close the protective cover.Connect the electrical connection to the engine oil pressure warning light switch.Connect the electrical connection for the rpm sensor.Connect the rapid connector for the fuel vapour recirculation pipe to the air chamber.Connect the electrical connection to the intake air temperature/pressure sensor and secure the electrical wiring with a collar.Connect the earth lead to the air conditioner compressor and fix it using the nut. Connect the electrical connection to the fuel vapour solenoid valve.Fasten the engine electrical wiring using a band.Connect the earth lead to the injection-ignition system control unit and secure with the nut. Connect the electrical connections to the fuel injection/ignition control unit. Connect the electrical connection to the throttle body integral with M.D.S.Connect the electrical connection to the engine coolant temperature sensor.Connect the electrical connection for the rear Lambda sensor for the catalytic converter.Connect the electrical connection for the front Lambda sensor for the catalytic converter.Connect the electrical connection to the cam angle sensor. Connect the lower coolant outlet hose from the radiator, radiator side, and tighten the band.Connect the upper coolant inlet hose to the radiator, thermostat side, and tighten the band. Place the hose from the air filter to the intake manifold back in its housing, connect it to the intake manifold and tighten the band.Connect the engine oil vapour inlet pipe to the intake manifold.Connect the engine oil vapour intake pipe to the tappet cover and tighten the band. Proceed with refitting  - 5530B52  Battery DRIP TRAY/SUPPORT - R.R. . Proceed with refitting  - 5530B10  battery - r+r . Refill the engine cooling system with coolant  - 0010T20  coolant change .