1016B10 SINGLE CYLINDER HEAD EXTENSION - CHANGE GASKET - Fiat - IDEA - eLearn

2400064 - 1016B10 single cylinder head extension - change gasket

) Position the vehicle on the ramp Drain the air conditioner coolant circuit - 0010T84 coolant for air conditioning system dehydrate and recharge . Proceed with removal - 4450B04 right front wheel r r Proceed with removal Proceed with removal - 7055B66 Engine compartment DUST SHIELD protection in right front wheel arch - R.R. Proceed with removal - 7055B91 Right front WHEEL ARCH LINER - R.R. Proceed with removal - 5530B10 battery - r+r Proceed with removal - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. Proceed with removal - 1060G90 diesel injection wiring harness - r r1. Disconnect the quick-release fitting of the coolant return pipe to the engine coolant reservoir, thermostat side.Undo the fuel filler cap and remove it to discharge the pressure in the system.2. Disconnect the rapid connector (2a) for the fuel supply pipe from the fuel filter to the pressure pump, pressure pump side and release it from the fastening (2b). 3. Disconnect the rapid attachment (3a) for the fuel return pipe to the tank, single fuel manifold pipe side and release it from the fastening (3b).

1. Loosen the band and disconnect the coolant return pipe from the engine coolant reservoir, reservoir side.

1. Undo the bolts (1a) and remove the duct (1b) complete with engine coolant reservoir return pipe (1c).

1. Manually push the clips (1a) and disconnect the return pipe from the injectors to the manifold (1b), injectors side.2. Loosen the band and disconnect the fuel return pipe from the pressure pump, pressure pump side.3. Undo the connectors (3a) and remove the pipe from the pressure pump to the fuel manifold (3b).

When refitting, fit a new pipe from the pressure pump to the fuel manifold.

4. Undo the connectors (4a) and remove the pipe from the fuel manifold to the injectors (4b).

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

5. Undo the bolts (5a) and remove the mounting brackets (5b) complete with single fuel manifold pipe (5c).6. Undo the bolt (6a) and remove the cam angle sensor (6b).

1. Undo the injector mounting bracket nut.2. Remove the washer (2a) and tapered washer (2b).3. Fit the injectors (3a), one at a time, using tools (3b) and (3c).

If the same injectors are being reused, mark the cylinder to which they belong so that they can be correctly refitted. If new fuel injector(s) are fitted, the self-learning procedure with the Examiner must be carried out.

	Name	Country
3b	Extractor	1.870.900.700

	Name	Country
3c	Extractor	1.870.739.000

Remove the fuel injectors complete with bracket.Repeat the above procedure to remove the remaining pair of injectors.4. Remove the injector seals from the single camshaft housing.

These seals are replaced each time they are refitted.

1. Loosen the band and disconnect the brake servo vacuum pipe, vacuum unit side.

1. Remove the caps (1a) and fit the tools (1b) on the camshafts in their place.

Fit the tool positioning it with the millings in a horizontal position and checking that it is correctly inserted in the housings in the camshafts.

	Name	Country
1b	Template	1.871.000.900

2. Fit a suitable (8 mm diameter) pin via the special opening in the gearbox.

Check that the lug is correctly fitted in the housing in the engine flywheel.

1. Use a spanner on the moving tensioner (1a) and remove the engine components single drive belt (1b).

1. Undo the bolts (1a) and remove the crankshaft pulley (1b).

1. Using the tools (1a) and (1b) for counter-torque, loosen the left hand thread bolt (1c) fastening the pulley support flange to the crankshaft.

	Name	Country
1a	Counter-torque	1.871.000.200

	Name	Country
1b	Support for counter-torque	1.860.831.000

1. Loosen the lower bolts fixing the alternator to the mounting.

1. Undo the upper bolt fixing the alternator to the mounting.2. Undo the bolt (2a) and disconnect the connector (2b) for the engine oil vapour recovery pipe from the timing cover with the chain drive. 3. Fit a suitable bracket for supporting the power unit and secure it using the upper alternator fixing bolt to the mounting.

Tighten the lower bolts fixing the alternator to the mounting.1. Fit the tool (1a), complete with support mountings (1b), then connect it to the bracket fitted previously using the rod (1c).

	Name	Country
1a	Crossmember	1.870.595.000

	Name	Country
1b	Support mountings	1.870.650.000

1. Undo the bolt (1a) and disconnect the pipe from the expansion valve to the compressor (1b), compressor side.

Seal the disconnected connectors, using suitable plugs, to prevent humidity and impurities from entering the system.

1. Loosen the band and disconnect the supply pipe, reservoir side, from the engine coolant reservoir.2. Undo the nut (2a) and the bolt (2b) and remove the engine coolant supply reservoir (2c).

1. Undo the nut fixing the air conditioning system pipes mounting bracket. 2. Undo the nuts (2a) and (2b), then remove the timing side power unit support flexible mounting (2c).

1. Undo the bolts fixing the air conditioning pipe mounting brackets to the timing side rigid engine support.

1. Undo the bolts (1a) and remove the timing side rigid engine support (1b) complete with engine lifting bracket (1c).

1. Undo the plug (1a) complete with O-ring and the bolt (1b) fixing the exhaust side camshaft toothed drive pulley.2. Undo the bolts (2a) and remove the cover (2b) complete with gasket.

Release the toothed pulley from the exhaust side camshaft working via the opening in the timing cover adjusting it on the inner rib of the timing cover.

After this operation the piston for the timing moving tensioner should be fully removed.

1. Undo the bolts fixing the timing cover to the single camshaft housing.2. Recover the brackets.3. Undo the bolts (3a) and (3b), then remove the single camshaft housing assembly (3c).4. Remove the single camshaft housing gasket.

Refitting ( Removing

) 1. Apply Fiat silicon sealant 71713687 or a similar product to the contact area between the cylinder head and the timing chain cover. 2. Position the gasket (2a) on the cylinder head, fitting it on the centering bushes (2b).3. Apply Fiat silicon sealant 71713687 or a similar product to the gasket between the lower cylinder head and the camshaft housing to the area in contact with the timing cover. 4. Also apply the same sealant to the surface of the timing cover gasket, following the black silicon line on the actual gasket.

Apply a thin layer of sealant to the timing cover gasket so that it is not too thick and to prevent excess sealant going inside the timing cover.

Working with the camshaft timing tools fitted, position the single camshaft housing taking care not to move the rockers from their position. Screw in the bolts fixing the single camshaft housing to the cylinder head without tightening them.1. Screw in and tighten the bolts shown fixing the timing cover to the single camshaft housing to torque.

During this stage, do not tighten the remining timing cover fixing bolts.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	TIMING COVER	M6	0.8 ÷ 1.0

1. Tighten the six rear bolts fixing the single camshaft housing to a torque of 0.9 daNm.2. Loosen the bolts (2a) ansd (2b) fixing the timing cover tightened previously. 3. Continue tightening the bolts fixing the camshaft housing to a torque of 0.9 daNm following the order illustrated in the diagram gradually working towards the timing cover.

1. Tighten the bolts fixing the single camshaft housing M8 (1a) to a pre-torque of 1.5 daNm and M7 (1b) to a pre-torque of 1.2 daNm.2. Tighten the bolts (2a) and (2b) fixing the single camshaft housing to the recommended torque.

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

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	CYLINDER HEAD EXTENSION	M8	(Lower cylinder head side) 2.5

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	CYLINDER HEAD EXTENSION	M7	(Lower cylinder head side) 1.8

Fit the remaining bolts fixing the timing cover to the single camshaft housing, then tighten all the bolts fixing the timing cover to the single camshaft housing to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	TIMING COVER	M6	0.8 ÷ 1.0

The single camshaft housing - cylinder head non alignment should not exceed the recommended value.

The camshaft housing only may project.

	Measurement		Value
-	Upper cylinder head - cylinder head misalignment (mm)		0.1

1. Fasten the tool to the timing cover by the inspection opening so that the pin is in the moving plate rib; using the tool lever, retract the chain tensioner piston so that it is locked.

	Name	Country
1	Lever	1.870.900.400

Fit the toothed pulley on the exhaust side camshaft working via the opening in the timing cover.Position the bolt fixing the gear and screw it in without tightening it to prevent the gear from being able to accidentally come out of the housing. Using the tool lever, fully retract the chain tensioner piston to allow the inner spring to be reloaded and ensure that the timing chain tension is correct. Release the chain tensioner piston checking that it is in contact with the moving plate.Remove the tool.

	Name	Country
-	Lever	1.870.900.400

1. Using the camshaft timing tools fitted previously, tighten the exhaust side camshaft toothed drive pulley fixing bolt to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	TIMING DUCT PULLEY	M12	(Exhaust camshaft side) 10.8 ÷ 13.2

2. Tighten the plug complete with O-ring.3. Place the tapper cover (3a), complete with gasket, back in its housing and fix it using the bolts (3b).

1. Place the timing side rigid engine support (1a), complete with engine lifting bracket (1b), in position and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	ENGINE MOUNT TIMING SIDE	M10	(Engine crankcase side) 5.7 ÷ 6.3

Tighten the bolts fixing the air conditioning pipe mounting brackets to the timing side rigid engine support.1. Place the timing side power unit support flexible mounting (1a) in position and secure it tightening the nuts (1b) and (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	FRONT RUBBER MOUNTS	M10	(Rigid support side) 4.5 ÷ 5.5

	Fastening	Component	Ø	Value(daNm)
1c	Nut	FRONT RUBBER MOUNTS	M10	(Bodyshell side) 4.1 ÷ 5.0

2. Tighten the nut securing the air conditioning system pipe bracket to the power unt flexible mounting block, timing side.

Refit the coolant reservoir in its seating and secure with the nut and bolt.Connect the engine coolant reservoir supply pipe and tighten the band.1. Connect the pipe from expansion valve to compressor (1b), compressor side and tighten the bolt (1b) to the recommended torque.

Replace the O-rings for the connectors using green coloured seals only, resistant to R134a refrigerant fluid. Lubricate the thread of the connectors using anti-freeze.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	EXPANSION VALVE - COMPRESSOR PIPE	M6	(Compressor side) 0.7 ÷ 1.1

Remove the safety tools used for supporting the power unit.

	Name	Country
-	Crossmember	1.870.595.000

	Name	Country
-	Support mountings	1.870.650.000

Undo the upper bolt, loosen the lower bolts fixing the alternator and remove the bracket used for supporting the power unit.Tighten the bolts fixing the alternator to the mounting to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	ALTERNATOR ASSEMBLY	M8	(Support side) 2.3 ÷ 2.8

Connect the connector for the engine oil vapour recovery pipe to the chain drive timing cover and tighten the bolt.

Make sure that the O-Ring is correctly positioned.

1. Tighten the left hand bolt (1a) fixing the pulley support flange to the crankshaft to the recommended torque using tools (1b) and (1c) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
1a	Left hand thread bolt	PULLEY SUPPORT FLANGE ON CRANKSHAFT	M14	(Crankshaft side) 21.9 ÷ 24.2

	Name	Country
1b	Counter-torque	1.871.000.200

	Name	Country
1c	Support for counter-torque	1.860.831.000

1. Place the crankshaft pulley (1a) back in its seating and secure it tightening the bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CRANKSHAFT PULLEY	M8	(Flange side) 2.3 ÷ 2.8

Adjust the moving tensioner and fit the engine components single drive belt using a spanner.Remove the pin from the hole on the gearbox.Remove the timing tools from the camshafts and tighten the plugs.

	Name	Country
-	Gauge	1.870.896.900

Connect the brake servo vacuum intake pipe, vacuum unit side and tighten the band.Place the new injector seals in their housings in the single camshaft housing.1. Place the injectors (1a), complete with brackets (1b), in their seats.

Before refitting, replace the copper seal on the injectors.

2. Refit in their seatings the tapered washer (2a) and washer (2b).3. atighten the nut fixing the injector mounting bracket to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3	Nut	INJECTORS(DIESEL)	M8	(Cylinder head side) 1.8 ÷ 2.2

1. Plact 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) 0.6 ÷ 0.8

2. Place the mounting brackets (2a), complete with single fuel manifold pipe (2b), in their housings and fasten them using the bolts (2c).3. Fit the new pipes from the fuel manifold to the injectors and secure them using the connectors without tightening them. 4. 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)
4	Connector	FUEL MANIFOLD LINE TO INJECTORS	M12	(Injector side) 2.3 ÷ 2.5

5. 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)
5	Connector	FUEL MANIFOLD LINE TO INJECTORS	M14	(Fuel manifold side) 2.7 ÷ 2.9

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

6. 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. 7. 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)
7	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M12	(Pressure pump side) 2.3 ÷ 2.5

8. 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)
8	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14	(Fuel manifold side) 2.7 ÷ 2.9

9. Connect the fuel return pipe from the pressure pump, pressure pump side, and tighten the band.10. Connect the fuel outlet pipe from the injectors (10a), injector side pushing it until the clips (10b) can be heard clicking.

Place the duct complete with coolant return pipe to the engine cooling system reservoir back in its housing and fix it using the bolts.Connect the rapid connector for the intermediate coupling for the tank fuel return pipe.Connect the rapid attachment for the fuel return pipe to the tank, fuel single fuel manifold pipe side and fasten it.Connect the rapid connector for the fuel supply pipe from the filter to the pressure pump, pressure pump side and fasten it. Connect the quick-release fitting on the coolant return pipe to the engine coolant reservoir, thermostat side. Proceed with refitting - 1060G90 diesel injection wiring harness - r r . Proceed with refitting - 5530B52 Battery DRIP TRAY/SUPPORT - R.R. . Proceed with refitting - 5530B10 battery - r+r . Proceed with refitting - 7055B91 Right front WHEEL ARCH LINER - R.R. . Proceed with refitting - 7055B66 Engine compartment DUST SHIELD protection in right front wheel arch - R.R. . Proceed with refitting . Proceed with refitting - 4450B04 right front wheel r r . Fill the air conditioner coolant circuit - 0010T84 coolant for air conditioning system dehydrate and recharge . Remove the car from the ramps.