1016C10 CYLINDER HEAD - R + R AND REPLACE GASKET - Fiat - IDEA - eLearn

2400067 - 1016C10 cylinder head - r + r and replace 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 r Proceed with removal - 1016B10 single cylinder head extension - change gasket1. Loosen the band and disconnect the upper coolant inlet hose to the radiator, thermostat side.

Recover the coolant which comes out in a suitable container.

2. Loosen the band and disconnect the oil vapour recirculation pipe from the rigid pipe.3. Loosen the bands and remove the air intake pipe to the turbocharger.4. Loosen the band fastening the coolant supply pipe to the engine oil heat exchanger, thermostat side.5. Loosen the band and disconnect the coolant outlet pipe from the climate control heater, water pump rigid inlet pipe side.

1. Loosen the band and disconnect the pipe from the heat exchanger to the air chamber, chamber side.2. Loosen the band and disconnect the coolant supply pipe to the climate control heater, E.G.R. system exhaust gas/water heat exchanger side.

1. Undo the bolt (1a) and remove the complete engine oil dipstick tube (1b).

1. Undo the nuts (1a) and remove the exhaust manifold heat shield (1b) complete with engine lifting bracket (1c).2. Undo the bolt fixing the coolant supply pipe to the engine oil heat exchanger, to the cylinder block/crankcase.3. Undo the bolts (3a) for the coolant supply pipe to the engine oil heat exchanger (3b) complete with gasket (3c).4. Undo the connectors (4a) and remove the turbocharer engine oil supply pipe (4b).

1. Loosen the band and disconnect the condensed engine oil recovery pipe, oil vapour separator side.

1. Undo the bolts fixing the water/exhaust gas heat exchanger for the E.G.R. system.

1. Working via the opening in the tappet cover, undo the bolt fixing the timing chain fixed plate to the cylinder head.2. Undo the bolts fixing the timing cover to the cylinder head.

1. Undo the nuts fixing the turbocharger to the exhaust manifold.

1. Undo the bolts (1a) and disconnect the air supply pipe between the turbocharger and the heat exchanger (1b), turbocharger side.2. Remove the gasket.3. Undo the bolts securing the engine oil return pipe from the turbocharger, engine crankcase side.

1. Tighten the nuts fastening the rigid section of the exhaust pipe between the catalytic converter and the silencer, silencer side.Release the rigid pipe for the exhaust pipe between the catalytic converter and silencer from the silencer.2. Loosen the collar (2a) and remove the rigid pipe for the exhaust pipe between the catalytic converter and the silencer (2b).

1. Undo the bolts fixing the catalytic converter mounting bracket to the manual gearbox/engine connecting bracket.2. Rremove the turbocharger (2a) complete with catalytic converter (2b).

1. Undo the bolts (1a) and remove the complete cylinder head (1b).2. Remove the cylinder head gasket.

Refitting ( Removing

) 1. Measure the projection of the pistons at two points at 180° on the gudgeon pin axis using a dial gauge and take the average of the two figures measured for each piston.

	Name	Country
1	Dial gauge mounting	1.870.404.001

Select the correct size cylinder head gasket, according to the maximum value of the averages of the projection for each individual piston.

	Measurement		Value
-	Gasket size (no opening) (mm)		0.67 ÷ 0.77
	Maximum average piston projection (mm)	0.028 ÷ 0.127

	Measurement		Value
-	Gasket size (no opening) (mm)		0.77 ÷ 0.87
	Maximum average piston projection (mm)	0.128 ÷ 0.227

	Measurement		Value
-	Gasket size (no opening) (mm)		0.87 ÷ 0.97
	Maximum average piston projection (mm)	0.228 ÷ 0.327

1. Apply fiat silicon sealant 71713687 or a similar product to the contact area between the cylinder block/crankcase and the timing cover. 2. Position the cylinder head gasket (2a) of the size selected previously on the cylinder block fitting it on the centering bushes (2b).3. Apply Fiat silicon sealant 71713687 or a similar product to the cylinder head gasket in the contact area with the timing cover. 4. Also apply the same sealant to the surface in contact with the timing cover cylinder head 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.

Place the cylinder head on the cylinder block/crankcase fitting it on the centering bushes.

Before moving the cylinderhead, apply grease to the chain tensioner pison to prevent it coming out accidentally whilst moving.

1. Screw in the bolts shown fixing the timing cover to the cylinder head and tighten to the recommended torque.

Do not tighten the bolt in the opening (a) during this stage.

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

Place the cylinder head fixing bolts in the housings and screw them in partly without tightening them. 1. Tighten just the two bolts shown in the diagram fastening the cylinder head to the cylinder block/crankcase to the recommended torque of 2.5 daNm.2. Loosen the bolts fixing the timing cover tightened previously.3. Continue tightening the cylinder head fixing bolts to a torque of 2.5 daNm following the order illustrated in the diagram working gradually towards the timing cover.

1. Tighten the cylinder head bolts (1a) to the recommended torque using the angular tightening tool (1b).

Follow the order shown in the diagram for each tightening sequence. The nominal tightening of 4.0 daNm is carried out in two distinct stages: a tightening to 2.0 daNm followed by a further tightening of 2.0 daNm.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	CYLINDER HEAD	M10	(Engine crankcase side) 3.8 ÷ 4.2 + 90? + 90 ?

	Name	Country
1b	Protractor	1.860.942.000

1. Fit the third bolt fixing the timing cover to the cylinder head, then tighten the three bolts fixing the timing cover to the cylinder head to the recommended torque.

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

The non alignment between the cylinder head and engine block should not exceed the recommended value.

The cylinder block/crankcase only is allowed to project.

	Measurement		Value
-	Cylinder head-cylinder block/crankcase non alignment (mm)		0.1

Place the turbocharger complete with catalytic converter in position.Tighten the bolts fixing the catalytic converter mounting bracket to the manual gearbox/engine connecting bracket.Refit the rigid exhaust pipe section between the catalytic converter and the silencer and secure it using the collar.Tighten the nuts fastening the rigid section of the exhaust pipe between the catalytic converter and the silencer, silencer side.Place a new gasket between the engine block and the turbocharger engine oil return pipe.1. Tighten the bolt fixing the enigne oil return pipe from the turbocharger, engine crankcase side, to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	OIL RETURN PIPE FROM TURBO	M6	(Turbocharger/engine crankcase side) 0.8 ÷ 1.0

2. Connect the air supply pipe between the turbocharger and the heat exchanger (2a), complete with gasket (2b), turbocharger side and secure it using the bolts (2c).

1. Tighten the nuts fixing the turbocharger to the exhaust manifold to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Nut	TURBOCHARGER	M8	(Exhaust manifold side) 2.3 ÷ 2.8

Tighten the bolt fixing the timing chain fixed plate to the cylinder head.Tighten the bolt fixing the water/exhaust gas heat exchanger for the E.G.R. system to the cylinder block/crankcase.Connect the condensed engine oil recovery pipe, oil vapour separator side and tighten the band.Connect the engine oil supply pipe to the turbocharger and secure by tightening the connectors to the recommended torque.

Replace the copper washers for the connectors.

	Fastening	Component	Ø	Value(daNm)
-	Connector	OIL DELIVERY PIPE TO TURBO	M10	(Turbocharger side/oil filter mounting) 1.1 ÷ 1.3

Fit the hose carrying coolant to the engine oil heat exchanger complete with gasket and secure using the band and bolts.Tighten the bolt fixing the coolant supply pipe to the engine oil heat exchanger to the cylinder block/crankcase.Place the exhaust manifold heat shield, complete with engine lifting bracket, back in its housing and fix it using the nuts.Place the engine oil dipstick tube in its seating and fix it using the bolt.Connect the coolant supply pipe to the climate control system heater, E.G.R. system exhaust gas/water heat exchanger side and tighten the band. Connect the pipe from the heat exchanger to the air chamber, chamber side and tighten the band. Connect the coolant return hose from the climate control heater on the side of the rigid inlet pipe to the water pump and tighten the pump.Place in its seating the air inlet pipe to the turbocharger and tighten the band.Connect the oil vapour recirculation pipe to the rigid pipe and tighten the band.Connect the upper coolant inlet hose to the radiator, thermostat side, and tighten the band. Proceed with refitting - 1016B10 single cylinder head extension - change gasket . 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 . Refill the engine cooling system with coolant - 0010T20 coolant change . 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.