3314220 - 1016D21 lh cylinder head - r r and replace gasket for versions with air conditioner (Automatic transmission)

Removing ( Refitting ) Position the vehicle on the ramp. Make sure that the ignition is OFF (STOP position), then disconnect the negative battery terminal (refer to op.   5530B10  battery - r+r ).

	Name	Connector
-	Battery	A1B

 - 7040D12  engine front side cover (one) lh or rh - r r (right and left)  - 7040D30  engine bay front beam cover - r r .  - 7040D14  engine bay rear side cover (one) lh or rh - r r (right and left)  - 1008C10  power unit upper reaction link r r .  - 1008C16  body link bracket - r r .  - 4450B10  Front WHEEL (one) - R.R. (left).  - 7055B39  front additional wheel arch half (one), lh or rh, front element - r r (right)  - 7055B54  under-engine guard - r r . Drain the engine coolant.

Collect the coolant in a suitable container.

1. Undo the nuts (1a) and remove the connecting hose between the left drain manifold and the turbocharger flange (1b).  - 1092G10  single engine belt r r . 1. Release the power assisted steering pipe from the band. Remove the power steering fluid reservoir cap and drain the fluid using a suitable syringe.1. Undo the connector (1a) and disconnect the fuel supply pipe (1b) from the power assisted steering pump. 1. Undo the bolt fixing the power assisted steering fluid reservoir to the protective timing cover.2. Raise the power assisted steering fluid reservoir, as necessary, and disconnect the return pipe from the heat exchanger to the reservoir, reservoir side.3. Remove the power assisted steering fluid reservoir, complete with pipe. 1. Undo the bolts (1a) and remove the upper protective timing cover (1b). 1. Undo the bolt (1a) and remove the single drive belt tensioner (1b). 1. Undo the bolt (1a) and remove the fixed single drive belt tensioner (1b). 1. Undo the bolts (1a) and remove the lower protective timing covers (1b). 1. Disconnect the electrical connections from the injectors and release the electrical wiring.

	Name	Connector
1	Injector	N70

 - 1072B42  left hand or right hand inlet manifold (one) - r+r . 1. Disconnect the vacuum intake pipe for the fuel pressure regulator from the air chamber.2. Undo the bolts (2a) and remove the fuel manifold (2b), complete with injectors and fuel pressure regulator. Release the oil vapour recirculation pipe from the band on the air chamber.1. Disconnect the right cylinder head spark plug leads and remove them after having released them from the fixings. 1. Disconnect the coolant inlet hose from the ignition coil mounting.2. Undo the bolts (2a) and remove the thermostat (2b), complete with hose. 1. Disconnect the electrical connection from the engine coolant temperature sensor.

	Name	Connector
1	Engine coolant temperature sensor-sender unit	K36

2. Disconnect the electrical connection from the intake air temperature sensor.

	Name	Connector
2	Air temperature sensor	K42

1. Undo the bolts fixing the rigid pipe mounting bracket to the thermostat support. 1. Loosen the band for the air inlet hose to the butterfly casing integrated with the D.V.L. 1. Loosen the band for the air outlet hose from the supercharging air/air heat exchanger.2. Loosen the bands for the hose from the flow meter to the turbocharger air inlet pipe. Release the electrical cables from the fixings on the thermostat support.1. Disconnect the fuel/oil vapour recirculation pipe from the hose between the flow meter and the turbocharger air inlet pipe. 1. Diconnect the vacuum intake pipe for the supercharging air by-pass valve from the air chamber. 1. Remove the air system hose assembly as illustrated in the diagram. 1. Disconnect the electrical connection from the throttle casing integrated with the D.V.L.

	Name	Connector
1	Integrated throttle body actuator	N75

1. Disconnect the vacuum socket pipe from the air chamber.2. Disconnect the fuel/oil vapour recirculation pipe from the air chamber.3. Undo the bolts fixing the oil vapour separator to the mounting bracket. 1. Undo the bolts (1a) and remove the air chamber (1b). 1. Disconnect the oil vapour recovery pipe from the right cylinder head tappet cover. 1. Diconnect the connecting hose to the thermostat support from the cylinder head.2. Undo the bolts (2a) and move the thermostat support (2b) away from the cylinder head. 1. Undo the bolts (1a) and remove the right cylinder head tappet cover (1b), complete with gasket (1c).  - 1088E11  fans with single engine duct - r+r . 1. Undo the nuts (1a) and the bolts (1b), then remove the heat shield (1c) from the left cylinder head exhaust manifold. 1. Undo the bolts fixing the power assisted steering pump front and rear mounting brackets.2. Move the power assisted steering pump to the side. 1. Undo the bolts (1a) and the nuts (1b), then remove the left cylinder head exhaust manifold (1c).2. Remove the gaskets.3. Undo the connector and remove the complete engine oil dipstick. 1. Undo the connector and disconnect the turbocharger oil supply pipe from the left cylinder head.2. Disconnect the upper radiator coolant inlet hose from the ignition coil mounting.3. Disconnect the electrical connection from the ignition coil.

	Name	Connector
3	Ignition coil	A30

1. Remove the engine oil filler cap.2. Undo the bolts (2a) and remove the spark plugs cover (2b). 1. Disconnect the high tension leads (1a) from the left cylinder head spark plugs using the tool (1b).

	Name	Country
1b	Pliers	1.820.636.000

2. Release the high tension leads from the left tappet cover.3. Disconnect the high tension leads from the ignition coil and remove them. 1. Undo the bolts (1a) and remove the ignition coil (1b). 1. Undo the bolts (1a) and remove the tappet cover for the left cylinder head (1b), complete with gasket (1c). 1. Rotate the crankshaft so that the references on the camshafts are aligned with the ones of the caps (cylinder no. 1 at T.D.C.). 1. Undo the bolts (1a) and remove the moving timing belt tensioner (1b). Remove the timing drive belt from the driven pullies.1. Undo the bolt fixing the left rear protective cover to the bracket on the engine for the reaction rod. 1. Undo the nuts (1a) and remove the left cylinder head (1b).

Two operators are needed for this operation.

2. Remove the left cylinder head gasket. Refitting ( Removing ) Fit a new left cylinder head gasket.

ASTADUR type cylinder head gaskets are fitted. The material from which these gaskets are made undergoes a polymerization process during the operation of the engine so that they become considerably harder during usage. In order for the polymerization of the gasket to take place it is necessary to: keep the gasket in its sealed container until fitting not lubricate or get oil on the gasket and the contact surfaces.

Place the left cylinder head back in its housing.

Two operators are needed for this operation.

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

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

	Fastening	Component	Ø	Value(daNm)
1a	Nut	CYLINDER HEAD	M12	Engine crankcase side 2.4 ÷ 2.6 ÷ 240?

	Name	Country
1b	Protractor	1.860.942.000

Tighten the bolt fixing the left rear protective cover to the bracket on the engine for the reaction rod.Fit the timing moving tensioner and fix it using the bolts without tightening them. Fit the timing belt and carry out the timing (refer to op.   1032B14  toothed timing belt - r + r for timing adjustment or replacement versions with air conditioner ). 1. Fit the left cylinder head tappet cover (1a), complete with gasket (1b), and fix it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	CAM COVERS	M7	Cylinder head side 1.0 - 1.3

Fit the ignition coil and fix it using the bolts.Connect the high tension leads to the ignition coil.Connect the high tension leads to the left cylinder head spark plugs and fix them to the fixings on the left cylinder head tappet cover.Fit the spark plugs cover on the left cylinder head and fix it using the bolts.Fit the engine oil filler cap.Connect the electrical connection to the ignition coil.Connect the upper radiator coolant inlet hose to the ignition coil mounting.Connect the turbocharger oil supply pipe to the left cylinder head and fix it tightening the connector to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Connector	OIL DELIVERY PIPE TO TURBO	M14	Left cylinder head side 2.6 - 3.2

1. Place the complete engine oil dipstick back in its housing and fix it using the connector.2. Fit the exhaust manifold for the left cylinder head (2a), complete with gaskets (2b), and fix them tightening the bolts (2c) and the nuts (2d) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2c	Nut	EXHAUST MANIFOLD/S	M8	Cylinder head side 2.2 - 2.7

	Fastening	Component	Ø	Value(daNm)
2d	Nut	EXHAUST MANIFOLD/S	M8	Cylinder head side 2.2 - 2.7

1. Place the power assisted steering pump (1a) back in its housing and fix the mounting brackets tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER STEERING PUMP SUPPORT/BRACKET	M8	Cylinder head side 1.9 - 2.3

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER STEERING PUMP SUPPORT/BRACKET	M8	Engine support side 1.9 - 2.3

Fit the heat shield for the left cylinder head exhaust manifold and fix it using the nuts and the bolt. - 1088E11  fans with single engine duct - r+r . 1. Fit the tappet cover for the right cylinder head (1a), complete with gasket (1b), and fix it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	CAM COVERS	M7	Cylinder head side 1.0 - 1.3

Place the thermostat support back in its housing, connect it to the cylinder heads and fix it using the bolts.Connect the oil vapour recovery pipe to the right cylinder head tappet cover.Fit the air chamber and fix it using the bolts.Fix the bolts fixing the oil vapour separator to the mounting bracket.Connect the fuel/oil vapour recirculation pipe to the air chamber.Connect the vacuum intake pipe to the air chamber.Connect the electrical connection to the throttle body integrated with the D.V.L.Place the air system hose assembly back in its housing.Connect the vacuum intake pipe for the supercharging air by-pass valve to the air chamber.Connect the fuel/oil vapour recirculation pipe to the hose between the flow meter and the turbocharger air inlet pipe.Fix the electrical wiring to the fixings on the thermostat support.Tighten the bands for the hose from the flow meter to the turbocharger air inlet pipe.Tighten the band for the air outlet hose from the supercharging air/air heat exchanger.Tighten the band for the air inlet hose to the butterfly casing integrated with the D.V.L.Tighten the bolts fixing the rigid pipe mounting bracket to the thermostat support.Connect the electrical connection to the intake air temperature sensor.Connect the electrical connection to the engine coolant temperature sensor.1. Fit the thermostat (1a), complete with hose (1b), and fix it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	THERMOSTAT	M6	Thermostat support side 0.7 - 0.9

Place the spark plug leads for the right cylinder head back in their housings, then connect them to the spark plugs and the ignition coil.Fix the oil vapour recirculation pipe to the band on the air chamber.Place the fuel manifold, complete with injectors and fuel pressure regulator, back in its housing, then fix it using the bolts.Connect the vacuum intake pipe for the fuel pressure regulator to the air chamber. - 1072B42  left hand or right hand inlet manifold (one) - r+r . Connect the electrical connections to the injectors.Fit the lower protective timing covers and fix them using the bolts.1. Fit the single belt fixed tensioner (1a) and fix it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FIXED SINGLE SERVICE BELT TENSIONER	M8	(Engine crankcase side) 1.6 - 2.0

1. Fit the single drive belt moving tensioner (1a) and fix it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	SINGLE SERVICES MOBILE BELT TENSIONER	M8	Engine crankcase side 2.1 - 2.6

Fit the upper protective timing cover and fix it using the bolts.Place the power assisted steering fluid reservoir, complete with connecting pipe to the power assisted steering pump, back in its housing.Connect the return pipe from heat exchanger to reservoir, reservoir side.Tighten the bolt fixing the power assisted steering fluid reservoir to the protective timing cover.1. Connect the supply pipe (1a) to the power assisted steering pump and fix it tightening the connector (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Connector	POWER STEERING PUMP SUPPLY PIPE	M18	Power assisted steering pump side 3.2 - 3.6

Fix the power assisted steering pipe to the band under the power assisted steering fluid reservoir. - 1092G10  single engine belt r r . Place the connecting hose between the left exhaust manifold and the turbocharger flange back in its housing and fix it tightening the nuts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	'UNO' MANIFOLD SLEEVE TO TURBO	-	Exhaust manifold side -

	Fastening	Component	Ø	Value(daNm)
-	-	'UNO' MANIFOLD SLEEVE TO TURBO	-	Turbocharger flange side -

 - 7055B54  under-engine guard - r r .  - 7055B39  front additional wheel arch half (one), lh or rh, front element - r r (right)  - 4450B10  Front WHEEL (one) - R.R. (left).  - 1008C16  body link bracket - r r .  - 1008C10  power unit upper reaction link r r .  - 7040D14  engine bay rear side cover (one) lh or rh - r r (right and left)  - 7040D30  engine bay front beam cover - r r .  - 7040D12  engine front side cover (one) lh or rh - r r (right and left) Supply the engine cooling system with the recommended fluid.

	Type	Component	Name	Qty.
-	Fluid [l]	ENGINE COOLING CIRCUIT	Alfa Romeo Climafluid Super Permanent -40°C	10.5

Connect the battery terminal (-).Fill the power steering circuit with the recommended fluid.

	Type	Component	Name	Qty.
-	Fluid [l]	POWER ASSISTED STEERING CIRCUIT	TUTELA GI/A	1.4

Bleed the power steerign system as described below.With the front wheels raised off the ground, with the engine switched off, carry out 4-5 complete steering wheel rotation cycles (left and right).Check and, if necessary, top up the fluid level in the reservoir.Remove the car from the ramp.Start the engine and carry out 4 - 5 full steering wheel turn cycles (right and left).Top up the fluid level in the reservoir.