3314221 - 1016D25 rh 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
.
- 4450B12 front or rear wheels (two) - r+r
.
- 7055B39 front additional wheel arch half (one), lh or rh,
front element - r r
(right and left)
- 7055B54 under-engine guard - r r
.
Drain the engine coolant. | Collect the coolant in a suitable
container. |
- 1076B70 exhaust pipe between pre-catalytic converter and
catalytic converter - r r
.
- 1064A48 sleeve connecting rh exhaust manifold and turbocharger
flange - r r and replace gaskets
.
Position a hydraulic jack under the gearbox.1. Undo the bolts for the gearbox side rigid power unit support.2. Undo the bolts fixing the gearbox side flexible mounting to the
front suspension frame.3. Remove the gearbox side rigid power unit support (3a), complete
with flexible mounting (3b).
Position a hydraulic jack under the oil
sump.1. Undo the nut securing the power unit rigid rear support to the
flexible mounting.
Raise the power unit using the hydraulic
jack and place a suitable shim between the power unit rigid rear support
and the flexible mounting. | The stud for the flexible mounting
should not come out of the rigid support. |
Lower the hydraulic jack slowly until the
bell housing is resting on the front suspension frame.Remove the hydraulic jack. - 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.
1. Undo the bolt (1a) and move the cam angle sensor (1b) away from
the bracket on the engine for the reaction rod.2. Disconnect the electrical connection for the detonation sensor.
| Name | Connector |
|---|
| 2 | Detonation sensor | K50 |
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.2. Disconnect the condensation oil return pipe from the separator.3. Remove the oil vapour separator, complete with pipes.
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.3. Undo the bolts (3a) and move the connector (3b) away from the
right cylinder head.
1. Undo the bolts (1a) and remove the right cylinder head tappet
cover (1b), complete with gasket (1c).
1. Disconnect the electrical connection from the air pressure sensor.
| Name | Connector |
|---|
| 1 | Data not available yet | - |
2. Release the electrical wiring from the engine compartment bulkhead
and move it.3. Undo the bolts (3a) and the nuts (3b) and remove the exhaus manifold
(3c) away from the right cylinder head.Remove the gaskets.
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 and
move them to the side.
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).
1. Undo the upper bolt fixing the alternator mounting bracket to
the right cylinder head.
Remove the timing drive belt from the driven
pullies.1. Undo the bolts (1a) and remove the right head drive pulley (1b).2. Undo the bolts (2a) and remove the right rear protective timing
cover (2b).3. 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 right cylinder head (1b). | Two operators are needed for this
operation. |
2. Remove the right cylinder head gasket.
Refitting
(
Removing
)
Fit a new right 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 right cylinder head back in its
housing. | Two operators are needed for this
operation. |
1. Tighten the nuts for the right cylinder head (1a) to the recommended
torque using the angular tightnening 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 |
1. Tighten the bolt fixing the left rear protective cover to the
bracket on the engine for the reaction rod.2. Fit the right rear protective timing cover (2a) and fix it using
the bolts (2b).3. Fit the right driven pulley (3a) and fix it tightening the bolts
(3b) to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 3b | Bolt | TIMING GEAR DRIVEN PULLEYS | - | Hub side - |
Tighten the upper bolt fixing the alternator
mounting bracket to the right cylinder head.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 |
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.Place the exhaust manifold for the right
cylinder head, complete with gaskets, back in its housing and fix
it tightening the bolts and the nuts to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Nut | EXHAUST MANIFOLD/S | M8 | Cylinder head side 2.2 - 2.7 |
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Nut | EXHAUST MANIFOLD/S | M8 | Cylinder head side 2.2 - 2.7 |
Fix the electrical wiring to the engine
compartment bulkhead.Connect the electrical connection to the
air pressure sensor.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 coolant connector on the right
cylinder head back in its housing and fix it using the bolts.Place the thermostat support back in its
housing, connect it to the cylinder heads and fix it using the bolts.Place the oil vapour separator, complete
with pipes, back in its housing.Connect the condensation oil return pipe
to the separator.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.Connect the electrical connection for the
detonation sensor.Place the cam angle sensor back in its
housing and fix it using the bolt to the bracket on the engine for
the reaction rod.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
.
Position a hydraulic jack under the oil
sump and raise it until the shim positioned previously between the rigid
rear power unit support and the flexible mounting comes out. | The stud for the flexible mounting
should not come out of the rigid support. |
1. Place the gearbox side rigid power unit support (1a), complete
with flexible mounting (1b), back in its housing.2. Tighten the bolts for the gearbox side support flexible mounting
to the front suspension frame to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2 | Bolt | GEARBOX SIDE RUBBER MOUNT | M8 | (Front suspension frame side) 2.4 - 2.9 |
3. Tighten the bolts for the gearbox side rigid power unit support
to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 3 | Bolt | POWER UNIT GEAR BOX END RIGID MOUNT | M9 | (Gearbox side) 3.0 - 3.6 |
Remove the hydraulic jack. - 1064A48 sleeve connecting rh exhaust manifold and turbocharger
flange - r r and replace gaskets
.
- 1076B70 exhaust pipe between pre-catalytic converter and
catalytic converter - r r
.
- 7055B54 under-engine guard - r r
.
- 7055B39 front additional wheel arch half (one), lh or rh,
front element - r r
(right and left)
- 4450B12 front or rear wheels (two) - r+r
.
- 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 steering 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.
