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)  - 4450B12  front or rear wheels (two) - r+r .  - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R. (right and left)  - 7055B54  under-engine guard - r r . Drain the engine coolant.

Collect the coolant in a suitable container.

 - 1008C10  power unit upper reaction link r r .  - 1008C16  body link bracket - r r . 1. Remove the power steering fluid reservoir cap and drain the fluid using a suitable syringe.2. Undo the bolt fixing the power assisted steering fluid reservoir. 1. Release the fluid supply pipe to the power steering box from the band on the power steering fluid reservoir mounting bracket.2. Lift the power steering fluid reservoir as necessary and remove the drip tray. 1. Undo the connectors (1a) and disconnect the supply and return pipes (1b) from the power steering pump. 1. Undo the bolts (1a) and remove the upper protective timing cover (1b). 1. Undo the bolts (1a) and remove the power steering fluid reservoir mounting bracket (1b). 1. Disconnect the power steering fluid reservoir return pipe.2. Remove the power steering fluid reservoir complete with supply pipe to the pump.  - 1092G10  single engine belt r r .  - 1092G14  engine component single belt mobile tensioner - r + r .  - 1092G20  engine component single belt fixed tensioner - one - r + r . 1. Undo the bolts (1a) and remove the lower protective timing covers (1b). 1. Undo the bolts (1a) and remove the moving timing belt tensioner (1b).Release the timing belt from the driven pullies.  - 1076B52  exhaust pipe (one) leaving l/h or r/h exhaust manifold - r + r .  - 1072B42  left hand or right hand inlet manifold (one) - r+r .  - 1056B62  l/h and r/h fuel pipe assembly - with injectors - r + r .  - 1048A34  sleeve(s) from flow meter to air supply capacity case - r + r . 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 electrical connection for the detonation sensor.

	Name	Connector
1	Knock sensor 2	K51

2. Disconnect the vacuum intake pipe from the air chamber.3. Disconnect the oil vapour recirculation pipe from the air chamber.4. Disconnect the fuel vapour recirculation pipe from the air chamber.5. Undo the bolts (5a) and move the oil vapour separator (5b) away from the air chamber. 1. Undo the bolts (1a) and remove the air chamber (1b). 1. Disconnect the oil vapour recovery pipe from the separator.2. Disconnect the condensation oil recovery pipe from the separator.3. Remove the oil vapour separator (3a) complete with oil vapour recirculation pipe. 1. Undo the bolts (1a) and remove the brackets (1b) securing the electrical wiring for the right cylinder head ignition coils.2. Disconnect the electrical connections from the right cylinder head ignition coils.

	Name	Connector
2	Ignition coil	A30

1. Undo the remaining bolts (1a) and remove the right cylinder head ignition coils (1b).2. Undo the bolt (2a) and remove the cam angle sensor from its seating on the right cylinder head (2b). Undo the bolts and move aside the mounting bracket for the electrical connections from the thermostat.1. Disconnect the electrical connection from the engine coolant temperature sensor.

	Name	Connector
1	Engine coolant temperature sensor-sender unit	K36

1. Undo the bolts (1a) and move the thermostat mounting (1b) complete with pipes, releasing it from the connections on the cylinder heads and the rigid fluid inlet pipe to the water pump.2. Move the coolant pipes connector away from the right cylinder head. Position a hydraulic jack under the gearbox. - 1008A42  gear box left rigid mount - r r .  - 1008A43  power unit rigid mount - automatic transmission side - r r . Lower the hydraulic jack slowly until the gearbox is resting on the front suspension frame.1. Undo the bolt (1a) and remove the upper fixed timing belt tensioner (1b). 1. Undo the bolts (1a) for the right head driven pullies, using the tool for counter-torque (1b).

	Name	Country
1b	Counter-torque	1.822.146.000

1. Remove the right head driven pullies (1a) using the tool (1b).

	Name	Country
1b	Extractor	1.860.954.001

1. Undo the bolts (1a) and remove the rear right timing belt protection (1b).2. Undo the bolt securing the rear left timing belt cover to the reaction rod bracket on the engine. 1. Undo the nuts (1a) and remove the bracket on the engine for the reaction rod (1b). 1. Undo the bolts (1a) and remove the right rocker cover (1b). 1. Undo the nuts (1a) and remove the right cylinder head (1b).

Two operators are needed for this operation.

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. Fit the bracket on the engine for the reaction rod (1a) and fix it tightening the nuts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	REACTION LINK BRACKET ON ENGINE	M10	Right cylinder head side 4.3 - 5.3

Tighten the bolt securing the rear left timing belt cover to the reaction rod bracket on the engine.Fit the rear right timing belt cover and fix it using the bolts.Fit the right head driven pullies and fix them using their bolts, without tightening them.1. Fit the upper fixed timing belt tensioner (1a) and tighten its bolt (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FIXED TENSIONER	M8	Front cover side 1.7 - 2.1

Place a hydraulic jack under the gearbox and raise until it is in the correct position.  - 1008A43  power unit rigid mount - automatic transmission side - r r .  - 1008A42  gear box left rigid mount - r r . Remove the hydraulic jack from under the gearbox.Refit the coolant pipes connector in its seating on the right cylinder head.Refit in its seating the thermostat mounting complete with pipes, and tighten the bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	THERMOSTAT MOUNT	M6	Cylinder head side 0.7 - 0.9

Connect the electrical connection to the engine coolant temperature sensor.Refit, in its seating on the thermostat, the electrical connections mounting bracket and fix it using the bolts.Fit the cam angle sensor in its seating on the right cylinder head and fix it using its bolt. - 1016A42  left hand cylinder head ignition coil cover - r+r .  - 5510C16  left hand cylinder head ignition coil - r+r .  - 1016A30  left cam cover - r + r and replace gasket . Remove the spark plug for cylinder no. 1.1. Fit the tool (1a), complete with dial gauge (1b), in the housing in the spark plug for the 1st cylinder.

	Name	Country
1a	Extension	1.825.013.000

Rotate the crankshaft, using small movements (in both directions), until the piston for cylinder no. 1 is at T.D.C. at the power stroke.

Make sure that the last crankshaft rotation is in the direction of operation.

2. Remove the camshaft bearing caps B and G from the right cylinder head and fit the jigs in their place.

	Name	Country
2	Gauge	1.825.040.000

1. Remove the camshaft bearing caps 4 and 7 from the left cylinder head and fit the jigs in their place.

	Name	Country
1	Gauge	1.825.040.000

Slacken the bolts on the left cylinder head camshaft pullies, using the tool as counter-torque.

	Name	Country
-	Counter-torque	1.822.146.000

Fit the timing belt moving tensioner and fix it using the bolt without tightening it.Fit the timing belt starting from the drive pulley and continuing in anti-clockwise direction, making sure that the drive sections are firmly taut.1. Fit the tool (1a) and secure it with the alternator bolt (1b) and the bolt (1c) to the water pump.

The tool tooth (1d) should press on the moving part of the timing belt tensioner.

	Name	Country
1a	Belt tensioner	1.860.950.000

2. Act on the nut (2a) for the belt tensioner tool until the moving reference on the belt tensioner (2b) is under the fixed reference. 1. Tighten the bolts (1a) on the camshaft pullies to the specified torque using the tools (1b) and (1c).

The tightening torque figure in the table is the nominal value; therefore the correct value must be calculated according to the length of the extension spanner 1.822.150.000

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	TIMING GEAR DRIVEN PULLEYS	M10	Camshaft side 6.8 - 8.4

	Name	Country
1b	Counter-torque	1.822.146.000

	Name	Country
1c	Extension for torque wrench	1.822.150.000

Remove the timing jigs.

	Name	Country
-	Gauge	1.825.040.000

Fit the camshaft caps in place of the removed jigs and tighten the bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAMSHAFT CAPS	M8	(Cylinder head side) 1.8 ÷ 2.0

Rotate the crankshaft through two revolutions in its direction of rotation to allow the timing belt to bed in.1. Check that the moving reference on the timing belt tensioner is aligned with the fixed reference.2. If the references do not line up, slightly discharge the tensioner acting on the tensioning tool nut and make sure that the references are aligned.3. Tighten the timing belt tensioner bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
3	Bolt	MOBILE TIMING TENSIONER	M8	Cylinder head side 1.7 - 2.1

Remove the belt tensioner tool.

	Name	Country
-	Belt tensioner	1.860.950.000

 - 1016A30  left cam cover - r + r and replace gasket .  - 5510C16  left hand cylinder head ignition coil - r+r .  - 1016A42  left hand cylinder head ignition coil cover - r+r . 1. Fit the right side rocker cover and tighten the bolts to the specified torque.

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

Fit the left cylinder head ignition coils and fix them using the bolts.Connect the electrical connections to the right cylinder head ignition coils.Fit the electrical wiring securing brackets for the right cylinder head ignition coils and fix them using the bolts.Place the oil vapour separator complete with oil vapour recirculation pipe back in its housing.Connect the condensation oil recovery pipe to the separator.Connect the oil vapour recovery pipe to the separator.Fit the air chamber and fix it using the bolts.Fix the oil vapour separator to the air chamber using the bolts.Connect the fuel vapour recovery pipe to the air chamber.Connect the oil vapour recirculation pipe from the air chamber.Connect the vacuum intake pipe from the air chamber.Connect the electrical connection for the detonation sensor.Connect the electrical connection to the throttle body integrated with the D.V.L. - 1048A34  sleeve(s) from flow meter to air supply capacity case - r + r .  - 1056B62  l/h and r/h fuel pipe assembly - with injectors - r + r .  - 1072B42  left hand or right hand inlet manifold (one) - r+r .  - 1076B52  exhaust pipe (one) leaving l/h or r/h exhaust manifold - r + r . Fit the lower protective timing covers and fix them using the bolts. - 1092G20  engine component single belt fixed tensioner - one - r + r .  - 1092G14  engine component single belt mobile tensioner - r + r .  - 1092G10  single engine belt r r . Place the power steering fluid reservoir, complete with supply pipe to the pump, back in its housing.Connect the return pipe to the power steering fluid reservoir.Fit the power steering fluid reservoir mounting bracket and fix it using the bolts.Fit the upper protective timing cover and fix it using the bolts.1. Connect the pipe from pump to power steering box, pump side, and tighten its connector to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Connector	PIPE BTWN PUMP + POWER STEERING BOX	M16	(Power steering pump side) 3.8 ÷ 4.2

2. Connect the feed pipe from reservoir to power steering pump, pump side, and tighten its connector to the specified torque.

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

Place the drip tray in its seating under the power steering fluid reservoir.Fix the fluid supply pipe to the power steering box to the band on the power steering fluid reservoir mounting.Tighten the power steering fluid reservoir bolt.Supply the engine cooling system with the recommended fluid.

	Type	Component	Name	Qty.
-	Fluid [l]	ENGINE COOLING CIRCUIT	Alfa Romeo Climafluid Super Permanent -40	10.3

 - 7055B54  under-engine guard - r r .  - 7055B42  Additional FRONT WHEEL ARCH (one), left or right - R.R. (right and left)  - 4450B12  front or rear wheels (two) - 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) 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.