3314411 - 1016B10 single cylinder head extension - change gasket
Removing
(
Refitting
)
Position the vehicle on the ramp.Ensure that the ignition key is in OFF
position, then disconnect the battery negative terminal (-). 
| Name | Connector |
|---|
| - | Battery | A1B |
Proceed with the removal
- 7040D12 engine front side cover
(one) lh or rh - r r
(Right and left
sides).
Proceed with removal
- 7040D30 engine bay front beam
cover - r r
.
Proceed with the removal
- 7040D14 engine bay rear side
cover (one) lh or rh - r r
(Right and
left sides).
Proceed with removal
- 1016A10 sound-proofing cover
- r + r
.
Proceed with removal
- 4450B04 right front wheel r
r
.
Proceed with removal
- 7055B54 under-engine guard -
r r
.
Proceed with the removal
- 7055B39 front additional wheel
arch half (one), lh or rh, front element - r r
(Right
side).
Proceed with removal
- 1092G10 single engine belt r r
.
Proceed with removal
- 1092A10 Crankshaft services PULLEY
- R.R.
.
Proceed with removal
- 1092G21 engine component single
belt fixed tensioner - r rwith belt removed
.
Proceed with removal
- 1008C10 power unit upper reaction
link r r
.
Proceed with removal
- 1032D12 timing system protective
cover(s) - r + r
.
Proceed with removal
- 1032B10 toothed timing belt -
r + r for timing adjustment or replacement
.
1. Disconnect the electrical connection from the cam angle sensor.
| Name | Connector |
|---|
| 1 | Cam angle sensor | K47 |
2. Undo the bolt (2a) and remove the cam angle sensor (2b).
1. Undo the connectors (1a) and (1b) and remove the pipes from the
fuel manifold to the injectors (1c). | Use new pipes from from fuel manifold
to injectors upon reassembly. |
1. Disconnect the electrical connections from the injectors.
| Name | Connector |
|---|
| 1 | Injector | N70 |
2. Undo the bolts (2a) and move the electrical wiring (2b) aside.3. Manually push the springs (3a) and disconnect the pipe from the
injectors to the fuel recovery manifold (3b), injectors side and
move aside.
1. Undo the nuts fixing the injector brackets.2. Remove the injectors (2a) complete with brackets using the tools
(2b) and (2c).  | If the same injectors are being
reused, mark the cylinder to which they belong so that they can
be correctly refitted. |
If new fuel injectors are fitted:
- determine the identification code stamped on the top;
- check that the new injectors(s) is (are) recognized by the
engine management control unit using the Examiner.
| Start removal beginning with the
fuel injector of cylinder no. 1 and continuing with the injectors for
cylinders 2, 3, 4 and 5. |
| Name | Country |
|---|
| 2b | Extractor | 1.870.739.000 |
| Name | Country |
|---|
| 2c | Extractor | 1.870.897.300 |
1. Undo the bolts securing the fuel return manifold pipe.
1. Undo the connectors (1a), (1b) and remove the pipe from the pressure
pump to the fuel manifold (1c). | When refitting, fit a new pipe
from the pressure pump to the fuel manifold. |
1. Disconnect the electrical connection from the fuel pressure sensor.
| Name | Connector |
|---|
| 1 | Fuel pressure sensor | K83 |
2. Undo the bolts (2a) and remove the single fuel manifold pipe
(2b) complete with fuel pressure sensor (2c).
1. Loosen the band and disconnect the vacuum pipe from the vacuum
pump.2. Disconnect the engine oil vapour recovery pipe, engine oil filler
fitting side.
Loosen the band and disconnect the air
supply duct from heat exchanger to inlet manifold, manifold side.1. Disconnect the electrical connections from the heater plugs.
| Name | Connector |
|---|
| 1 | Heater plugs | A40 |
2. Disconnect the hose from the rigid vacuum pipe leading to the
turbocharger vane actuator solenoid. 3. Undo the bolts (3a) and remove the rigid vacuum pipe leading
to the turbocharger vane actuator solenoid (3b).
1. Undo the bolts (1a) and remove the single cylinder head extension
(1b).Remove the cylinder head extension gasket.
Refitting
(
Removing
)
1. Remove the plugs (1a) and fit the camshaft timing tools (1b)
in the upper cylinder head. | Check that the tools are correctly
inserted in the housings in the camshafts. |
| Name | Country |
|---|
| 1b | Gauge | 1.870.896.900 |
Remove the inlet side camshaft timing tool
and tighten the plug.
Fit a new cylinder head extension gasket.1. Place the complete upper cylinder head (1a) back in its housing
and secure it tightening the bolts (1b) to the recommended torque. 
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1b | - | - | - | - |
Proceed with refitting
- 1032B10 toothed timing belt -
r + r for timing adjustment or replacement
.
Fit the rigid pipe leading to the turbocharger
vane actuator solenoid back in its housing and secure with the nuts.
Connect the hose to the rigid vacuum pipe
leading to the turbocharger vane actuator solenoid. Connect the electrical connections to the
heater plugs.Conect the air supply hose from the heat
exchanger to the inlet manifold, inlet manifold side, and tighten
the band.Connect the oil vapour recovery pipe, oil
filler fitting side.Connect the vacuum intake pipe to the vacuum
unit and tighten the band.1. Place the single fuel manifold pipe (1a), complete with fuel
pressure sensor (1b), back in its housing and secure it tightening
the bolts (1c) to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1c | Connector | OIL DELIVERY PIPE TO TURBO | M10 | (Turbocharger side/engine oil heat exchanger)
1.1 ÷ 1.3 |
2. Connect the electrical connection to the fuel pressure sensor.
1. 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. 2. 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) |
|---|
| 2 | Connector | PRESSURE PUMP LINE TO FUEL MANIFOLD | M14 | (Pressure pump side) 2.3 |
3. 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) |
|---|
| 3 | Connector | PRESSURE PUMP LINE TO FUEL MANIFOLD | M14 | (Fuel manifold side) 2.3 |
Tighten the bolts securing the fuel return
manifold pipe.1. Refit the injectors (1a) complete with brackets and secure by
tightening the nuts (1b) to the specified torque. | Start the refitting beginning
with the injector for cylinder no. 5 and continuing with the injectors for
cylinders 4, 3, 2 and 1. |
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1b | Nut | INJECTORS(DIESEL) | M8 | (Camshaft housing side) 3.0 |
Place the pipe from the injectors to the
fuel recovery manifold back in its housing and connect it to the injectors
pushing it until the clips can be heard clicking into place.Place the electrical wiring back in its
seating and fix it using the bolts.Connect the electrical connections to the
injectors.1. Fit the new pipes from the fuel manifold to the injectors and
secure them using the connectors without tightening them. 2. 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) |
|---|
| 2 | Connector | FUEL MANIFOLD LINE TO INJECTORS | M12 | |
3. 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) |
|---|
| 3 | Connector | FUEL MANIFOLD LINE TO INJECTORS | M12 | |
| Clean the threaded seats for the
above-mentioned pipe on the manifold and the injectors using heptane. |
Place the cam angle sensor back in its
housing and fix it using the bolt.Connect the electrical connection to the
cam angle sensor
Proceed with refitting
- 1032D12 timing system protective
cover(s) - r + r
.
Proceed with refitting
- 1008C10 power unit upper reaction
link r r
.
Proceed with refitting
- 1092G21 engine component single
belt fixed tensioner - r rwith belt removed
.
Proceed with refitting
- 1092A10 Crankshaft services PULLEY
- R.R.
.
Proceed with refitting
- 1092G10 single engine belt r r
.
Proceed with the refitting
- 7055B39 front additional wheel
arch half (one), lh or rh, front element - r r
(Right
side).
Proceed with refitting
- 7055B54 under-engine guard -
r r
.
Proceed with refitting
- 4450B04 right front wheel r
r
.
Proceed with refitting
- 1016A10 sound-proofing cover
- r + r
.
Proceed with the refitting
- 7040D14 engine bay rear side
cover (one) lh or rh - r r
(Right and
left sides).
Proceed with refitting
- 7040D30 engine bay front beam
cover - r r
.
Proceed with the refitting
- 7040D12 engine front side cover
(one) lh or rh - r r
(Right and left
sides).
Connect the negative (-) battery terminal.Remove the car from the ramps.
