184000816 - 1016C10 CYLINDER HEAD - R + R AND REPLACE GASKET

Removing ( Refitting ) Position the vehicle on the ramp    Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE.Proceed with removal 1016A10 sound-proofing cover - r + r .Proceed with removal    Op. 5530B10 BATTERY - R+R.Proceed with removal    Op. 5530B52 BATTERY CRADLE - R R.Proceed with removal    Op. 7055B54 UNDER-ENGINE GUARD - R R.Proceed with removal    Op. 1008A46 CAM SHAFT LEFT RIGID MOUNT - R R.Proceed with removal    Op. 4450B04 RIGHT FRONT WHEEL R R.Proceed with removal    Op. 7055B91 RIGHT FRONT SUPPLEMENTARY WHEEL ARCH R R.Proceed with removal 1092G10 single engine belt r r .Proceed with removal    Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R.Proceed with removal    Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT.Proceed with removal 2710A35 intermediate drive shaft mount - r r .Temporarily fit the timing side rigid power unit support.Proceed with removal 1060F50 fuel return manifold - r r .Proceed with removal    Op. 1060F20 PRESSURE PUMP/MANIFOLD PIPE - R R.Proceed with removal    Op. 1048A10 AIR CLEANER FILTERING ELEMENT - REPLACE.Proceed with removal 1076B70 exhaust pipe between pre-catalytic converter and catalytic converter - r r .Proceed with removal    Op. 1048B14 AIR DELIVERY PIPE BETWEEN TURBO CHARGER AND HEAT EXCHANGER - REPLACE.Proceed with removal    Op. 1084B42 ENGINE OIL RETURN PIPE FROM TURBO - R + R.Proceed with removal 1064A19 TURBOCHARGER - EXHAUST MANIFOLD - EXHAUST PIPE CONNECTING HOSE - R.R. .Proceed with removal 1080C24 e.g.r. system solenoid - r + r .1. Disconnect the vacuum pipe from the pneumatic valve on the throttle body.2. Loosen the band and disconnect the air supply hose from the heat exchanger to the inlet manifold, electro-pneumatically controlled throttle body side.3. Loosen the band and disconnect the vacuum pipe from the vacuum pump.4. Disconnect the vacuum reservoir vacuum pipe, T-connector side. 1. Loosen the bands and disconnect the coolant supply and return pipes to the climate control system heater.2. Loosen band and disconnect the upper coolant inlet hose to the radiator, thermostat side.3. Disconnect the electrical connection from the engine coolant temperature sensor.

	Name	Connector
3	Engine temperature sender unit	K36

1. Undo the bolts (1a) and remove the electro-pneumatically controlled throttle body (1b), complete with expansion joint connected to the E.G.R. (1c).2. Loosen the band and disconnect the oil vapour recovery pipe from the tappet cover.3. Loosen the band and disconnect the coolant return pipe from the engine coolant reservoir, thermostat side. 1. Loosen the bands (1a), undo the bolts (1b) and remove the engine coolant reservoir coolant return pipe (1c). 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. 1. Disconnect the electrical connections from the heater plugs.

	Name	Connector
1	Heater plug	A40

1. Disconnect the electrical connection from the cam angle sensor.

	Name	Connector
1	Timing sensor.	K47

1. Disconnect the electrical connection from the excess pressure sensor.

	Name	Connector
1	Turbocharging sensor	K82

2. Disconnect the electrical connection from the solenoid on the vacuum tank.

	Name	Connector
2	Butterfly casing solenoid valve	L62

1. Disconnect the electrical connection from the fuel pressure sensor.

	Name	Connector
1	Fuel pressure sensor	K83

2. Disconnect the electrical connection from the fuel pressure regulator.

	Name	Connector
2	Fuel pressure regulator	N77

1. Loosen the band and disconnect the lower radiator coolant outlet hose from the radiator, water pump rigid inlet pipe end.2. Loosen the collar and disconnect the engine oil vapour recirculation pipe from the tappet cover. 1. Undo the bolts (1a) and remove the tappet cover (1b), complete with seal. 1. Undo the bolts fixing the cylinder head to the engine block.2. Remove the cylinder head assembly.Remove the cylinder head gasket. Refitting ( Removing ) Make sure that the cylinder head centering bushes are present and correctly positioned in the engine block.Place a new cylinder head gasket in the housing taking care that it is the same size as the one removed.Position the cylinder head on the crankcase.1. Tighten the cylinder head bolts (1a) to the recommended torque using the angular tightening tool (1b).

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	CYLINDER HEAD	M12	(Engine crankcase side) 6.5 + 90° + 90° + 90°

	Name	Country
1b	Protractor	1.860.942.000

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

Place the tappet cover (1b) complete with gasket back in its housing and secure it using the bolts.Connect the engine oil vapour recovery pipe to the tappet cover and tighten the band.Connect the lower radiator coolant outlet hose to the water pump rigid inlet pipe and tighten the band.Connect the electrical connection to the fuel pressure regulator.Connect the electrical connection to the fuel pressure sensor.Connect the electrical connection to the solenoid on the vacuum tank.Connect the electrical connection to the excess pressure sensor.Connect the electrical connection to the cam angle sensorConnect the electrical connections to the heater plugs.Place the electrical wiring back in its seating and fix it using the bolts.Connect the electrical connections to the injectors.Place the coolant return pipe to the engine cooling system reservoir back in its housing and fix it using the bolts, connect it and tighten the bands.Connect the oil vapour recovery pipe to the tappet cover and secure with a band.Place the electro-pneumatically controlled throttle body complete with expansion joint connected to the E.G.R. back in its housing and secure it using the bolts.Connect the electrical connection to the engine coolant temperature sensor.Connect the upper coolant inlet hose to the radiator, thermostat side, and tighten the band.Connect the coolant supply and return pipes to the climate control heater and tighten the bands.Connect the vacuum reservoir vacuum intake pipe, T-connector side.Connect the vacuum intake pipe to the vacuum unit and tighten the band.Connect the air supply hose from the heat exchanger to the inlet manifold, electro-pneumatically controlled throttle body side, and tighten the band.Connect the vacuum pipe to the pneumatic valve on the throttle body.Proceed with refitting 1080C24 e.g.r. system solenoid - r + r .Proceed with refitting 1064A19 TURBOCHARGER - EXHAUST MANIFOLD - EXHAUST PIPE CONNECTING HOSE - R.R. .Proceed with refitting    Op. 1084B42 ENGINE OIL RETURN PIPE FROM TURBO - R + R.Proceed with refitting    Op. 1048B14 AIR DELIVERY PIPE BETWEEN TURBO CHARGER AND HEAT EXCHANGER - REPLACE.Proceed with refitting 1076B70 exhaust pipe between pre-catalytic converter and catalytic converter - r r .Proceed with refitting    Op. 1048A10 AIR CLEANER FILTERING ELEMENT - REPLACE.Proceed with refitting    Op. 1060F20 PRESSURE PUMP/MANIFOLD PIPE - R R.Proceed with refitting 1060F50 fuel return manifold - r r .Remove the timing side rigid power unit support fitted temporarily.Proceed with refitting 2710A35 intermediate drive shaft mount - r r .Proceed with refitting    Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT.Proceed with refitting    Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R.Proceed with refitting 1092G10 single engine belt r r .Proceed with refitting    Op. 7055B91 RIGHT FRONT SUPPLEMENTARY WHEEL ARCH R R.Proceed with refitting    Op. 4450B04 RIGHT FRONT WHEEL R R.Proceed with refitting    Op. 1008A46 CAM SHAFT LEFT RIGID MOUNT - R R.Proceed with refitting    Op. 7055B54 UNDER-ENGINE GUARD - R R.Proceed with refitting    Op. 5530B52 BATTERY CRADLE - R R.Proceed with refitting    Op. 5530B10 BATTERY - R+R.Proceed with refitting 1016A10 sound-proofing cover - r + r .    Op. 0010T20 COOLANT CHANGE.    Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE.Remove the car from the ramps.