3024768 - 1016C10 cylinder head - r + r and replace gasket

Removing ( Refitting ) Position the vehicle on the ramp.Proceed with removal  - 5530B10  battery - r+r .Proceed with the removal  - 4450B10  Front WHEEL (one) - R.R. (Right side).Proceed with the removal  - 7055B64  Engine compartment DUST shield in front wheel arch (one), left or right - R.R. (Right side).Proceed with removal  - 7055B54  under-engine guard - r r .1. Disconnect the lower coolant outlet hose from the radiator and drain the engine coolant.

Manually press the springs and remove the rapid attachment for the hose.

Recover the coolant using a suitable container.

Proceed with removal  - 1016A40  ignition coil cover on cylinder head- r+r .Proceed with removal  - 5510C14  ignition coil/s - r+r .Proceed with removal  - 1016A20  single cam cover - r + r and replace gasket .Proceed with removal  - 1056B60  single fuel manifold pipe, with injectors - r + r .Proceed with removal  - 1072D10  modular inlet manifold - r+r .1. Undo the bolts (1a) and remove the bracket (1b) connecting the intake manifold to the bracket on the engine for the reaction rod. 1. Disconnect the coolant supply pipe to the air conditioning system heater, thermostat side.2. Disconnect the coolant return pipe from the air conditioning system heater, on the side of the rigid fluid intake to the coolant pump.3. Disconnect the flexible coolant supply pipe from the rigid pipe to the engine oil heat exchanger.4. Disconnect the upper coolant inlet hose to the radiator, thermostat side. Proceed with removal  - 1072C44  exhaust manifold heat shield on bulkhead - r+r .1. Undo the bolt fixing the engine oil dipstick tube.2. Remove the tube for the engine oil dipstick. 1. Unscrew the nuts securing the catalytic preconverter to the exhaust manifold.2. Undo the nuts fixing the catalytic pre-converter to the mounting bracket. 1. Undo the plug and drain the engine oil.

Collect the engine oil in a suitable container.

1. Release and remove the engine oil filter using a suitable tool.2. Undo the pin (2a) and disconnect the engine oil heat exchanger (2b) from the crankshaft oil seal front cover. 1. Disconnect the engine coolant system supply pipe from the water pump rigid inlet pipe. Proceed with removal  - 1092G10  single engine belt r r .Proceed with removal  - 1092A10  Crankshaft services PULLEY - R.R. .Proceed with removal  - 1092G20  engine component single belt fixed tensioner - one - r + r .Proceed with removal  - 1092G14  engine component single belt mobile tensioner - r + r .Proceed with removal  - 1032D12  timing system protective cover(s) - r + r .Proceed with removal  - 1092E10  counter-rotating shaft drive toothed belt - r + r .Proceed with removal  - 1032B10  toothed timing belt - r + r for timing adjustment or replacement .1. Undo the bolts (1a) and remove the cylinder head (1b).

To undo/tighten the cylinder head bolts, use the ordinary spanner USAG 233 1/2 S.

2. Remove the cylinder head gasket. Refitting ( Removing ) Place the cylinder head gasket back in its housing.

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 process to take place it is necessary to: keep the gasket in its sealed container until it is fitted; not lubricate or get oil on the gasket and the contact surfaces.

Position the cylinder head on the cylinder block, taking care that the camshafts are positioned with the front cams facing outwards (valves closed).1. Tighten the bolts (1a) fixing the cylinder head to the recommended torque using the angular tightening tool (1b).

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

To undo/tighten the cylinder head bolts, use the ordinary spanner USAG 233 1/2 S.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	CYLINDER HEAD	M10	(Engine crankcase side) 4.0 + 90˚ + 90˚ + 90 ˚

	Name	Country
1b	Protractor	1.860.942.000

The value of 4.0 daNm should be implemented by tightening to 2.0 daNm and then increased by a torque of 2.0 daNm until the nominal value of 4.0 daNm is reached.

Proceed with refitting  - 1032B10  toothed timing belt - r + r for timing adjustment or replacement .Proceed with refitting  - 1092E10  counter-rotating shaft drive toothed belt - r + r .Proceed with refitting  - 1032D12  timing system protective cover(s) - r + r .Proceed with refitting  - 1092G14  engine component single belt mobile tensioner - r + r .Proceed with refitting  - 1092G20  engine component single belt fixed tensioner - one - r + r .Proceed with refitting  - 1092A10  Crankshaft services PULLEY - R.R. .Proceed with refitting  - 1092G10  single engine belt r r .Connect the engine cooling system supply pipe to the water pump rigid outlet pipe.Place the engine oil heat exchanger back in its housing and fix it to the crankshaft front oil seal cover using the pin.Refit the engine oil filter in its seating and tighten it fully by hand.1. Tighten the engine oil drain plug to the crankcase sump to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	-	ENGINE OIL DRAIN PLUG	M18	(Crankcase sump side) 1.8 ÷ 2.2

Tighten the nuts fixing the catalytic pre-converter to the mounting bracket to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	CATALYTIC PRE-CONVERTER	M8	(Manifold side) 2.7 ÷ 3.3

Tighten the nuts fixing the front section of the exhaust pipe to the mounting bracket.Place the engine oil dipstick tube in its seating and fix it using the bolt.Proceed with refitting  - 1072C44  exhaust manifold heat shield on bulkhead - r+r .Connect the upper coolant inlet hose to the radiator, thermostat side.Connect the flexible coolant supply pipe to the rigid pipe to the engine oil heat exchanger.Connect the coolant return hose from the air conditioning system heater on the side of the rigid inlet pipe to the water pump.Connect the coolant supply pipe to the air conditioning system heater, thermostat side.Place the bracket connecting the intake manifold to the bracket on the engine for the reaction rod back in its housing and fix it using the bolts.Proceed with refitting  - 1072D10  modular inlet manifold - r+r .Proceed with refitting  - 1056B60  single fuel manifold pipe, with injectors - r + r .Proceed with refitting  - 1016A20  single cam cover - r + r and replace gasket .Proceed with refitting  - 5510C14  ignition coil/s - r+r .Proceed with refitting  - 1016A40  ignition coil cover on cylinder head- r+r .Connect the lower coolant outlet hose from the radiator.Proceed with refitting  - 7055B54  under-engine guard - r r .Proceed with the refitting  - 7055B64  Engine compartment DUST shield in front wheel arch (one), left or right - R.R. (Right side).Proceed with the refitting  - 4450B10  Front WHEEL (one) - R.R. (Right side).Proceed with refitting  - 5530B10  battery - r+r .Refill the engine oil lubrication system  - 1084A10  ENGINE OIL - Check level and top up, if necessary .Refill the cooling system  - 0010T20  coolant change .Remove the car from the ramps.