1016C10 CYLINDER HEAD - R + R AND REPLACE GASKET - Alfa - 147 - eLearn

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

) - 1008C10 power unit upper reaction link r r - 1016A10 sound-proofing cover - r + r - 1008C14 engine link bracket - r r - 4450B04 right front wheel r r - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. - 1092G10 single engine belt r r - 1092A10 Crankshaft services PULLEY - R.R. - 1060G80 ds electric injection control unit - r r - 1032B10 toothed timing belt - r + r for timing adjustment or replacement - 5530B10 battery - r+rPosition a suitable container for collecting the coolant fluid.Disconnect the lower radiator pipe and completely drain the engine coolant into the special container.1. Disconnect the recirculation pipe (1a) and the water supply pipe (1b) to the rigid water supply pipe to the pump from the engine coolant reservoir.

1. Disconnect the engine oil vapour recovery pipes (1a) and (1b) from the tappet cover.2. Disconnect the upper radiator pipe from the thermostat.3. Disconnect the vacuum pipe from the vacuum unit.

1. Disconnect the upper flexible coolant pipe (1a) and the lower flexible coolant pipe (1b) from the rigid supply section to the engine oil heat exchanger.2. Undo the fixing bolts (2a) and remove the rigid section of the supply pipe to the heat exchanger.

1. Disconnect the engine coolant pipes connected to the rigid pipe.2. Undo the bolts fixing the pump rigid water inlet pipe.3. Remove the rigid pump coolant inlet pipe, recovering the gasket underneath.

1. Undo the retaining bolts.2. Remove the heat shield for the exhaust manifold.

1. Undo the bolt (1a) fixing the turbocharger reinforcement bracket (1b) to the cylinder block/crankcase.2. Undo the bolts (2a) fixing the turbocharger rigid oil return pipe (2b).

1. Undo the bolts (1a) fixing the rigid EGR pipe (1b) to the exhaust manifold.2. Undo the fixing nuts (2a) and release the exhaust manifold/turbocharger assembly (2b) from the cylinder head pins.

1. Open the band and disconnect the air pipe from the throttle body.

1. Disconnect the two supply and return pipes to the heater from the thermostat.2. Disconnect the electrical connection for the engine coolant temperature sensor.

	Name	Connector
2	Engine temperature sender unit	K36

3. Disconnect the vacuum pipe (3a) to the vacuum reservoir and the pipe (3b) to the variable geometry turbocharger from the connectors on the vacuum pipe.

1. Undo the nuts fixing the return manifold to the intake manifold.2. Disconnect the recirculation pipe.3. Remove the rigid supply pipe from the pressure pump to the single fuel supply manifold.

Fit a new high pressure pipe from the pressure pump to the fuel manifold upon reassembly.

1. Disconnect the electrical connections (1a), (1b), (1c), (1d), (1e) and (1f).

	Name	Connector
1a	Injector	N70

	Name	Connector
1b	Air conditioning compressor engagement electro-magnet	L20

	Name	Connector
1c	Fuel pressure sensor	K83

	Name	Connector
1d	EGR solenoid	L30

	Name	Connector
1e	Turbocharging sensor	K82

	Name	Connector
1f	Timing sensor.	K47

	Name	Connector
-	Plug preheating control unit	M15

2. Undo the retaining bolts (2a) and remove the injection wiring (2b).

1. Undo the bolts fixing the tappet cover to the cylinder head.2. Remove the tappet cover with vapour separator incorporated.3. Undo the fixing bolts (3a) and remove the timing belt side shield (3b).

Remove the oil present in the cylinder head.1. Undo the bolts fixing the cylinder head.2. Position a bracket (2a) fixed to the exhaust manifold stud and fasten the hook (2b) to it for moving the cylinder head later on in safety. 3. Position a second hook at the intake manifold.Secure the chains to a hydraulic lift.4. Lift and remove the cylinder head, complete with intake manifold.Recover the cylinder head gasket.

Refitting ( Removing

) Fit a new cylinder head gasket to the cylinder block/crankcase, taking care that it is the same thickness as the old one.

ASTADUR type cylinder head gaskets are fitted.

The material from which these gaskets are made undergoes a polymerisation 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 follow the precautions listed below. Keep the gasket sealed in its nylon container and only take it out shortly before fitting.Do not lubricate it or get oil or grease on it.Position the cylinder head on the cylinder block/crankcase.Release the supporting hooks and remove the mounting bracket.1. Tighten the bolts securing the cylinder head to the cylinder block/crankcase to the recommended torque following the order shown in the diagram and using the angular tightening tool.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CYLINDER HEAD	M12	(Engine crankcase side) 6.5 + 90˚ + 90˚ + 90˚

	Name	Country
1	Protractor	1.860.942.000

The value of 6.5 daNm should be implemented by tightening to 2.0 daNm and then increased by a torque of 4.5 daNm until the nominal value of 6.5 daNm is reached.

Remove the brackets, chains and hooks positioned previously for lifting the cylinder head.Fit the tappet cover on the cylinder head.Tighten the bolts fixing the tappet cover to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAM COVER	M6	WHITE

Connect the electrical connections disconnected previously.

	Name	Connector
-	Injector	N70

	Name	Connector
-	Air conditioning compressor engagement electro-magnet	L20

	Name	Connector
-	Fuel pressure sensor	K83

	Name	Connector
-	EGR solenoid	L30

	Name	Connector
-	Turbocharging sensor	K82

	Name	Connector
-	Timing sensor.	K47

	Name	Connector
-	Plug preheating control unit	M15

Tighten the bolts fixing the injection wiring to the intake manifold.Fit a new rigid supply pipe from the pressure pump to the single fuel supply manifold and tighten the connectors to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M12	(Pressure pump side) 2.2

	Fastening	Component	Ø	Value(daNm)
-	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14	(Fuel manifold side) 2.2

Clean the threaded seats for the above mentioned pipe on the manifold and the pressure pump using heptane.

Tighten the nuts fixing the return manifold to the intake manifold.Connect the fuel recirculation pipe to the injectors.Connect the vacuum pipe to the vacuum reservoir and the pipe to the variable geometry turbocharger to the connectors on the vacuum pipe.Connect the electrical connection for the engine coolant temperature sensor.

	Name	Connector
-	Engine temperature sender unit	K36

Connect the two heater supply and return pipes to the thermostat.Connect the throttle casing air pipe.Fit the exhaust manifold/turbocharger assembly on the cylinder head pins.Tighten the nuts securing the manifold to the cylinder head to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	EXHAUST MANIFOLD/S	M8	(Cylinder head side) 2.5

Position the EGR exhaust gas supply pipe and tighten the bolts fixing it to the exhaust manifold.Fit the exhaust manifold heat shield.Fit the pump rigid water inlet pipe with a new gasket underneath.Tighten the bolts fixing the water inlet rigid pipe to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	COOLANT PUMP RIGID INLET PIPE	M6	(Cylinder head) 0.9

Connect the engine coolant pipes to the rigid pipe.Fit the rigid section of the supply pipe to the heat exchanger and tighten the fixing bolts.Connect the upper and lower flexible coolant pipes to the rigid section of the supply pipe to the engine oil heat exchanger.Connect the vacuum pipe to the vacuum unit.Connect the upper radiator hose to the thermostat.Connect the engine oil vapour recovery pipes to the tappet cover.Connect the recirculation pipe and the coolant supply pipe to the rigid supply pipe to the pump to the engine coolant reservoir.Connect the lower radiator hose. - 5530B10 battery - r+r - 1032B10 toothed timing belt - r + r for timing adjustment or replacement - 1060G80 ds electric injection control unit - r r - 1092A10 Crankshaft services PULLEY - R.R. - 1092G10 single engine belt r r - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. - 4450B04 right front wheel r r - 1008C14 engine link bracket - r r - 1016A10 sound-proofing cover - r + r - 1008C10 power unit upper reaction link r r - 0010T20 coolant change - 0010T21 coolant check density and top up if necessary