1016B10 SINGLE CAMSHAFT HOUSING - REPLACE GASKET - Fiat - STILO - eLearn

3362398 - 1016B10 SINGLE CAMSHAFT HOUSING - REPLACE GASKET

) Position the vehicle on a lift. Op. 4450B04 RIGHT FRONT WHEEL - R.R 1016A10 COPERCHIO INSONORIZZANTE - S.R.With the ignition key in the OFF position, disconnect the negative battery terminal.

	Description	Connector
-	Battery	A1B

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.. 7055B42 PASSARUOTA supplementare ANTERIORE (uno), sx o dx - S.R.both sides 1092G10 CINGHIA unica comando organi motore - S.R. Op. 1092A10 CRANKSHAFT PULLEY - R + R 1092G14 TENDITORE MOBILE cinghia unica organi motore - S.R. 1092G21 TENDITORE FISSO cinghia unica organi motore - S.R. a cinghia staccata Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R1. Loosen the nut retaining the timing belt moving tensioner.2. Release and remove the toothed timing drive belt.

1. Remove the intake air cold air pipe.

1. Disconnect the electrical connections from the injectors.

	Description	Connector
1	Injector	N70

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

	Description	Connector
2	Timing sensor	K47

Disconnect the electrical connections for the spark plugs.3. Disconnect the electrical connection for the air conditioning compressor electro-magnet coupling.

	Description	Connector
3	Air conditioning compressor engagement electro-magnet	L20

Unscrew the earth lead on the air conditioner compressor.Release the electrical wiring from the band on the timing cover.4. Unscrew the bulkhead coupling bolts and move the electrical wiring aside.

1. Press clips (1a) by hand and disconnect the pipe from the injectors to the fuel recovery manifold (1b), injector side, and move aside.2. Unscrew the connectors (2a) and (2b) and remove the pipes from the fuel manifold to injectors (2c).

Use new pipes from the fuel manifold to the injectors when refitting.

1. Undo the injector bracket retaining nuts.2. Remove the injectors (2a) complete with brackets using the tools (2b).

If the injectors are being reused, mark the cylinder to which they belong so that they can be correctly refitted.If a new injector/new inectors are fitted:- determine the identification code stamped on the top surface;- check, using an Examiner, the the new injector(s) is (are) recognized by the engine management control unit.

Begin removal starting from the injector for cylinder 1 and proceed to the injectors for cylinders 2, 3 and 4.

	Description	Code
2b	Extractor	1.870.897.300

1. Undo the connectors (1a), (1b) and remove the pipe from the pressure pump to the fuel manifold (1c).

Use a new pipe from the pressure pump to the fuel manifold when refitting.

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

	Description	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. Disconnect the bands to the ends.2. Unscrew the bolt securing the engine oil vapour pipe to the pipe carrying water to the pump.3. Remove the rigid section of the engine oil vapour pipe.

1. Loosen the collar and disconnect the vacuum pipe from the brake servo.2. Loosen the band and disconnect the engine oil vapour recovery pipe from the engine oil filler.

1. Disconnect the electrical connection from the engine coolant temperature sensor.

	Description	Connector
1	Engine temperature sending unit	K36

1. Undo the bolts (1a) and remove the engine oil filler (1b).2. Remove the gasket.

1. Undo the bolts (1a) and remove the vacuum unit (1b).2. Remove the gasket.

1. Undo the fixing bolts (1a), then remove the single camshaft housing (1b) with camshafts.Remove the gasket.

Refitting ( Removing

) Fit a new gasket on the cylinder head surface.1. Remove the plugs (1a) and fit camshaft timing tools (1b) on the camshaft housing.

Check that the tools are correctly fitted in the housings in the camshafts.

	Description	Code
1b	Templates	1.870.986.900

Remove the intake camshaft timing tool and tighten the plug.

1. Position the cylinder head extension assembly (1a) in its housing and secure it by tightening the bolts (1b) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1b	Bolt	CYLINDER HEAD EXTENSION	M8	(Cylinder head) 2.5

2. Loosen the bolt fixing the exhaust side camshaft pulley.

1. Undo the bolt fixing the crankcase front cover shown in the diagram.Fit the timing drive belt on the drive gear, checking that the belt teeth are correctly inserted in the gear grooves.2. Fit the tool (2a), fasten it using the calibrated screw (2b) and tighten nut (2c).

The crankshaft must be rotated, using small movements, to allow the locating dowel to be fitted on the timing drive pulley.

	Description	Code
2a	Template	1.860.905.000

	Description	Code
2b	Calibrated screw	1.860.905.010

1. Fully fit the toothed timing drive belt.2. Use a screwdriver on the tensioner (2a) tab for leverage until the mobile tensioner pointer (2b) is in the maximum tension position, then tighten the tensioner nut (2c).3. Loosen the tensioner nut and move the mobile tensioner pointer (3a) until it is aligned with reference hole (3b) and in this position tighten tensioner nut (3c) to the specified torque.

	Fastening	Component	dia	Value(daNm)
3c	Nut	FIXED TENSIONER	M8	2..5

4. Tighten the bolt fixing the exhaust side camshaft toothed pulley to the recommended torque.

	Fastening	Component	dia	Value(daNm)
3	Bolt	TIMING DRIVEN PULLIES	M12	12

Remove the timing tools.

	Description	Code
-	Templates	1.870.986.900

	Description	Code
-	Template	1.860.905.000

	Description	Code
-	Calibrated screw	1.860.905.010

Rotate the crankshaft through two revolutions.Recheck the timing by refitting the timing tools.

nly fit the exhaust side camshaft template because the intake side template seat is not accessible.

Check the alignment of the tensioning references on the timing moving tensioner.Tighten the bolt fixing the crankcase front cover removed previously.

	Fastening	Component	dia	Value(daNm)
-	Bolt	FRONT COVER CRANKSHAFT	M6	0.9

Tighten the plug on the cylinder head extension that was removed for fitting the exhaust side timing tool.Connect the electrical connection from the engine coolant temperature sensor.

	Description	Connector
-	Engine temperature sending unit	K36

Fit the vacuum pump in its housing complete with a new gasket and tighten the bolts to torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	VACUUM PUMP FOR BRAKES	M6	0.5 + 50°

Fit the engine oil filler fitting in its housing complete with a new gasket and tighten the bolts to torque.Connect the pipe from the engine oil filler to the separator.Connect the vacuum pipe to the vacuum unit.1. Fit the single fuel manifold pipe (1a) complete with fuel pressure sensor (1b) and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1c	Bolt	INJECTOR FUEL MANIFOLD (DIESEL)	M8	2.5

2. Connect the electrical connection to the fuel pressure sensor.

	Description	Connector
2	Fuel pressure sensor	K83

1. Fit a new pipe from the pressure pump to the single fuel manifold and secure 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 spanner.

	Fastening	Component	dia	Value(daNm)
2	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14 X 1.5	(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 commercial wrench.

	Fastening	Component	dia	Value(daNm)
3	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14 X 1.5	(Manifold side) 2.3

1. Fit the injectors (1a) in their seats complete with brackets and tighten the nuts (1b) to the recommended torque.

Refit starting from the injector for cylinder 4 and proceed to the injectors for cylinders 3, 2 and 1..

	Fastening	Component	dia	Value(daNm)
1b	Nut	INJECTORS(DIESEL)	M8 X 1.25	2.5

Fit new pipes from the fuel manifold to the injectors and secure with connectors without tightening.Tighten the connectors for the pipes from the fuel manifold to the injector side injectors to the recommended torque using an appropriate commercial wrench.

	Fastening	Component	dia	Value(daNm)
-	Connector	PIPE FUEL MANIFOLD TO INJECTORS	M12 x 1.5	(Injector side) 2.3

Tighten the connectors for the pipes from the fuel manifold to the fuel manifold side injectors to the recommended torque using an appropriate commercial wrench.

	Fastening	Component	dia	Value(daNm)
-	Connector	PIPE FUEL MANIFOLD TO INJECTORS	M12 x 1.5	(Manifold side) 2.3

Clean the threaded pipe seats on the manifold and injectors with heptane.

Connect the pipe from the injectors to the fuel recovery manifold to the injectors and push home until the clips click into place.Place the electrical wiring in position and tighten the bulkhead coupling bolts.Connect the electrical connections for the injectors.

	Description	Connector
-	Injector	N70

Connect the electrical connection to the timing sensor.

	Description	Connector
-	Timing sensor	K47

Connect the electrical wiring to the heater plugs.

	Description	Connector
-	Heater plug	A40

Connect the electrical connection for the air conditioning compressor electro-magnet coupling.

	Description	Connector
-	Air conditioning compressor engagement electro-magnet	L20

Unscrew the earth lead on the air conditioner compressor.Fit the intake air inlet pipe in its seat. Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R 1092G21 TENDITORE FISSO cinghia unica organi motore - S.R. a cinghia staccata 1092G14 TENDITORE MOBILE cinghia unica organi motore - S.R. Op. 1092A10 CRANKSHAFT PULLEY - R + R 1092G10 CINGHIA unica comando organi motore - S.R. 7055B42 PASSARUOTA supplementare ANTERIORE (uno), sx o dx - S.R. Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.Connect the negative battery terminal. 1016A10 COPERCHIO INSONORIZZANTE - S.R. Op. 4450B04 RIGHT FRONT WHEEL - R.RRemove the vehicle from the lift.