1016C10 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET - Fiat - STILO - eLearn

3362546 - 1016C10 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET

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

	Description	Connector
	Battery	See A001 BATTERY

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. Op. 7055B42 FRONT WHEEL ARCH LINER (ONE), LEFT OR RIGHT - R.R.On both sides Op. 1092G10 SINGLE ENGINE BELT - R.R Op. 1092A10 CRANKSHAFT PULLEY - R + R Op. 1092G14 ENGINE COMPONENT SINGLE BELT MOVING TENSIONER - R + R Op. 1092G21 ENGINE COMPONENT SINGLE BELT FIXED TENSIONER - R.R. WITH BELT REMOVED Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + ROp. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R Op. 1016B10 SINGLE CAMSHAFT HOUSING - REPLACE GASKET1. Disconnect the lower radiator coolant outlet hose.

Collect the coolant that comes out in a suitable container.

1. Remove rockers (1a) complete with hydraulic tappets (1b).

Arrange the hydraulic tappets on a surface free of impurities and also mark their positions on removal so that they can be refitted in the correct position.

1. Disconnect the radiator upper coolant inlet hose.2. Disconnect the heater coolant supply pipe.3. Disconnect the coolant delivery pipe to the coolant/exhaust gas heat exchanger for the EGR system.4. Disconnect the coolant delivery pipe from the coolant/exhaust gas heat exchanger for the EGR system.5. Disconnect the engine coolant return pipe from the heater.

1. Unscrew the bolts securing the rigig air delivery pipe from the flange on the throttle body.2. Unscrew the bolt securing the rigid air delivery pipe to the intake from the body.3. Move the pipe back from the throttle body and secure at maximum distance from the throttle body.

1. Disconnect the electrical connection from the EGR system solenoid valve

	Description	Connector
1	EGR solenoid valve	See L030 EGR SOLENOID

2. Disconnect the electrical connection from the air temperature/pressure sensor.

	Description	Connector
2	Air pressure - temperature sensor	See K044 AIR PRESSURE - TEMPERATURE SENSOR

3. Disconnect the electrical connection from the turbocharger vane actuator solenoid valve secured to the front end.

	Description	Connector
3	Turbine variable geometry control solenoid	See L036 TURBINE VARIABLE GEOMETRY CONTROL SOLENOID VALVE

4. Disconnect the electrical connection for the fuel pressure regulator.

	Description	Connector
4	Fuel pressure regulator	See N077 FUEL PRESSURE REGULATOR

- Release the electrical wiring from the band and move it to the side.5. Disconnect the band.6. Remove the rigid water recirculation pipe to the reservoir.

1. Disconnect the coolant pipe from the filler pipe.2. Undo the bolts fixing the coolant filler pipe.3. Remove the coolant filler pipe to the pump, taking care to recover the underlying gasket.

1. Undo the retaining nuts.2. Remove the exhaust manifold heat shield.

- Raise the lift.1. Undo the fixing bolts.2. Remove the catalytic converter heat shield.

1. Unscrew the fastenings securing the catalytic preconverter to flange (1a) on the first section of the exhaust pipe and the reinforcement bracket (1b).

1. Undo the nuts (1a) and remove the catalytic preconverter reinforcement bracket (1b).

1. Undo the nut.2. Remove the water-oil heat exchanger heat shield.

1. Unscrew the EGR gas pipe bolts from the manifold.2. Unscrew the bolt securing the metal band from the exchanger.3. Remove the pipe carrying exhaust gas to the turbocharger.

1. Undo collars (1a) and remove the air pipe from the filter to the turbocharger (1b).

1. Disconnect the outlet pipe to the air-air exchanger from the turbocharger.

1. Undo the connector and disconnect the turbocharger oil supply pipe.2. Unscrew the bolts and disconnect the oil return pipe from the turbocharger to the crankcase from its seat on the crankcase.

1. Disconnect the pipe to the variable geometry actuator.2. Undo the nuts securing the exhaust manifold to the cylinder head.3. Remove the exhaust manifold with turbocharger and catalytic preconverter.- Recover the exhaust manifold and gasket from its seat.

1. Disconnect the rapid connector for the fuel return pipe from the fuel filter, fuel return manifold pipe side.2. Disconnect the rapid connector for the fuel return pipe to the tank, fuel return manifold pipe side.3. Loosen the band and disconnect the fuel return pipe from the pressure pump, fuel return manifold pipe side.

1. Undo the bolts (1a) and remove the fuel return manifold pipe (1b) complete with pipe from the injectors to the fuel recovery manifold (1c).

1. Loosen the collar securing the water/gas heat exchanger exhaust gas recirculation pipe for the EGR system.2. Undo the fixing bolts (2a) and remove the E.G.R. system solenoid valve (2b) complete with hose.- Remove the gasket.

1. Undo the upper bolts fixing the vacuum reservoir and engine oil separator mounting bracket to the cylinder head.

1. Disconnect the vacuum pipe from the pneumatic valve on the throttle casing.

1. Undo the bolts fixing the cylinder head to the engine block.2. Undo the bolt fixing the cylinder head to the pressure pump mount.3. Remove the cylinder head.- Recover the underlying gasket.

Refitting ( Removing

) - Clean the contact areas between the engine block and the cylinder head thoroughly.

over the cylinder liners/bores and pistons to prevent the penetration of impurities or foreign bodies.

- Place the cylinder head centering bushes on the cylinder block.- Fit a new cylinder head gasket taking care to ensure that it is the same size as the one removed.

Position the first cylinder at T.D.C.; rotate the crankshaft a further two teeth of the toothed timing drive pulley to lower the pistons thereby preventing any interference with the valves whilst fitting the cylinder head.

Position the cylinder head on the cylinder block/crankcase.1. Follow the order illustrated below for the tightening of the cylinder head.

1. Tighten the cylinder head bolts (1a) to the recommended torque using the angular tightening tool (1b):

	Value daNm	Fastening	Component	dia
1a	2+6.5+90°+90°+90°	Bolt	Cylinder head	M12

The figure of 2 daNm in the table below is a tightening value for all the bolts following the order illustrated in the diagram.

	Description	Code	Function
1b	Torque wrench	Tightening cylinder head bolts to cylinder block	1.860.942.000

Follow the order shown in the previous figure for each tightening sequence.

- Tighten the bolt fixing the cylinder head to the pressure pump support to torque.

	Value daNm	Fastening	Component	dia
-	2.5	Bolt	Cylinder head	M8

- Connect the vacuum pipe for the pneumatic valve on the throttle casing.- Tighten the upper bolts fixing the vacuum reservoir and engine oil separator mounting bracket to the cylinder head.- Fit the E.G.R. system solenoid valve complete with seal and secure it tightening the bolts to the recommended torque.- Tighten the bolt securing the collar of the exhaust gas recirculation pipe to the EGR valve to the exchanger.- Fit the fuel return manifold pipe and secure with bolts.- Connect the rapid connector for the fuel return pipe from the fuel filter.- Connect the quick connector of the fuel return pipe to the tank.- Connect the fuel return pipe from the pressure pump.- Fit a new exhaust manifold gasket.- Fit the exhaust manifold with turbocharger and catalytic preconverter.- Tighten the self-locking nuts fixing the exhaust manifold to the cylinder head.

	Value daNm	Fastening	Component	dia
-	2.5	Nuts	Exhaust manifold	M8

- Connect the pipe to the variable geometry actuator.- Connect the oil return pipe from the turbocharger to the crankcase and tighten the bolts to torque.

	Value daNm	Fastening	Component	dia
-	2.5	Bolt	Engine oil return pipe	M8

- Connect the turbocharger oil supply pipe and tighten the connector to torque.

	Value daNm	Fastening	Component	dia
-	1.5	Bolt	Engine oil delivery pipe	M12

- Connect the outlet pipe to the air-air exchanger to the turbocharger.- Fit the air filter connection pipe to the turbocharger and secure using the collars.- Fit the E.G.R. system water/exhaust gas heat exchanger exhaust gas inlet pipe and tighten the fastening band.- Tighten the bolts fixing the E.G.R. system water/exhaust gas heat exchanger exhaust gas inlet pipe to the exhaust manifold to the recommended torque.- Fit the water-oil heat exchanger heat shield and tighten the fixing nut.- Fit the catalytic preconverter reinforcement bracket and tighten the nuts securing it to the crankcase.

	Value daNm	Fastening	Component	dia
-	2.5	Nuts	Preconverter bracket	M8 (oil sump)

- Tighten the nuts fixing the first section of the exhaust pipe to the catalytic pre-converter.

	Value daNm	Fastening	Component	dia
-	2.5	Nuts	Engine/manifold exhaust pipe	M8

- Tighten the bolts fixing the catalytic converter to the mounting bracket to torque.

	Value daNm	Fastening	Component	dia
-	2.5	Nuts	Catalytic preconverter	M8 (support bracket)

- Fit the catalytic converter heat shield and tighten the lower bolts to torque.

	Value daNm	Fastening	Component	dia
-	0.9	Bolt	Exhaust manifold heat shield	M6 (support bracket)

- Lower the lift.- Fit the exhaust manifold heat shield and tighten the nuts.

	Value daNm	Fastening	Component	dia
-	0.9	Nuts	Exhaust manifold heat shield	M6

- Fit the water pump rigid inlet pipe complete with gasket and tighten the bolts .

	Value daNm	Fastening	Component	dia
-	0.9	Bolt	Engine coolant pump rigid inlet pipe	M6

- Connect the coolant outlet pipe from the climate control system heater, on the side of the rigid pipe carrying coolant into the coolant pump and tighten the collar.- Connect the coolant delivery pipe from the coolant/exhaust gas heat exchanger for the EGR system, water pump rigid inlet pipe side and tighten the band.- Connect the lower coolant inlet hose from the radiator, water pump rigid coolant inlet pipe side and tighten the band.- Fit the rigid water recirculation pipe to the reservoir and connect to the thermostat.- Connect the electrical connection to the fuel pressure regulator.

	Description	Connector
-	Fuel pressure regulator	See N077 FUEL PRESSURE REGULATOR

- Connect the electrical connection from the EGR system solenoid valve

	Description	Connector
-	Turbine variable geometry control solenoid	See L036 TURBINE VARIABLE GEOMETRY CONTROL SOLENOID VALVE

- Disconnect the electrical connection from the air temperature/pressure sensor.

	Description	Connector
-	Air pressure - temperature sensor	See K044 AIR PRESSURE - TEMPERATURE SENSOR

- Connect the electrical connection from the turbocharger vane actuator solenoid valve secured to the front end.

	Description	Connector
-	Turbine variable geometry control solenoid	See L036 TURBINE VARIABLE GEOMETRY CONTROL SOLENOID VALVE

- Secure the electrical wiring to the collars.- Tighten the bolts securing the rigid air delivery pipe from the flange on the throttle body.- Connect the upper coolant inlet hose to the radiator.- Connect the heater coolant supply pipe.- Connect the coolant delivery pipe to the coolant/exhaust gas heat exchanger for the EGR system.- Connect the coolant delivery pipe from the coolant/exhaust gas heat exchanger for the EGR system.- Connect the engine coolant return pipe from the heater.- Fit the rockers with hydraulic tappets.- Connect the lower radiator coolant outlet hose. Op. 1016B10 SINGLE CAMSHAFT HOUSING - REPLACE GASKET Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.ROp. 5530B10 BATTERY - R+R Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R Op. 1092G21 ENGINE COMPONENT SINGLE BELT FIXED TENSIONER - R.R. WITH BELT REMOVED Op. 1092G14 ENGINE COMPONENT SINGLE BELT MOVING TENSIONER - R + R Op. 1092A10 CRANKSHAFT PULLEY - R + R Op. 1092G10 SINGLE ENGINE BELT - R.R Op. 0010T20 ENGINE COOLANT - CHANGE Op. 7055B42 FRONT WHEEL ARCH LINER (ONE), LEFT OR RIGHT - R.R.On both sides Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.- Connect the negative battery terminal. Op. 1016A10 SOUND-PROOFING COVER - R.R Op. 4450B04 RIGHT FRONT WHEEL - R.R- Remove the vehicle from the lift.