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

Removing ( Refitting ) Place the car on a lift.    Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R..Position a suitable container to collect the coolant.Disconnect the lower radiator hose.    1016A40 ignition coil cover on cylinder head- r+r    Op. 5530B56 BATTERY DRIP TRAY COVER - R.R.Disconnect the battery negative terminal.    Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R    Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R    Op. 1056B14 THROTTLE CASE - R + R    Op. 1072B10 INLET MANIFOLD - R + R AND REPLACE SEAL    1072D50 device (vis) with adjustable air ducts - r r    Op. 1088E10 RADIATOR COOLING FAN - R + R    Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R    Op. 1072C10 EXHAUST MANIFOLD - R + R AND REPLACE SEAL1. Disconnect the lower pipe and the upper pipe from the thermostat.2. Disconnect the pipes from the rigid pipe.Disconnect the supply and return pipes. 1. Disconnect the heater supply and return pipes.2. Disconnect the supply pipe from the water pump.3. Disconnect the earth lead from the cylinder head.4. Disconnect the electrical connection from the engine coolant temperature sensor.

	Name	Connector
4	Engine temperature sender unit	K36

5. Disconnect the recirculation pipe from the connector on the thermostat. 1. Disconnect the engine coolant pipe from the reservoir to the water pump rigid inlet pipe. 1. Disconnect the electrical connections from the ignition coils.

	Name	Connector
1	Ignition coil	A30

	Name	Connector
1	Ignition coil	A30B

	Name	Connector
1	Ignition coil	A30C

	Name	Connector
1	Ignition coil	A30D

	Name	Connector
1	Ignition coil	A30E

2. Undo the bolts fixing the ignition coils to the tappet cover.3. Release the electrical wiring from the securing bands.4. Remove the ignition coils. 1. Remove the spark plugs underneath. 1. Undo the bolts (1a) and remove cam cover (1b), complete with seal.     Op. 4450B04 RIGHT FRONT WHEEL - R.R    7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R.    1092D10 air conditioner compressor drive belt - r + r    1092B68 belt from a/c compressor to alternator drive r + r    Op. 1092A10 CRANKSHAFT PULLEY - R + R1. Using a specially shortened 5 mm socket wrench, undo the bolts fixing the shield.2. Remove the timing belt guard. 1. Undo the nut for the automatic tensioner in order to loosen the timing drive belt tension.2. Remove the timing drive belt from the drive pullies. 1. Undo the bolt fixing the cover behind the exhaust side timing pulley to the cylinder head.2. Undo the bolts (2a), using the spanner (2b) and remove the cylinder head (2c).Remove the cylinder head gasket underneath.

	Name	Country
2b	Hexagonal splined wrench	1.852.154.000

Refitting ( Removing ) Position the cylinder head gasket on the cylinder block.

The cylinder head gasket is of the Astadur type. 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/crankcase, taking care that the camshafts are positioned with the front cams facing outwards (valves closed).1. Tighten the bolts (1a) fixing the cylinder head, in successive stages, using the spanner (1b) for torque tightening and the spanner (1c) for angular tightening.

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

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	CYLINDER HEAD	M10	4 + 90° + 90°

	Name	Country
1b	Hexagonal splined wrench	1.852.154.000

	Name	Country
1c	Protractor	1.860.942.000

1. Undo the bolt (1a) for the timing driven pulley, exhaust side using the tools (1b) and (1c) for counter-torque.

	Name	Country
1b	Support for counter-torque	1.860.831.000

	Name	Country
1c	Spanner for camshaft pulley rotation	1.860.831.002

2. Slacken the bolts (2a) on the inlet side camshaft pulley, using the tool (2b) for counter-torque.

	Name	Country
2b	Counter-torque	1.860.856.000

1. Fit the tool (1a), complete with dial gauge (1b), in the housing of the spark plug for cylinder no. 1.

	Name	Country
1a	Probe mount	1.860.895.000

Rotate the crankshaft until the piston for cylinder no. 1 is at T.D.C. at the combustion stroke.2. With cylinder no. 1 at T.D.C., check that the reference on the crankshaft drive gear coincides with the reference on the crankshaft front cover. Undo the bolts and remove the third inlet side camshaft cap and the second exhaust side camshaft cap.

Mark the position of the camshaft caps following removal so that they can be positioned correctly upon refitting.

1. Fit templates (1a) in place of the camshaft caps removed and fix it tightening the bolts (1b).

Check that the camshaft cam profile matches the tool correctly.

	Name	Country
1a	Gauge	1.870.828.000

1. Fit the toothed timing belt following the order;toothed drive pulley (1a)fixed tensioner (1b)exhaust side toothed driven pulley (1c)intake side toothed driven pulley (1d)mobile tensioner (1e)coolant pump pulley (1f).

When fitting, ensure that the arrow stamped on the belt is facing in the direction of engine rotation. Three notches on the belt must also line up, during the initial fitting, with notches on the toothed drive pulley and on the intake and exhaust toothed driven pulleys.

1. Using a screwdriver, apply force to the automatic tensioner tab (1a) so that the tensioner is in the maximum tension position, then tighten the nut (1b) fixing the tensioner to the support.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	MOBILE TIMING TENSIONER	M8	2.5

1. Tighten the bolts (1a) for the camshaft toothed driven pulley, inlet side, to the recommended torque using the tool (1b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
1a	Bolt	TIMING GEAR DRIVEN PULLEYS	M6	(Inlet side) 0.9

	Name	Country
1b	Counter-torque	1.860.856.000

2. Tighten the bolts (2a) for the camshaft driven pulley, exhaust side, to the recommended torque using the tools (2b) and (2c) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	TIMING GEAR DRIVEN PULLEYS	M12	(Exhaust side) 12

	Name	Country
2b	Support for counter-torque	1.860.831.000

	Name	Country
2c	Spanner for camshaft pulley rotation	1.860.831.002

Undo the fixing bolts and remove the jigs.

	Name	Country
-	Gauge	1.870.828.000

Fit the camshaft caps removed previously and tighten the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	Camshaft caps	M7	1.5

Rotate the crankshaft through two revolutions in its normal direction of rotation.Loosen the moving tensioner nut.3. Using a screwdriver, rotate the timing moving tensioner so that the tensioner moving reference (3a) coincides with the fixed reference (3b).4. Tighten the nut for the moving tensioner to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	MOBILE TIMING TENSIONER	M8	2.5

Remove the tool complete with dial gauge.

	Name	Country
-	Probe mount	1.860.895.000

Fit the spark plugs for the cylinders and tighten them to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	SPARK PLUGS	M14 x 1.25	2.7

Position the timing drive belt cover and secure it using the fixing bolts.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	BELT PROTECTION COVER	M6	0.9

    Op. 1092A10 CRANKSHAFT PULLEY - R + R.    1092B68 belt from a/c compressor to alternator drive r + r    1092D10 air conditioner compressor drive belt - r + r    7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R.    Op. 4450B04 RIGHT FRONT WHEEL - R.RPosition the tappet cover and secure it using the fixing bolts.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAM COVER	M6	0.9

Position the ignition coils and secure them using the fixing bolts.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	IGNITION COIL/REEL	M6	0.9

Connect the electrical connections to the ignition coils.

	Name	Connector
-	Ignition coil	A30

	Name	Connector
-	Ignition coil	A30B

	Name	Connector
-	Ignition coil	A30C

	Name	Connector
-	Ignition coil	A30D

	Name	Connector
-	Ignition coil	A30E

Connect the engine coolant pipe from the reservoir to the water pump rigid inlet pipe.Connect the connector recirculation pipe to the thermostat.Connect the electrical connection to the engine coolant temperature sensor.

	Name	Connector
-	Engine temperature sender unit	K36

Connect the cylinder head earth lead.Connect the supply pipe from the water pump.Connect the supply and return pipes to the heater.Connect the supply and return pipes.Connect the pipes to the rigid pipe.Connect the upper and lower pipes to the thermostat.    Op. 1072C10 EXHAUST MANIFOLD - R + R AND REPLACE SEAL    Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R    Op. 1088E10 RADIATOR COOLING FAN - R + R    1072D50 device (vis) with adjustable air ducts - r r    Op. 1072B10 INLET MANIFOLD - R + R AND REPLACE SEAL    Op. 1056B14 THROTTLE CASE - R + R    Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R    Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.RConnect the battery negative terminal.    Op. 5530B56 BATTERY DRIP TRAY COVER - R.R.    1016A40 ignition coil cover on cylinder head- r+r    Op. 0010T21 ENGINE COOLANT - CHECK DENSITY AND CHANGE, IF NECESSARY    Op. 0010T20 ENGINE COOLANT - CHANGE