194000248 - 1016C10 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET

Removing ( Refitting ) - Position the vehicle on a lift.- Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).

	Description	Connector
-	Battery	See A001 BATTERY

1. Remove the sound insulation cover fastened to the engine by three pins. 1. Loosen the band and disconnect the engine oil vapour recovery pipe from the cylinder head cover.2. Loosen the bands and remove the air supply hose from the air flow meter to the throttle casing. 1. Disconnect the electrical connection from the air flow meter.

	Description	Connector
1	Air flow meter	See K041 AIR FLOW METER

2. Undo the bolts (2a) and remove the air filter cover (2b), complete with air flow meter (2c).3. Remove the air cleaner filter element. 1. Release the fuel vapour pipe (1a) from the band (1b) on the air filter casing. 1. Disconnect the cold air intake from the air filter casing.2. Remove the air filter casing fastened to the bodyshell by three pins. 1. Connect the tool to the bleed valve on the fuel supply pipe and discharge the fuel pressure.

Follow the safety instructions and specific recommendations.

Tool	Description	Function	Validity
2000002900	Breather connector	Fuel system pressure drainage	1.82.2

1. Undo the connector (1a), disconnect the fuel supply pipe (1b), fuel manifold pipe side and move it to the side. 1. Disconnect the electrical connection from the ignition coil module.

	Description	Connector
1	Ignition coil	See A030 IGNITION COIL

2. Undo the bolts (2a) and remove the ignition coil module (2b). 1. Undo the nut (1a), loosen the bands and remove the engine coolant return pipe to the supply reservoir (1b). 1. Disconnect the electrical connection for the front Lambda sensor to the catalytic converter.

	Description	Connector
1	Lambda sensor on catalyzer	See K017 LAMBDA SENSOR ON CATALYZER

2. Disconnect the electrical connection for the rear Lambda sensor to the catalytic converter.

	Description	Connector
2	Lambda sensor on catalyzer - 2	See K018 LAMBDA SENSOR ON CATALYZER - 2

1. Unscrew the bolts securing the timing side engine wiring brackets. 1. Unscrew the bolts securing the tappet cover side engine wiring brackets. 1. Release the gearbox side wiring mounting bracket from the fastenings.2. Move the engine wiring to the side.3. Disconnect the electrical connection for the radio interference condenser.

	Description	Connector
3	Interference filter	See P087 NOISE FILTER

1. Undo the nut (1a) and disconnect the earth lead (1b) from the tappet cover. 1. Undo the bolts (1a) and remove the tappet cover (1b). 1. Disconnect the electrical connection from the air conditioning system multi-stage pressure switch.

	Description	Connector
1	4 stage pressure switch	See K010 4 STAGE PRESSURE SWITCH

1. Disconnect the electrical connections from the injection/ignition system control unit.

	Description	Connector
1	Engine management control unit	See M010 ENGINE MANAGEMENT CONTROL UNIT

2. Disconnect the engine coupling.

	Description	Connector
2	Engine coupling	See D029 ENGINE CABLES/ENGINE SERVICES CABLE COUPLING

1. Tighten the bolts fixing the fuel manifold pipe. 1. Release the fuel manifold pipe (1a) from its housing complete with injectors (1b) and remove it after having disconnected the electrical connections (1c) from the injectors.

	Description	Connector
1c	Injector	See N070 INJECTOR

1. Disconnect the electrical connection from the throttle casing with D.V.L.

	Description	Connector
1	Integrated throttle casing actuator	See N075 INTEGRATED THROTTLE CASING ACTUATOR

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

	Description	Connector
2	Absolute pressure sensor	See K048 ABSOLUTE PRESSURE SENSOR

1. Undo the bolt (1a) and remove the engine oil dipstick tube (1b) assembly after having released it from the electrical wiring.2. Undo the bolt fixing the electrical wiring mounting bracket to the air chamber. 1. Loosen the band and disconnect the radiator lower coolant outlet hose, cylinder head side.

Collect the coolant that comes out in a suitable container.

1. Disconnect the intermediate rapid connector for the fuel vapour pipe. 1. Disconnect the rapid connector for the fuel vapour recovery pipe, air chamber side. 1. Disconnect the electrical connection from the fuel vapour recovery solenoid valve.

	Description	Connector
1	Fuel vapour recovery solenoid valve	See L010 FUEL VAPOUR RECOVERY SOLENOID VALVE

2. Release the fuel vapour recovery solenoid valve from the fastening, then remove it complete with pipes. 1. Disconnect the quick-release fitting for the brake servo vacuum intake pipe, air chamber side.     Op. 4450B04 RIGHT FRONT WHEEL - R.R    Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.1. Undo the nuts (1a) and disconnect the front section of the exhaust pipe (1b), catalytic converter side.

Fasten the section of the exhaust pipe disconnected so that it is not hanging loose. The front section of the exhaust pipe including the flexible pipe can be fastened to the bodyshell appropriately using, for example metal wire.Bends in the flexible pipe at angles of between 5° and 10°, starting from the planned fitting position, can damage the flexible pipe.

2. Remove the gasket. 1. Undo the water pump coolant drain plug.

Collect the coolant that comes out in a suitable container.

    Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.1. Undo the radiator coolant drain plug.

Collect the coolant in a suitable container.

- Remove the spark plugs to facilitate the subsequent operations of rotating the engine.1. Rotate the crankshaft until cylinder no. 4 is at T.D.C. during the explosion stroke; in this condition the reference (1a) on the inner part of the crankshaft pulley should be aligned with the reference (1b) on the timing chain cover. 1. Undo the bolts (1a) and remove the timing chain upper plate (1b). 1. Undo the automatic timing chain tensioner and remove it. 1. If there is no mark (1b) on the fixed timing hydraulic tensioner (1a), then the tensioner should be replaced with a new one, including a new tensioner moving plate. 1. Support the power unit using a hydraulic hoist (1a) and the tool (1b) connected to the mounting brackets (1c).

Tool	Description	Function	Validity
1871001700	Balance	Removing-refitting power unit

1. Undo the bolts (1a), (1b) and the nut (1c) and remove the flexible mounting for the timing side power unit front support (1d). - Fasten the timing chain to the exhaust side camshaft toothed drive pulley using a band.1. Loosen the bolts fixing the camshaft drive pulleys.

Apply counter-torque to the camshafts.

2. Remove the inlet side timing drive pulley. 1. Undo the access cap to the belt tensioner pad upper fixing bolt.2. Undo the upper belt tensioner pad fixing bolt. - Place the flexible mounting for the timing side power unit front support in its housing temporarily and secure it using the bolts and the nut.- Remove the hydraulic hoist and tool used for supporting the power unit.

Tool	Description	Function	Validity
1871001700	Balance	Removing-refitting power unit

1. Undo and remove the front Lambda sensor on the catalytic converter.2. Undo the bolts (2a) and remove the heat shield (2b). 1. Undo the nuts (1a) and remove the exhaust manifold and catalytic converter (1b).- Remove the gasket. 1. Undo the bolts (1a) and remove the injection/ignition system control unit (1b).

One of the bolts also secures the earth lead.

1. Undo the bolts (1a) and the nuts (1b) and remove the air chamber (1c) complete with throttle casing integrated with D.V.L. (1d).- Remove the seals. 1. Undo the bolts (1a) and (1b) fixing the cylinder head to the engine block.

The bolts (1b) are loosened first by 1/4 turn, then 1/2 a turn in the order illustrated in the diagram.

- Remove the cylinder head.

Two mechanics are needed for this operation.Take care to release the timing chain and the exhaust side camshaft drive pulley.

- Remove the cylinder head gasket. Refitting ( Removing ) - Clean any residues of gasket from the the cylinder head - engine block matching surfaces.- Carry out a visual inspection of the components:- Check that the planarity of the lower cylinder head plane is within the recommended values, if this is not the case, replace the cylinder head (the cylinder head lower plane cannot be reground).

Measurement	Value		Validity
Cylinder head lower surface flatness (mm)	0.05		1.82.2 16V

- Place the cylinder head gasket in position.

The gasket should be positioned with the word "TOP" facing upwards.

- Place the cylinder head in position.

Two mechanics are needed for this operation.- Check that the centering bushes are correctly positioned.Take care to raise the timing chain and the exhaust side camshaft drive pulley.

1. Tighten the new cylinder head fixing bolts to the recommended torque using the angular tightening tool.

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

Component	Fastening	dia	Value (daNm)	Validity
Cylinder head	Bolt (to be replaced)	M11 x 1.5	(engine crankcase side) 3.0 + 90° +60° +15°	2.2

Tool	Description	Function	Validity
1860942000	Torque wrench	Tighten bolts to torque plus angle

2. Tighten the new bolts securing the cylinder head to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Cylinder head	Timing side bolts (to replace)	M8 X 1.25	(engine crankcase side) 3.5	2.2

- Support the power unit using a hydraulic hoist and the tool connected to the mounting brackets.

Tool	Description	Function	Validity
1871001700	Balance	Removing-refitting power unit

- Tighten the bolts and the nut and remove the flexible mounting for the timing side power unit front support fitted temporarily.1. Tighten the upper bolt fixing the belt tensioner pad to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing fixed chain tensioner pad	Upper bolt	M6 x 1	(cylinder head side) 0.8	2.2

2. Place the access cap for the belt tensioner pad upper in its housing and tighten the fixing bolt to the recommended torque.

Replace the seal.

Component	Fastening	dia	Value (daNm)	Validity
Cap for timing fixed chain tensioner pad upper bolt	-	M22 x 1.5	6.5	2.2

- Remove the band used for fastening the timing chain to the exhaust side camshaft toothed drive pulley.1. Place the inlet side camshaft toothed drive pulley (1a) in its housing and secure it without tightening the new bolt (1b).2. Fit the camshaft timing tools.

Rotate the inlet side camshaft and insert the pin (2a) for the timing tool in the opening in the pulley.

Tool	Description	Function	Validity
2000000900	Template	Camshaft timing adjustment	2.2

3. If necessary, rotate the crankshaft until cylinder no. 4 is at T.D.C. during the explosion stroke; in this condition the reference (3a) on the inner part of the crankshaft pulley should be aligned with the reference (3b) on the timing chain cover.

Rotate the crankshaft slowly and evenly (in the direction of rotation of the engine).

Make sure that the timing chain is not stuck.

4. Fit the timing chain on the inlet side camshaft drive pulley.

The light blue mesh (4a) should be in line with the "INT" mark stamped on the inlet side camshaft drive pulley.

5. Place the exhaust side camshaft toothed drive pulley (5a) in its housing and secure it without tightening the new bolt (5b).

Rotate the exhaust side camshaft until the pink mesh (5c) is in line with the "EXH" mark on the exhaust side camshaft drive pulley.

- Retract the pin for the camshaft timing tool from the inlet side camshaft drive pulley. - The diagram illustrates the dismantling of the timing fixed hydraulic tensioner.

Replace the seals.

- Before it can be refitted the timing hydraulic tensioner must be pre-loaded as described below.1. Place the piston in a vice fitted with protective jaws.2. Insert the piston in the tensioner casing pressing it and rotating it as illustrated in the diagram until the pin (2a) is inserted in the notch (2b).3. Press and, at the same time, rotate the piston until the pin (3a) engages in the groove (3b).- Insert the piston assembled in this way in the tensioner casing. 1. Place the timing hydraulic tensioner in position and tighten it to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing fixed hydraulic tensioner	-	M27 x 2	7.5	2.2

1. Hydraulic tensioner in operating position.

Place the timing hydraulic tensioner in the operating position exerting manual pressure on the chain in the area shown in the diagram. This tensions the chain which, acting on the moving plate, allows the release of the moving tensioner piston.The operating spring is heard to make a "clack" noise when the tensioner piston is operated.

If the chain remains soft then the tensioner is not in the operating position.

- Rotate the crankshaft through 720°, then place cylinder no. 4 at T.D.C. during the explosion stroke; in this condition the reference on the inner part of the crankshaft pulley should be aligned with the reference on the timing chain cover.

When the crankshaft is rotated the tensioner piston should follow the chain during the rotation stage.

- Check the timing making sure that the tool pins coincide with the opening in the camshaft pullies.

If they are not aligned, fit the timing chain again no longer taking any notice of the coloured chain meshes as T.D.C. references.

- Remove the tool.

Tool	Description	Function	Validity
2000000900	Template	Camshaft timing adjustment	2.2

1. Place the timing chain upper plate (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing upper chain tensioner pad	Bolt (with thread-locking agent)	M6 x 1	(cylinder head side) 1.0	2.2

1. Tighten the new camshaft drive pulley fixing bolts to the recommended torque tightening the exhaust side pulley fixing bolt first.

Apply counter-torque to the camshafts.

Component	Fastening	dia	Value (daNm)	Validity
Camshaft toothed drive pullies	Bolt (to be replaced)	M12 x 1.75	(camshaft side) 8.5 + 30° + 15°	2.2

- Fit the spark plugs and tighten them to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Spark plugs	-	M14 x 1.25	(cylinder head side) 2.2	2.2

1. Place the timing power unit front support flexible mounting (1a) in its housing and secure it tightening the bolts (1b) and (1c) and the nut (1d) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support flexible mounting	Bolt	M10	(rigid support side) 5.0 - 6.0	1.82.21.9 JTD 16v1.9 JTD 8v

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support flexible mounting	Bolt	M10	(bodyshell side) 5.0 - 6.0

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support flexible mounting	Nut	M10	(bodyshell side) 5.0 - 6.0

- Remove the hydraulic hoist and tool used for supporting the power unit.

Tool	Description	Function	Validity
1871001700	Balance	Removing-refitting power unit

- Clean the contact surfaces- Place the new gaskets in their housings on the air chamber.1. Refit the air chamber (1a) complete with throttle casing integrated with D.V.L. (1b) back in its housing and secure it tightening the nuts (1c) and the bolts (1d) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Air chamber	Nut	M6 x 1	(cylinder head side) 0.9	2.2

Component	Fastening	dia	Value (daNm)	Validity
Air chamber	Bolt	M6 x 1	(cylinder head side) 0.9	2.2

1. Place the injection/ignition system control unit (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

One of the bolts also secures the earth lead (1c).

Component	Fastening	dia	Value (daNm)	Validity
Injection/ignition system control unit	Bolt	M6 x 1	(air chamber side) 0.9	2.2

- Place a new gasket back in position.1. Place the exhaust manifold (1a) in its housing and secure it by tightening the new nuts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Exhaust manifold with catalytic converter	Nut (to replace)	-	(cylinder head side) 2.0	1.82.2

1. Place the heat shield (1a) in its housing and secure it using the bolts (1b).2. Position the front Lambda sensor in its housing and tighten it to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Front Lambda sensor to catalytic converter	- (with special black grease)	M18 x 1.5	(exhaust manifold with catalytic converter side) 4.0	2.2

- Tighten the radiator coolant drain plug.    Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.- Remove the hydraulic hoist and tool used for supporting the power unit safely.

Tool	Description	Function	Validity
1871001700	Balance	Removing-refitting power unit

1. Tighten the coolant drain plug to the water pump to the recommended torque.

Apply sealant to the plug before fitting it.

Component	Fastening	dia	Value (daNm)	Validity
Drain plug on water pump	-	M20 x 1.5	(water pump side) 2.0	2.2

1. Place a new gasket in position.2. Connect the front section of the exhaust pipe (2a), exhaust manifold side with the catalytic converter and tighten the new nuts (2b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Rigid pipe for exhaust pipe between catalytic converter and silencer	Nut (to replace)	M8	(exhaust manifold with catalytic converter side) 1.6	2.2

    Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.    Op. 4450B04 RIGHT FRONT WHEEL - R.R- Connect the quick-release fitting for the brake servo vacuum intake pipe, air chamber side.- Place the fuel vapour recovery solenoid valve complete with pipes in its housing and secure it.- Connect the electrical connection to the fuel vapour recovery solenoid valve.- Connect the rapid connector for the fuel vapour recovery pipe, air chamber side.- Connect the intermediate rapid connector for the fuel vapour pipe.- Connect the radiator lower coolant inlet hose, cylinder head side, and tighten the band.- Tighten the bolt fixing the electrical wiring mounting bracket to the air chamber.- Place the engine oil dipstick pipe back in its housing and fasten it with the bolt.- Secure the electrical wiring to the fastenings on the engine oil dipstick tube.- Connect the electrical connection to the air pressure sensor.- Connect the electrical connection to the throttle casing with D.V.L.- Connect the electrical connections to the injectors, then place the fuel manifold pipe, complete with injectors, in its housing.- Tighten the bolts fixing the fuel manifold pipe to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Fuel manifold pipe	Bolt	M6 x 1	(cylinder head side) 0.9	2.2

- Connect the engine coupling.- Connect the electrical connections to the injection/ignition system control unit.- Connect the electrical connection to the air conditioning system multi-stage pressure switch.1. Place the tappet cover (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Replace the seals (1c).

Component	Fastening	dia	Value (daNm)	Validity
Tappet cover	Bolt	M6 x 1	(cylinder head side) 0.9	2.2

- Connect the earth loom to the tappet cover and secure it using the nut.- Connect the electrical connection for the radio interference condenser.- Refit the engine wiring- Fasten the gearbox side engine wiring mounting bracket.- Fasten the bolts securing the tappet cover side engine wiring brackets.- Fasten the timing side engine wiring brackets using the bolts.- Connect the electrical connection for the rear Lambda sensor to the catalytic converter.- Connect the electrical connection for the front Lambda sensor to the catalytic converter.- Place the coolant return pipe to the engine coolant reservoir in position and tighten the bands and the nut.1. Place the ignition coil module (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Ignition coil module	Bolt	M6 x 1	(tappet cover side) 0.9	2.2

2. Connect the electrical connection to the ignition coil module. 1. Place the fuel supply pipe (1a) in its housing, connect it and tighten the connector (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Front fuel supply pipe	Connector	-	(fuel manifold side) 1.0	2.2

- Place the air filter casing in its housing and secure it to the bodyshell using the three pins.- Connect the cold air intake to the air filter casing.- Fasten the fuel vapour pipe to the air filter casing using the band.- Fit the air filter filter element in place.- Fit the cover for the air filter, complete with air flow meter, and secure it using the bolts.- Connect the electrical connection to the air flow meter.- Place the air supply hose from the air flow meter to the throttle casing back in its housing and secure it using the bands.- Connect the engine oil vapour recovery pipe to the cylinder head cover and secure it using the band.- Place the sound insulation cover back in its housing and secure it to the engine using the three pins.- Connect the negative battery terminal.    Op. 0010T20 ENGINE COOLANT - CHANGE- Remove the vehicle from the lift.