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

198000228 - 1016C10 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET

) Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 7055B65 ENGINE COMPARTMENT DUST COVER IN LEFT FRONT WHEEL ARCH - R.R. Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. Op. 0010T20 ENGINE COOLANT - CHANGE Op. 1092G10 SINGLE ENGINE BELT - R.R Op. 1016A10 SOUND-PROOFING COVER - R.R Op. 1092A10 CRANKSHAFT PULLEY - R + R Op. 1032D26 TIMING SYSTEM FRONT PROTECTIVE COVER (UPPER PART) - R.R. Op. 1032D27 TIMING SYSTEM FRONT PROTECTIVE COVER (LOWER PART) - R.R. Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT Op. 1060E30 PRESSURE PUMP DRIVE PULLEY - R.R. Op. 1060F50 FUEL RETURN MANIFOLD - R.R. Op. 1060E10 DIESEL INJECTION PRESSURE PUMP - R.R. - Move the alternator away from the engine block with reference to Op. 5530A10 ALTERNATOR - R+R Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE Op. 1060E40 PRESSURE PUMP SUPPORT - R.R. Op. 1076B20 REAR EXHAUST SILENCER - R + R - For versions with DPF only: Op. 1080B81 PARTICULATE FILTER (D.P.F.) - R.R.- For versions without DPF only: Op. 1080B62 CATALYTIC CONVERTER - R + R Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R Op. 1048A41 HOSE FROM FLOW METER TO TURBOCHARGER - R.R. Op. 1080C83 EXHAUST GAS INLET PIPING FROM EXHAUST MANIFOLD TO HEAT EXCHANGER EGR - R R Op. 1048B19 TURBOCHARGER AIR OUTLET HOSE -R.R. Op. 1064A27 PIPE BETWEEN VACUUM RESERVOIR AND ACTUATOR CONTROL SOLENOID VALVE - R.R. Op. 1048A10 AIR FILTER ASSEMBLY - R.R. Op. 1048B27 RIGID PIPE FOR AIR INLET TO THROTTLE BODY - R R 1. Disconnect the hoses (1a) from the water pump rigid water return pipe and the pipe (1b) from the heat exchanger rigid water pipe.

1. Disconnect the engine oil vapour recovery pipes (1a) and (1b) from the tappet cover.2. Loosen the band and disconnect the vacuum pipe from the vacuum unit.3. Loosen the band and disconnect the radiator coolant supply hose, thermostat side.

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

	Description	Connector
2	Engine coolant temperature sensor/sender unit	See K036 ENGINE COOLANT TEMPERATURE SENSOR/SENDER UNIT

3. Disconnect the vacuum pipe for the vacuum reservoir, brake servo vacuum pipe side.

1. Disconnect the electrical connections for the injectors and open the wiring retaining clips.

	Description	Connector
1	Injector	See N070 INJECTOR

2. Undo the bolts fixing the wiring duct to the intake chamber.

1. Disconnect the electrical connection for the E.G.R. solenoid valve.

	Description	Connector
1	EGR solenoid valve	See L030 EGR SOLENOID VALVE

2. Disconnect the electrical connection for the excess pressure sensor.

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

1. Detach the fuel pressure sensor electrical connection.

	Description	Connector
1	Fuel pressure sensor	See K083 FUEL PRESSURE SENSOR

1. Undo nut (1a), remove the glow plug preheating control unit (1b) and disconnect electrical connection (1c).

	Description	Connector
1	Heater plugs control unit	See M015 PLUG PREHEATING CONTROL UNIT

- Move the engine wiring aside.1. Undo the bolts fixing the cam cover to the cylinder head.2. Remove the tappet cover.3. Undo the fixing bolts (3a) and remove the side timing belt guard (3b).

- Draw off the engine oil from the chambers in the cylinder head.1. Loosen the bolts fixing the cylinder head.2. Position a bracket (2a) to be connected to the hook (2b) for the removal of the cylinder.3. Position a second hook on the intake manifold.- Secure the chains to the hydraulic lift using the tool.

Tool	Description	Function	Validity
1871001700	Balance	Removing/ refitting power unit

4. Lift and remove the cylinder head, complete with intake manifold.- Keep the cylinder head gasket from the cylinder block.

- To check the flatness of the lower cylinder head surface and grind if necessary, refer to Op. 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

Refitting ( Removing

) - Measure the projection of the pistons to select the correct size cylinder head gasket with reference to Op. 1004E20 ENGINE - DISMANTLE AND REASSEMBLE FOLLOWING OPERATION 1004E10 - WASH AND CHECK DISMANTLED PARTS - REFIT CYLINDER HEAD AND OIL SUMP - DOES NOT INCLUDE REPAIRS TO CYLINDER HEAD AND AUXILIARY UNIT - Place the cylinder head centering bushes on the cylinder block.- Refit the new cylinder head gasket in its seat. - Position the cylinder head on the cylinder block/crankcase.- Remove the lifting tools.1. Tighten the bolts fixing the cylinder head to the cylinder block to the recommended torque following the order illustrated.

Component	Fastening	dia	Value (daNm)	Validity
Cylinder head	Bolt	M12	6.2 ÷ 6.8 + 90° + 90° + 90°	1.9 JTD

- Place the tappet cover in position on the cylinder head and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Tappet cover	Bolt	M6	0.8 ÷ 1.0

- Position the engine wiring and secure it to the intake manifold tightening the fixing bolts.- Connect the electrical connection to the heater plugs control unit.- Place the heater plugs control unit in position and tighten the nut.- Connect the electrical connection for the excess pressure sensor.- Connect the electrical connection for the E.G.R. solenoid valve.- Secure the electrical connection for the fuel pressure sensor.- Secure the electrical connections for the injectors.- Connect the vacuum pipe for the vacuum reservoir, brake servo vacuum pipe side.- Connect the electrical connection for the engine coolant temperature sensor.- Connect the two supply and return pipes to the heater, thermostat side.- Connect the radiator coolant supply hose, thermostat side, and tighten the band.- Connect the vacuum pipe to the vacuum unit and tighten the band.- Connect the two engine oil vapour recovery pipes to the tappet cover.- Connect the return hoses from the radiator and engine oil heat exchanger to the water rigid return pipe.- Connect the flexible pipe to the engine oil heat exchanger rigid water pipe and secure it using the band. Op. 1048B27 RIGID PIPE FOR AIR INLET TO THROTTLE BODY - R R Op. 1048A10 AIR FILTER ASSEMBLY - R.R. Op. 1064A27 PIPE BETWEEN VACUUM RESERVOIR AND ACTUATOR CONTROL SOLENOID VALVE - R.R. Op. 1048B19 TURBOCHARGER AIR OUTLET HOSE -R.R. Op. 1080C83 EXHAUST GAS INLET PIPING FROM EXHAUST MANIFOLD TO HEAT EXCHANGER EGR - R R Op. 1048A41 HOSE FROM FLOW METER TO TURBOCHARGER - R.R. Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD - R+R Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R - For versions without DPF only: Op. 1080B62 CATALYTIC CONVERTER - R + R - For versions with DPF only: Op. 1080B81 PARTICULATE FILTER (D.P.F.) - R.R. Op. 1076B20 REAR EXHAUST SILENCER - R + R Op. 1060E40 PRESSURE PUMP SUPPORT - R.R. Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE - Place the alternator in position and secure it to the mounting with reference to Op. 5530A10 ALTERNATOR - R+R Op. 1060E10 DIESEL INJECTION PRESSURE PUMP - R.R. Op. 1060F50 FUEL RETURN MANIFOLD - R.R. Op. 1060E30 PRESSURE PUMP DRIVE PULLEY - R.R. Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT Op. 1032D27 TIMING SYSTEM FRONT PROTECTIVE COVER (LOWER PART) - R.R. Op. 1032D26 TIMING SYSTEM FRONT PROTECTIVE COVER (UPPER PART) - R.R. Op. 1092A10 CRANKSHAFT PULLEY - R + R Op. 1092G10 SINGLE ENGINE BELT - R.R Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R. Op. 7055B65 ENGINE COMPARTMENT DUST COVER IN LEFT FRONT WHEEL ARCH - R.R. Op. 4450B12 FRONT WHEELS (TWO) - R+R Op. 0010T20 ENGINE COOLANT - CHANGE Op. 1016A10 SOUND-PROOFING COVER - R.R