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

Removing ( Refitting )     Op. 4450B12 FRONT WHEELS (TWO) - R+R     Op. 1016A10 SOUND-PROOFING COVER - R.R     Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.     Op. 0010T20 ENGINE COOLANT - CHANGE     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. 1092G10 SINGLE ENGINE BELT - R.R     Op. 1092A10 CRANKSHAFT PULLEY - R + R     Op. 1092G14 ENGINE COMPONENT SINGLE BELT MOVING TENSIONER - R + R     Op. 1092G20 ENGINE COMPONENT SINGLE BELT FIXED TENSIONER - R + R     Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R     Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT     Op. 1060F36 PIPES (ALL) FROM FUEL MANIFOLD TO INJECTOR - R.R.     Op. 1060F10 FUEL INJECTORS - R.R.     Op. 1060F20 PIPE FROM PRESSURE PUMP TO FUEL MANIFOLD - R.R.     Op. 1060F52 FUEL RETURN PIPE FROM INJECTORS - R.R.     Op. 1060F30 SINGLE FUEL MANIFOLD PIPE - R.R.     Op. 1016B10 SINGLE CAMSHAFT HOUSING - REPLACE GASKET     Op. 1036H55 HYDRAULIC TAPPET (ONE) - REPLACE WITH CAMSHAFT HOUSING REMOVED    Op. 1076B20 REAR EXHAUST SILENCER - 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. 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    Op. 1080C24 E.G.R. SYSTEM SOLENOID - R + R     Op. 1080D34 ENGINE OIL VAPOUR SEPARATOR - R + R 1. Loosen the band and disconnect the flexible coolant supply pipe to the engine oil heat exchanger, water pump return pipe side.2. Loosen the band and disconnect the water outlet hose from the radiator, water pump return pipe side.3. Loosen the band and disconnect the flexible coolant return pipe to the engine oil heat exchanger, water pump return pipe side. 1. Loosen the band and disconnect the radiator coolant supply hose, thermostat side.2. Loosen the band and disconnect the water return pipe to the heater, water pump rigid return pipe side. 1. Loosen the band and disconnect the water supply pipe to the heater, thermostat side.2. Disconnect the vacuum pipe from the throttle casing actuator. 1. Detach the swirl actuator electrical connection.

	Description	Connector
1	Flow modifier solenoid valve	See L064 FLOW MODIFYING SOLENOID VALVE

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.- Remove the gasket. 1. Position the cylinder head (1a) in a vice using the tool (1b).

Tool	Description	Function	Validity
1860470000	Mount	Overhaul cylinder head

1. Loosen the band and disconnect the flexible degassing pipe from the rigid pipe.2. Undo the nuts (2a) and remove the intake chamber assembly (2b). 1. Undo the heater plugs (1a) and remove them using the special tool (1b).

Tool	Description	Function	Validity
2000003200	Spanner	Removing/refitting glow heater plugs	1.9 JTD 16v

1. Loosen the band and disconnect the flexible supply pipe to the engine oil heat exchanger.2. Undo the bolts (2a) and remove the water pump rigid return pipe (2b) complete with gasket. 1. Loosen the band and disconnect the water supply pipe to the E.G.R. heat exchanger.2. Undo the bolts (2a) and remove the thermostat (2b) complete with O-ring. 1. Undo bolts (1a) and remove exhaust gas heat exchanger assembly for the E.G.R. system (1b). 1. Undo the bolts (1a) and remove the coolant pump (1b) complete with gasket. Refitting ( Removing ) - Clean any residues of the old gasket from the lower cylinder head plane.- Check that the planarity of the lower cylinder head plane corresponds to the recommended values.

Measurement	Value	Validity
Engine cylinder head lower surface flatness (mm)	< 0.1

- If the planarity of the lower cylinder head plane does not correspond to the recommended figures, regrind it without exceeding the minimum permitted height.

Measurement	Value	Validity
Cylinder head lower plane minimum permitted height (mm)	107 +/- 0.05	1.9 JTD 16v

- Refit the water pump, complete with new gasket, in its housing and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Water pump	Bolt	M8	2.3 ÷ 2.8	1.9 JTD

- Place the exhaust gas heat exchanger for the E.G.R. system back in its housing and secure it by tightening the bolts to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
E.G.R. exhaust gas heat exchanger	Bolt	M8	2.3 ÷ 2.8	1.9 JTD

- Place the thermostat in its housing with the new O-ring and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Thermostat	Bolt	M8	2.3 ÷ 2.8	1.9 JTD

- Connect the water supply pipe to to the E.G.R. heat exchanger and tighten the band.- Place the water pump rigid return pipe, complete with new gasket, in position and tighten the bolts.- Connect the flexible water supply pipe to the engine oil heat exchanger and tighten the band.- Refit the heater plugs using the tool and tighten them to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Glow heater plug	-	M9	0.7 ÷ 0.9	1.9 JTD 16v

Tool	Description	Function	Validity
2000003200	Spanner	Removing/refitting glow heater plugs	1.9 JTD 16v

- Replace the intake chamber in its housing and secure it by tightening the nuts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Air chamber	Nut	M8	2.3 ÷ 2.8	1.9 JTD

- Connect the flexible degassing pipe to the rigid pipe and tighten the band.- Remove the cylinder head from the vice and from the tool.1. Position the cylinder head locating bushes on the crankcase as shown in the figure.

The locating bushes between the crankcase and cylinder head are shorter (12.5 mm) than the bushes between the cylinder head and the camshaft housing (16.0 mm); take great care not to reverse them as this could impair engine operation.

- Fit a new cylinder head gasket in position.

If the cylinder head has to be refaced, use a new cylinder head gasket that is the same size as the one removed. If the cylinder head required levelling, calculate the thickness of the new cylinder head to be used (see operation 1004E20).

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 crankcase.

Do not reuse the cylinder head bolts because they undergo permanent lengthening whenever they are tightened so they must be replaced.

1. Tighten the bolts securing the cylinder head to the recommended torque.

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

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

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

Component	Fastening	dia	Value (daNm)	Validity
Pressure pump support	Bolt (to be replaced)	M8	2.3 ÷ 2.8	1.9 JTD

- Connect the swirl actuator electrical connection.- Connect the vacuum pipe to the throttle casing actuator.- Connect the supply pipe to the heater, thermostat side and tighten the band.- Connect the water return pipe to the heater, water pump rigid return pipe side and tighten the band.- Connect the supply hose to the radiator, thermostat side, and tighten the band.- Connect the flexible coolant return pipe to the engine oil heat exchanger, water pump return pipe side and tighten the band.- Connect the water outlet hose to the radiator, water pump return pipe side and tighten the band.- Connect the flexible coolant supply pipe to the engine oil heat exchanger, water pump return pipe side and tighten the band.     Op. 1080D34 ENGINE OIL VAPOUR SEPARATOR - R + R     Op. 1080C24 E.G.R. SYSTEM SOLENOID - R + R     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 with DPF only:    Op. 1080B81 PARTICULATE FILTER (D.P.F.) - R.R.- For versions without DPF only:    Op. 1080B62 CATALYTIC CONVERTER - R + R     Op. 1076B20 REAR EXHAUST SILENCER - R + R     Op. 1036H55 HYDRAULIC TAPPET (ONE) - REPLACE WITH CAMSHAFT HOUSING REMOVED    Op. 1016B10 SINGLE CAMSHAFT HOUSING - REPLACE GASKET     Op. 1060F30 SINGLE FUEL MANIFOLD PIPE - R.R.     Op. 1060F52 FUEL RETURN PIPE FROM INJECTORS - R.R.     Op. 1060F20 PIPE FROM PRESSURE PUMP TO FUEL MANIFOLD - R.R.     Op. 1060F10 FUEL INJECTORS - R.R.     Op. 1060F36 PIPES (ALL) FROM FUEL MANIFOLD TO INJECTOR - R.R.     Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT     Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R     Op. 1092G20 ENGINE COMPONENT SINGLE BELT FIXED TENSIONER - R + R     Op. 1092G14 ENGINE COMPONENT SINGLE BELT MOVING TENSIONER - R + R     Op. 1092A10 CRANKSHAFT PULLEY - R + R     Op. 1092G10 SINGLE ENGINE BELT - 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. 0010T20 ENGINE COOLANT - CHANGE     Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.     Op. 1016A10 SOUND-PROOFING COVER - R.R     Op. 4450B12 FRONT WHEELS (TWO) - R+R