1016C10 CYLINDER HEAD - R + R AND REPLACE GASKET - Fiat - DOBLO - eLearn

2584167 - 1016C10 cylinder head - r + r and replace gasket

) Position the vehicle on a lift.Drain the air conditioning refrigerant circuit Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND RECHARGE.Carry out Op. 4450B04 RIGHT FRONT WHEEL - R.R..Carry out Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R..Carry out .Carry out Op. 5530B10 BATTERY - R+R.Carry out Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R..Carry out Op. 1060G90 SYSTEM CABLE LOOM - R.R..Carry out Op. 0010T20 ENGINE COOLANT - CHANGE.Carry out Op. 1016B10 SINGLE CAMSHAFT HOUSING - REPLACE GASKET.1. Loosen the band and disconnect the upper radiator coolant inlet hose, thermostat side.

Collect the coolant that comes out in a suitable container.

2. Loosen the band and disconnect the oil vapour recircuation hose from the rigid pipe.3. Loosen the band and remove the air intake pipe to the turbocharger.4. Loosen the collar securing the coolant supply pipe to the engine oil heat exchanger, thermostat side.

1. Loosen the collar and disconnect the pipe from the heat exchanger to the air capacity chamber, chamber side.2. Loosen the collar and disconnect the pipe carrying coolant to the climate control system heater, on the EGR system exhaust gas/water heat changer side.

1. Undo retaining bolt (1a) and remove the engine oil dipstick tube (1b).

1. Undo the bolts (1a) and remove the exhaust manifold heat shield (1b) complete with engine lifting bracket (1c).2. Undo the bolt securing the engine oil heat exchanger coolant supply pipe to the engine block.3. Undo the bolts (3a) and remove the engine oil heat exchanger coolant supply pipe (3b) complete with gasket (3c).4. Undo the connectors (4a) and remove the turbocharger engine oil supply pipe (4b).

1. Loosen the collar and disconnect the condensed engine oil recovery pipe, oil vapour separator side.

1. Loosen the bands (1a) and disconnect the coolant outlet and inlet pipes (1b) from the climate control system heater.

1. Unscrew the bolt securing the water/exhaust gas heat exchanger for the EGR to the crankcase.

1. Working through the hole in the camshaft cover, unscrew the bolt securing the pad fastening the timing chain to the cylinder head.2. Undo the bolts fixing the timing cover to the cylinder head.

1. Undo the nuts fixing the turbocharger to the exhaust manifold.

1. Undo the bolts (1a) and disconnect the air supply pipe between the turbocharger and the heat exchanger (1b), turbocharger side.2. Remove the gasket.3. Undo the bolts securing the engine oil return pipe from the turbocharger, crankcase side.

1. Undo the nut (1a) and loosen the collar securing the exhaust pipe to the catalyzer (1b).2. Release the exhaust pipe from the flexible mountings and disconnect the pipe from the catalyzer.

1. Do not distort the front flexible pipe beyond the angular value of X = 20° and the cutting value of Y = 25 mm.

The front hose must be protected against any mechanical damage from outside. It should not come into contact with corrosive products; the front flexible pipe cannot withstand any distortion when it is in position.

Failure to follow these precautions will result in the shortening of the life of the flexible pipe; separation or dismantling the exhaust line is compulsory for operations that require the power unit to be raised.

1. Undo the bolt fixing the catalytic converter mounting bracket to the manual gearbox/engine bracket.2. Remove the turbocharger (2a) complete with catalytic converter (2b).

1. Undo the bolts (1a) and remove the cylinder head assembly (1b).2. Remove the cylinder head gasket.

Refitting ( Removing

) 1. Measure the piston projection in two places at 180° on the gudgeon pin axis using the gauge and support and take the average of the two values measured for each piston.

	Description	Code
1	Dial gauge support	1.870.404.001

Select the correct size cylinder head gasket depending on the maximum value between of the averages of the projection for each individual piston.

	Measurement		Value
-	Cylinder head gasket size (no hole) (mm)		0.67 ÷ 0.77
	Average - maximum piston projection (mm)	0.028 ÷ 0.127

	Measurement		Value
-	Cylinder head gasket size (no hole) (mm)		0.77 ÷ 0.87
	Average - maximum piston projection (mm)	0.128 ÷ 0.227

	Measurement		Value
-	Cylinder head gasket size (no hole) (mm)		0.87 ÷ 0.97
	Average - maximum piston projection (mm)	0.228 ÷ 0.327

1. Apply Fiat silicon sealant 71713687 or a similar product to the contact area between the cylinder head and the timing cover.2. Position the cylinder head gasket (2a) ofn the thickness selected previously and fit onto the locating bushes (2b).3. Apply Fiat 71713687 type silicon sealant or a similar product to cylinder head gasket in the contact area with the timing cover.4. Also apply a strip of the same sealant to the surface of the timing cover gasket following the black line of silicon on the actual gasket.

Apply a thin layer of sealant to the timing cover gasket so that it is not too thick and avoid excess sealant inside the timing cover.

Position the cylinder head on the engine block, fitting into the locating bushes.

Before moving the cylinder head, apply grease to the belt tensioner piston to prevent it emerging accidentally during moving.

1. Screw in and tighten the bolts fixing the timing cover to the cylinder head to torque.

During this stage, do not tighten the bolt into hole (a).

	Fastening	Component	dia	Value(daNm)
1	Bolt	TIMING COVER	M6	0.8 ÷ 1.0

Position the cylinder head bolts in their seats and screw in partly without tightening.1. Tighten only the two bolts shown in the figure securing the cylinder head to the engine block to the specified torque of 2.5 daNm.2. Loosen the bolts fixing the timing cover tightened previously.3. Continue tightening the bolts fixing the camshaft housing to a torque of 2.5 daNm following the order illustrated working gradually towards the timing cover.

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

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

The nominal tightening of 4.0 daNm is performed in two stages: a pretightening to 2.0 daNm followed by an additional tightening of 2.0 daNm.

	Fastening	Component	dia	Value(daNm)
1a	Bolt	CYLINDER HEAD	M10	(Engine crankcase side) 3.8 - 4.2 +90 + 90?

	Description	Code
1b	Torque wrench	1.860.942.000

1. Insert the third bolt securing the timing cover to the cylinder head, then tighten the three bolts securing the timing cover to the cylinder head to the specified torque.

	Fastening	Component	dia	Value(daNm)
1	Bolt	TIMING COVER	M6	0.8 ÷ 1.0

The misalignment between the cylinder head - crankcase should not exceed the recommended value.

It is only possible for the cylinder head to protrude from the crankcase.

	Measurement		Value
-	Cylinder head - crankcase misalignment (mm)		0.1

Refit the turbocharger complete with catalytic converter.Tighten the bolt fixing the catalytic converter mounting bracket to the manual gearbox/engine bracket.Connect the exhaust pipe to the catalyzer, taking care not to distort the flexible section.Tighten the nut for the collar securing the pipe to the catalytic converter.Position the flexible mountings at the exhaust pipe securing points.Position a new gasket between the crankcase and the engine oil return pipe to the turbocharger.1. Tighten the bolts securing the engine oil return pipe from the turbocharger, crankcase side, to the specified torque.

	Fastening	Component	dia	Value(daNm)
1	Bolt	OIL RETURN PIPE FROM TURBO	M6	(Turbocharger/ngine crankcase side) 0.8 - 1.0

2. Connect the air delivery pipe between the turbocharger and heat exchanger (2a) complete with gasket (2b), turbocharger side, and secure with bolts (2c).

1. Tighten the nuts fixing the turbocharger to the exhaust manifold to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1	Nut	TURBOCHARGER	M8	(Exhaust manifold side) 2.3 - 2.8

Tighten the bolt securing the timing belt fixed pad to the cylinder head.Tighten the bolt securing the water/exhaust gas heat exchanger for the EGR to the crankcase.Connect the coolant outlet and inlet pipes to the climate control system heater and tighten the collars.Connect the condensed engine oil recovery pipe, oil vapour separator side, and tighten the collar.Position the pipe carrying engine oil to the turbocharger in its housing and secure it tightening connectors to the recommended torque.

Replace the copper washers on the connectors.

	Fastening	Component	dia	Value(daNm)
-	Connector	OIL DELIVERY PIPE TO TURBO	M10	(Turbocharger/oil filter mount side) 1.1 - 1.3

Reposition the pipe carrying coolant to the engine oil heat exchanger complete with gasket, then tighten the collar and bolts.Tighten the bolt securing the pipe carrying coolant to the engine oil heat exchanger to the crankcase.Refit the exhaust manifold heat shield with the engine lift bracket and secure with the nuts.Place the engine oil dipstick pipe back in its housing and fasten it with the bolt.Connect the pipe carrying coolant to the climate control system heater, on the EGR system exhaust gas/water heat changer side and tighten the collar.Connect the pipe from the heat exchanger to the air capacity chamber, chamber side, and tighten the band.Refit the air intake pipe to the turbocharger and tighten the collar.Connect the oil vapour recirculation hose to the rigid pipe and tighten the collar.Connect the upper coolant input sleeve to the radiator, thermostat side, and tighten the band.Carry out Op. 1016B10 SINGLE CAMSHAFT HOUSING - REPLACE GASKET.Carry out Op. 1060G90 SYSTEM CABLE LOOM - R.R..Carry out Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R..Carry out Op. 5530B10 BATTERY - R+R.Refill the engine cooling system Op. 0010T20 ENGINE COOLANT - CHANGE.Carry out .Carry out Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R..Carry out Op. 4450B04 RIGHT FRONT WHEEL - R.R..Refill the air conditioning refrigerant circuit Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM - DEHYDRATE AND RECHARGE.Remove the vehicle from the lift.