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

Removing ( Refitting ) Position the vehicle on a lift.Disconnect the negative battery terminal.

	Description	Connector
-	Battery	See A001 BATTERY

    Op. 4450B04 RIGHT FRONT WHEEL - R.R.    Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R.    Op. 5530B10 BATTERY - R+R    Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R.    Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R.R.    Op. 1048A10 AIR FILTER ASSEMBLY - R.R.    Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R    Op. 1036G48 REAR SEAL FOR CAMSHAFT FOR ONE CAMSHAFT HOUSING, LEFT OR RIGHT - R.R. AND REPLACE SEAL    Op. 1072B50 AIR INTAKE CHAMBER - R.R.    Op. 1072B14 INLET MANIFOLD - R+R AND REPLACE SEAL WITH AIR CONVEYOR/BOX REMOVED    Op. 1080B94 FRONT LAMBDA SENSOR AT CATALYTIC CONVERTER - R.R.    Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD R+R1. Loosen the nut (1a) on the catalytic converter band, undo the bolts (1a) on the flange securing the catalytic converter.2. Undo the nuts fixing the catalytic converter to the exhaust manifold. 1. Raise the lift and undo the bolts (1a) fixing the lower heat shield bracket (1b) and remove it.2. Disconnect the electrical connection for the rear Lambda sensor and move the catalytic converter away from the exhaust manifold.

	Description	Connector
2	Lambda sensor on catalyzer	See K17 LAMBDA SENSOR ON CATALYZER ( ENGINE )

    Op. 1088B10 ENGINE COOLING SUPPLY RESERVOIR - R.R.    Op. 4130B10 POWER STEERING FLUID RESEVOIR - R.R.1. Disconnect the electrical connection for the engine coolant temperature sensor.

	Description	Connector
1	I.E. engine temperature sensor	See K45 COOLANT TEMPERATURE SENDER UNIT ( ENGINE )

2. Disconnect the radiator coolant supply and return pipe from the thermostat, then drain any remaining coolant into the special container.3. Disconnect the supply reservoir coolant return pipe from the thermostat.4. Disconnect the passenger compartment heater coolant supply pipe from the thermostat.5. Disconnect the heater coolant return pipe from the thermostat.     Op. 1092B50 ALTERNATOR/WATER PUMP DRIVE BELT - R.R.    Op. 1092B82 AUXILARY BELT MOVING TENSIONER (ONE) -R+R    Op. 1092A10 CRANKSHAFT PULLEY - R + R    Op. 1008b10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE    Op. 1008a46 TIMING SIDE POWER UNIT RIGID SUPPORT - R.R.    Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R    Op. 5510C14 IGNITION COIL/S - R+R    Op. 5510D10 SPARK PLUGS - R+R    Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT    Op. 1032C30 FIXED TIMING SYSTEM TENSIONER - R + R WITH TIMING BELT REMOVED    Op. 1032B40 TOOTHED DRIVEN PULLEY (ONE) - R + R WITH TIMING BELT REMOVED1. Undo the bolts (1a) and remove the timing belt upper rear guard (1b).     Op. 1016B26 RIGHT CAMSHAFT HOUSING - R.R. WITH TIMING BELT REMOVED - REPLACE GASKET    Op. 1016B22 LEFT CAMSHAFT HOUSING - R.R. WITH TIMING BELT REMOVED - REPLACE GASKET1. Using the tool (1a), loosen the bolts (1b) fixing the cylinder head to the cylinder block/crankcase.

	Description	Code
1a	Spanner	1.852.157.000

2. Disconnect the electrical connection for the timing sensor.

	Description	Connector
2	Timing sensor	See K47 TIMING SENSOR ( ENGINE )

Position a hydraulic jack beneath the engine block.Release the rod for the crossmember positioned for supporting the engine, then remove the actual crossmember. This operation is necessary to allow the extraction of the reinforcement bracket for the power assisted steering pump on the exhaust manifold.    Op. 1092C10 POWER STEERING AND/OR SELF-LEVELLING SUSPENSION PUMP DRIVE BELT - R + R1. Undo the nuts (1a) fixing the reinforcement bracket to the exhaust manifold and undo the nut (1b) fixing it to the power steering pump mounting.2. Remove the reinforcement bracket from the engine compartment. Remove the engine supporting crossmember.

	Description	Code
-	Crossmember	1.870.595.000

1. Insert a spacer (1a) on the power steering pump support (1b), then secure the crossmember rod (1c) to the mounting (1d). 1. Position an ordinary spacer (1a) between the support for the power steering pump (1b) and the bracket (1c) on the alternator (1d). This operation is necessary to prevent the power steering pump support from rotating resulting in the unbalancing of the engine during the final removal operations of the cylinder head.Remove the lift from underneath the vehicle. 1. Remove the bolts (1a) loosened previously, then remove the head (1b).2. Remove the underlying gasket. Refitting ( Removing ) Clean the contact surfaces between the cylinder head and engine block.Fit a new cylinder head gasket with the word ALTO stamped on it facing the operator.

The cylinder head gasket is the Astadur type. The material from which the gasket is made undergoes a polymerization process during the operation of the engine so that it becomes considerably harder during usage. In order for the polymerization process to take place, it is necessary to:keep the gasket sealed in its casing until it is fittednot lubricate the gasket or the contact surfaces with oil.

Place the cylinder head in position.Tighten all the bolts fixing the cylinder head.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.

	Fastening	Component	dia	Value(daNm)
1a	Bolt	CYLINDER HEAD	M10	(Engine crankcase side) 4 +90° ++90°

	Description	Code
1b	Torque wrench	1.860.942.000

Position the hydraulic lift underneath the vehicle.Remove the general shim positioned previously between the power steering pump support and the alternator.Release the rod for the engine supporting crossmember from the mounting and remove the spacer on the power steering pump support.Position the reinforcement bracket on the exhaust manifold and tighten the fixing nuts to the recommended torque.

	Fastening	Component	dia	Value(daNm)
-	Nut	POWER STEERING PUMP SUPPORT/BRACKET	M10 X 1.25	(Cylinder head) 5

Connect the rod for the engine supporting crossmember to the mounting on the power steering pump support.    Op. 1092C10 POWER STEERING AND/OR SELF-LEVELLING SUSPENSION PUMP DRIVE BELT - R + R    Op. 1092C12 POWER STEERING PUMP DRIVE BELT - ADJUST TENSIONConnect the electrical connection for the timing sensor.

	Description	Connector
-	Timing sensor	See K47 TIMING SENSOR ( ENGINE )

    Op. 1016B22 LEFT CAMSHAFT HOUSING - R.R. WITH TIMING BELT REMOVED - REPLACE GASKET    Op. 1016B26 RIGHT CAMSHAFT HOUSING - R.R. WITH TIMING BELT REMOVED - REPLACE GASKETPosition the upper rear guard for the timing belt and tighten the fixing bolts to the recommended torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	TIMING GUARD ASSEMBLIES	M6x16	(Camshaft housing) 0.9

	Fastening	Component	dia	Value(daNm)
-	Bolt	TIMING GUARD ASSEMBLIES	M8 X 22	(Camshaft housing) 2.5

	Fastening	Component	dia	Value(daNm)
-	Bolt	TIMING GUARD ASSEMBLIES	M10 X 1.25	(Camshaft housing) 5

    Op. 1032B40 TOOTHED DRIVEN PULLEY (ONE) - R + R WITH TIMING BELT REMOVED    Op. 1032C30 FIXED TIMING SYSTEM TENSIONER - R + R WITH TIMING BELT REMOVED    Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT    Op. 5510D10 SPARK PLUGS - R+R    Op. 5510C14 IGNITION COIL/S - R+R    Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R    Op. 1008a46 TIMING SIDE POWER UNIT RIGID SUPPORT - R.R.    Op. 1008b10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE    Op. 1092A10 CRANKSHAFT PULLEY - R + R    Op. 1092B82 AUXILARY BELT MOVING TENSIONER (ONE) -R+R    Op. 1092B50 ALTERNATOR/WATER PUMP DRIVE BELT - R.R.    Op. 1092B54 ALTERNATOR/WATER PUMP DRIVE BELT - ADJUST TENSIONConnect the heater coolant return pipe to the thermostat.Connect the heater coolant supply pipe to the thermostat.Connect the supply reservoir coolant return pipe to the thermostat.Connect the radiator coolant supply and return pipe to the thermostat.Connect the electrical connection for the engine coolant temperature sensor.

	Description	Connector
-	I.E. engine temperature sensor	See K45 COOLANT TEMPERATURE SENDER UNIT ( ENGINE )

    Op. 4130B10 POWER STEERING FLUID RESEVOIR - R.R.    Op. 1088B10 ENGINE COOLING SUPPLY RESERVOIR - R.R.Raise the lift and place the catalytic converter in its original position moving it closer to the exhaust manifold.Connect the electrical connection for the rear Lambda sensor.

	Description	Connector
-	Lambda sensor on catalyzer	See K17 LAMBDA SENSOR ON CATALYZER ( ENGINE )

Position the lower heat shield bracket and tighten the fixing bolts.Lower the lift and tighten the nuts fixing the catalytic converter to the exhaust manifold to the recommended torque.

	Fastening	Component	dia	Value(daNm)
-	Nut	EXHAUST MANIFOLD/S	M8	(Catalytic converter) 2.5

Tighten the bolts fixing the catalytic converter to the retaining flange to the recommended torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	EXHAUST MANIFOLD/S	M8	(Catalytic converter) 3

Tighten the nut on the catalytic converter retaining band.    Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD R+R    Op. 1080B94 FRONT LAMBDA SENSOR AT CATALYTIC CONVERTER - R.R.    Op. 1072B14 INLET MANIFOLD - R+R AND REPLACE SEAL WITH AIR CONVEYOR/BOX REMOVED    Op. 1072B50 AIR INTAKE CHAMBER - R.R.    Op. 1036G48 REAR SEAL FOR CAMSHAFT FOR ONE CAMSHAFT HOUSING, LEFT OR RIGHT - R.R. AND REPLACE SEAL    Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R    Op. 1048A10 AIR FILTER ASSEMBLY - R.R.    Op. 1048A32 HOSE FROM AIR FILTER TO INTAKE MANIFOLD - R.R.    Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R.    Op. 5530B10 BATTERY - R+R    Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R.    Op. 4450B04 RIGHT FRONT WHEEL - R.R.    Op. 0010T20 ENGINE COOLANT - CHANGE    Op. 0010T71 POWER STEERING FLUID CHECK LEVEL AND TOP UP IF NECESSARYConnect the negative battery terminal.

	Description	Connector
-	Battery	See A001 BATTERY

Remove the vehicle from the lift.