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. Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R. Op. 1048A10 AIR FILTER ASSEMBLY - R.R. Op. 4450B04 RIGHT FRONT WHEEL - R.R. Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R. Op. 1016A22 CAM COVER WITH FUEL DUCT - R + R AND REPLACE GASKETHave a suitable container for collecting the coolant ready.1. Disconnect the lower engine pipe from the radiator (1a), from the thermostat (1b) and from the connector (1c) on the rigid section of the pump water filler pipe.2. Remove the lower pipe from the engine compartment.

1. Disconnect the upper engine pipe from the radiator (1a) and from the thermostat (1b).2. Remove the upper pipe from the engine compartment.Then remove the container used for collecting the engine coolant.

1. Disconnect the pipe (1a) and the heater unit water supply and return pipe (1b) from the thermostat.

1. Disconnect the two fuel supply and return pipes (1a) and (1b) from the injection pump.2. Also disconnect the recirculation pipe from the return pipe.3. Undo the retaining bolts.4. Loosen the bands (4a) and disconnect the flexible pipes (4b) from the thermostat and from the intake manifold.5. Remove the rigid pipe.6. Disconnect the vacuum pipe for the brake servo.

1. Undo the upper retaining bolts.2. Undo the centre fixing nut.3. Remove the exhaust manifold heat shield.

1. Disconnect the coolant reservoir pipe from the connector on the rigid pipe supplying water to the pump.2. Undo the fixing bolts (2a) and remove the engine coolant reservoir (2b).

Have a suitable container for collecting the power steering system fluid ready.1. Disconnect the rapid connector (1a) and separate the two oil pipes (1b) and drain the fluid into the special container.

After having completely drained the power steering system fluid, reconnect the rapid connector.

Lower the vehicle.1. Undo the bolts fixing the power assisted steering fluid pump reservoir.2. Disconnect the two pipes (2a) and (2b).3. Remove the power steering pump fluid reservoir.

1. Undo the bolts fixing the EGR valve gas supply pipe from the exhaust manifold.2. Undo the bolts (2a) fixing the EGR valve to the rigid coolant pipe and the bolt (2b) to the rigid pipe to the heat exchanger.3. Disconnect the electrical connection (3a) and remove the EGR valve (3b) complete with exhaust gas supply pipe for the actual valve.

	Description	Connector
3a	EGR solenoid valve	See L30 EGR SOLENOID VALVE ( ENGINE )

1. Undo the connector (1a) and disconnect the heat exchanger water return pipe from the rigid pipe (1b).2. Undo the bolts fixing the rigid pipe to the cylinder head.3. Undo the bolts (3a) fixing the rigid pipe to the bracket (3b) on the thermostat.4. Remove the rigid water intake pipe to the pump.

1. Undo the retaining nuts.2. Separate the exhaust manifold from the studs on the cylinder head.

Op. 1092G10 SINGLE ENGINE BELT - R.R. Op. 1092A10 CRANKSHAFT PULLEY - R + R1. Undo the retaining bolts.2. Remove the lower part of the timing belt guard.

Lower the vehicle.1. Undo the retaining bolts.2. Remove the timing belt upper guards.

If the vehicle is equipped with air conditioning, release the wiring for the compressor electromagnet coupling before removing the two guards.

Place a hydraulic jack under the engine to support it.1. Undo the three nuts securing the support to the bodyshell.2. Undo the two nuts securing the support to the engine.3. Remove the timing side engine support.

1. Loosen the fixing nut (1a), loosen the timing belt (1b) tension and remove it.

Refit the timing side rigid support locking the fixing nuts without tightening them to torque.1. Undo the connectors for the rigid supply pipes to the injectors.2. Undo the connectors (2a) on the injection pump for the rigid supply pipes, then remove the injector rigid supply pipes (2b).

1. Disconnect the electrical connections for the spark plugs.2. Disconnect the electrical connection for the engine coolant temperature sensor from the thermostat.

	Description	Connector
1	Heater plugs	See A040 HEATER PLUGS

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

1. Undo the fixing bolts (1a) and remove the side guard (1b) for the timing belt.2. Using the spanner (2a) undo the bolts (2b) fixing the cylinder head to the cylinder block.

	Description	Code
2a	Spanner	1.852.154.000

3. Raise the cylinder head and remove it from the engine compartment.If necessary, place the cylinder head in the vice and dismantle it.Remove the seal.

Refitting ( Removing

) Fit a new cylinder head gasket on the cylinder block taking care to ensure that it is the same size as the one removed.The cylinder head gasket is 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 the gasket must be kept in its sealed nylon container and only taken out just before fitting to prevent getting oil on it.Position the cylinder head on the cylinder block/crankcase.1. Tighten the bolts fixing the cylinder head to the cylinder block to a pre-torque of 2 daNm following the order illustrated in the diagram and use tools (1a) and (1b) for the angular tightening.

	Fastening	Component	dia	Value(daNm)
-	Bolt	CYLINDER HEAD	M12	6.5 + 90° + 90° + 90°

	Description	Code
1a	Spanner	1.852.154.000

	Description	Code
1b	Torque wrench	1.860.942.000

Fit the timing belt side guard.Connect the electrical connections for the spark plugs.Connect the electrical connection for the engine coolant temperature sensor to the thermostat.

	Description	Connector
-	Heater plugs	See A040 HEATER PLUGS

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

Fit the rigid fuel supply pipes and tighten the connectors on the pump and on the injectors to torque.

	Fastening	Component	dia	Value(daNm)
-	Connector	INJECTOR FUEL DELIVERY PIPES DIESEL	M12 x 1.5	2.5

1. Position the engine at TDC for cylinder no. 1 (approximate TDC), checking that the locating dowel for the pump on the crankshaft is on the engine axis and facing downwards.Provisionally fit the cover on the tappets without securing it.2. Position the camshaft pulley so that the reference (2a) on it is aligned with the reference (2b) on the tappet cover.3. Position the injection pump drive pulley so that the reference (3a) on it is aligned with the reference (3b) on the pump support.

1. Remove the engine oil pump fixing bolt.2. Fit the timing belt on the crankshaft gear.3. Fit the pin for the tool for positioning the engine at T.D.C.4. Rotate the crankshaft using small movements to allow the pulley locating dowel (4a) to enter the opening in the tool (4b).

	Description	Code
3	Template	1.860.905.000

5. Lock the tool in position using a nut (5a) and service bolt (5b).

Place a hydraulic jack under the engine to support it.Undo the three nuts securing the support to the bodyshell.Undo the two nuts securing the support to the engine.Remove the timing side engine support.1. Check that the bolts fixing the injection pump pulley are slack, insert a cylindrical shaped centering pin (1a) with a 6 mm outer diameter of an appropriate length that allows it to be inserted about 40 mm into the opening (1b) in the pump shaft through the slot (1c) in the pulley. If the pin is not fully inserted, rotate the injection pump shaft by adjusting the nut (1d) until the openings are aligned.

1. Complete the fitting of the timing belt following the order illustrated.

When fitting the belt, check that the alignments for the timing pulley and the injection pump pulley with the references are maintained.

Fit the timing side engine support tightening the fixing nuts on the bodyshell and on the engine to torque.

	Fastening	Component	dia	Value(daNm)
-	Nut	RIGID ENGINE MOUNT, TIMING SIDE	M10 X 1.25	(Bodyshell side) 4.3

	Fastening	Component	dia	Value(daNm)
-	Nut	RIGID ENGINE MOUNT, TIMING SIDE	M10 X 1.25	(Engine side) 5

2. Adjusting the semi-automatic tensioning device, place the tensioner pointer (2a) in the maximum tension position, then lock the fixing nut (2b).3. Lock the rotation of the injection pump pulley inserting two M6 service bolts (3a) in the openings in the actual pulley which should correspond to the threaded openings in the pump mounting (correct timing). Tighten the bolts (3b) fixing the injection pump pulley to torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	INJECTION PUMP TOOTHED DRIVE PULLEY	M8	2.5

Do not use the centering pin to lock the rotation of the injection pump pulley because the injection pump shaft could be ruined.

Remove the two service bolts fitted for locking the injection pump pulley.Remove the centering pin from the injection pump.Remove the tool for T.D.C.

	Description	Code
-	Template	1.860.905.000

Rotate the crankshaft throught two revolutions in its normal direction of rotation.4. Loosen the nut fixing the tensioner and, working carefully, position the tensioner (4a) reference in line with the reference opening (4b), then tighten the nut (4c) fixing the belt tensioner to torque.

	Fastening	Component	dia	Value(daNm)
4c	Nut	MOBILE TIMING TENSIONER	M8	2.5

Rorate the crankshaft again through two revolutions in its normal direction of rotation.Reposition the tool for measuring T.D.C. for cylinder no. 1 and check that the centering pin is inserted (about 40 mm) in the opening in the injection pump.Fit the timing belt upper guards.Raise the vehicle.Fit the lower part of the timing belt guard. Op. 1092A10 CRANKSHAFT PULLEY - R + R Op. 1092G10 SINGLE ENGINE BELT - R.R.Fit the exhaust manifold fitting it on the studs on the cylinder head.Tighten the upper nuts fixing the exhaust manifold.

	Fastening	Component	dia	Value(daNm)
-	Nut	EXHAUST MANIFOLD/S	M8	(Cylinder head side) 2.5

Fit the rigid inlet water pipe on the pump.Tighten the bolts fixing the rigid pipe to the cylinder head to torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	COOLANT PUMP RIGID INLET PIPE	M6	0.9

Tighten the connector for the water return pipe to the heat exchanger.Tighten the bolts fixing the rigid pipe on the bracket on the thermostat.Fit the EGR valve complete with exhaust gas supply pipe.Connect the electrical connection for the EGR solenoid valve.

	Description	Connector
-	EGR solenoid valve	See L30 EGR SOLENOID VALVE ( ENGINE )

Tighten the bolts fixing the EGR valve to the cylinder head.Tighten the bolts fixing the EGR valve gas supply pipe to the exhaust manifold to torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	PIPE TO EGR VALVE	M8	2.5

Fit the power steering pump fluid reservoir.Disconnect the two pipes and tighten the bolts fixing the reservoir to the mounting.Fasten the power steering fluid pipe to the bodyshell.Fit the engine coolant reservoir and tighten the fixing bolts.Connect the coolant reservoir pipe from the connector on the rigid pipe supplying water to the pump.Fit the exhaust manifold heat shield.Tighten the bolts and the nut fixing the shield.Fit the rigid recirculation pipe and tighten the fixing bolts.Connect the flexible pipes to the rigid water recirculation pipe.Connect the vacuum pipe for the brake servo.Connect the two fuel supply and return pipes to the injection pump.Connect the recirculation pipe to the fuel return pipe.Connect the two heater coolant supply and return pipes to the thermostat.Fit the upper engine pipe and connect the ends to the radiator and to the thermostat.Fit the lower pipe in the engine compartment.Connect the lower engine pipe to the radiator, to the thermostat and to the connector on the rigid section of the pump water filler pipe.Top up the power steering system fluid level.

	Type	Component	Description	Qty.
-	Oil [l]	POWER ASSISTED STEERING CIRCUIT	TUTELA GI/A	-

Op. 5530B10 BATTERY - R+R Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R. Op. 1048A10 AIR FILTER ASSEMBLY - R.R. Op. 4450B04 RIGHT FRONT WHEEL - R.R. Op. 1016A22 CAM COVER WITH FUEL DUCT - R + R AND REPLACE GASKET Op. 0010T20 ENGINE COOLANT - CHANGE Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R.Remove the vehicle from the lift.