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

Removing ( Refitting ) Position the vehicle on a lift.    Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R.    Op. 5530B10 BATTERY - R+R    Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R.    Op. 1048A10 AIR FILTER ASSEMBLY - R.R.Position a suitable container for collecting the coolant.1. Disconnect the upper radiator pipe from the thermostat. 1. Lift up the clip (1a), release the cable from the connector (1b) on the throttle control and from the bracket (1c), then place the accelerator control cable (1d) at the side. 1. Disconnect the engine rpm sensor electrical connector.

	Description	Connector
1	Rpm sensor	See K46 RPM SENSOR ( ENGINE )

1. Disconnect the electrical connector for the throttle position sensor.

	Description	Connector
1	Throttle position sensor	See K56 THROTTLE POSITION SENSOR ( ENGINE )

2. Disconnect the electrical connector for the idle speed actuator.

	Description	Connector
2	Idle actuator	See N74 IDLE ACTUATOR

3. Unscrew the fixing bolt (3a) and disconnect the earth on the throttle body (3b).

	Description	Connector
3b	Injection control unit earth	See C60 EARTH ON ENGINE ( ENGINE )

4. Disconnect the intake air pressure/temperature sensor.

	Description	Connector
4	Integrated air temperature sensor	See K43 INTEGRATED AIR TEMPERATURE SENSOR ( ENGINE )

1. Adjust the fixing levers (1a) and disconnect the electrical connectors for the injection control unit (1b).

	Description	Connector
1b	Engine management control unit	See M010 ENGINE MANAGEMENT ECU

1. Adjust the fastening clip (1a), detach the cable ducting (1b) for the injector wiring from the slots (1c) on the tappet cover. 1. Disconnect the electrical connectors for the ignition coils.

	Description	Connector
1	ignition coils	See A30 IGNITION 'COIL ( ENGINE )

1. Disconnect the electrical connector for the coolant temperature sensor.

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

2. Undo the bolts (2a) fixing the plastic filler (2b), then move it away from the connector on the intake manifold complete with coolant hose (2c). 1. Disconnect the oil vapour recovery pipe from the tappet cover. 1. Disconnect the electrical connection for the timing sensor from the cover

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

1. Disconnect the electrical connectors for the injectors (1a) and place the cable duct (1b) at the side.

	Description	Connector
1a	Injector	See N070 INJECTOR

1. Remove the protective cap (1a) from the fuel manifold breather valve (1b) and use the tool (1c) to discharge the fuel pressure.Collect the fuel in a suitable container.

	Description	Code
1c	Rapid attachment connector	1.870.684.000

1. Disconnect the fuel supply pipe rapid connector.2. Disconnect the electrical connector for the fuel vapour flow enablement solenoid valve.

	Description	Connector
2	Fuel vapour recovery solenoid valve	See L10 FUEL VAPOUR RECOVERY SOLENOID VALVE ( ENGINE )

3. Disconnect the evaporation control system pipe.4. Disconnect the brake servo vacuum pipe. 1. Undo the fixing nuts (1a), open the retaining band (1b) and remove the cable duct mounting bracket (1c). 1. Undo the fixing nut and bolt.2. Disconnect the high tension leads from the spark plugs.3. Remove the ignition unit complete with spark plug high tension leads. Remove the injection electrical wiring from the clips located behind the intake manifold.1. Undo the fixing nuts (1a) and remove the intake manifold complete with throttle body (1b0. 1. Undo the fixing bolts (1a) and remove the tappet cover (1b).     Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD R+R1. Undo the nuts securing the exhaust manifold to the cylinder head.     Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + RRaise the vehicle.1. Undo the bolt fixing the exhaust manifold retaining bracket.     Op. 4450B04 RIGHT FRONT WHEEL - R.R.    Op. 1092B60 ALTERNATOR DRIVE BELT - R + R    Op. 1092A10 CRANKSHAFT PULLEY - R + R    Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT1. Undo the fixing bolts (1a) and remove the single cylinder head (1b).2. Remove the underlying gasket. Refitting ( Removing ) Clean the contact surfaces between the cylinder head and engine block.Position the cylinder head gasket with the wording "ALTO" [TOP] so that it can be read by the operator.The cylinder head gasket is ASTADUR type.Because the gasket is made out of special material, it undergoes a polymerisation process during engine operation and hardens considerably 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.1. Position the cylinder head (1a) and tighten the fixing bolts (1b) to a pre-torque of 2 daNm and then to torque following the order and the figures given.

	Fastening	Component	dia	Value(daNm)
1b	Bolt	CYLINDER HEAD	M9 x 1.25	3 + 90° + 90°

2. Always following the same tightening order, complete the angular tightening of the bolts using a suitable tool.

	Description	Code
2	Torque wrench	1.860.942.000

    Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT    Op. 1092A10 CRANKSHAFT PULLEY - R + R    Op. 1092B60 ALTERNATOR DRIVE BELT - R + R    Op. 4450B04 RIGHT FRONT WHEEL - R.R.Tighten the bolt fixing the exhaust manifold retaining bracket to torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	CATALYTIC CONVERTER (ONE)	M8	(Collar to gearbox) 2.8

Lower the vehicle.    Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + RTighten the nuts securing the exhaust manifold to the cylinder head to torque.

	Fastening	Component	dia	Value(daNm)
-	Nut	CATALYTIC CONVERTER (ONE)	M8	(Manifold to cylinder head) 3

    Op. 1072C44 EXHAUST MANIFOLD HEAT SHIELD R+RFit the tappet cover and secure it using the fixing bolts.

	Fastening	Component	dia	Value(daNm)
-	Bolt	CAM COVER	M6	1

Fit the intake manifold and secure it tightening the nuts to the recommended torque.

	Fastening	Component	dia	Value(daNm)
-	Nut	INLET MANIFOLD	M18 x 1.25	2.7

Position the ignition coil mounting assembly and tighten the fixing nut and bolt.Connect the high tension leads to the spark plugs.Position the mounting bracket for the cable duct and tighten the fixing nuts.Connect the fuel supply pipe rapid connector.Connect the electrical connector for the fuel vapour flow enablement solenoid valve.

	Description	Connector
-	Fuel vapour recovery solenoid valve	See L10 FUEL VAPOUR RECOVERY SOLENOID VALVE ( ENGINE )

Connect the evaporation control system pipe.Connect the brake servo vacuum pipe.Place the cable duct in position and connect the electrical connecotrs for the injectors.

	Description	Connector
-	Injector	See N070 INJECTOR

Connect the oil vapour recovery pipe to the tappet cover.Connect the electrical connection for the timing sensor.

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

Fit the plastic filler complete with coolant hose.Secure the filler to the intake manifold and tighten the fixing bolts.Connect the electrical connector for the coolant temperature sensor.

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

Connect the electrical connectors for the ignition coils.

	Description	Connector
-	Ignition coil	See A30 IGNITION 'COIL ( ENGINE )

Connect the electrical connectors to the junction unit.

	Description	Connector
-	Engine management control unit	See M010 ENGINE MANAGEMENT ECU

Connect the electrical connector for the throttle position sensor.

	Description	Connector
-	Throttle position sensor	See K56 THROTTLE POSITION SENSOR ( ENGINE )

Connect the electrical connector for the idle speed actuator.

	Description	Connector
-	Idle actuator	See N74 IDLE ACTUATOR

Connect the earth to the throttle casing and secure it using the fixing bolt.

	Description	Connector
-	Injection control unit earth	See C60 EARTH ON ENGINE ( ENGINE )

Connect the intake air pressure/temperature sensor.

	Description	Connector
-	Integrated air temperature sensor	See K43 INTEGRATED AIR TEMPERATURE SENSOR ( ENGINE )

Connect the engine rpm sensor electrical connector.

	Description	Connector
-	Rpm sensor	See K46 RPM SENSOR ( ENGINE )

Reposition the accelerator control cable on the mounting bracket and fit it on the throttle valve.Connect the upper radiator pipe to the thermostat.    Op. 1048A10 AIR FILTER ASSEMBLY - R.R.    Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R.    Op. 5530B10 BATTERY - R+R    Op. 1068A10 ACCELERATOR PEDAL CONTROL - CHECK, ADJUST IF NECESSARY AND LUBRICATE    Op. 0010T21 COOLANT - CHECK DENSITY AND TOP UP IF NECESSARY    Op. 7055B54 PROTECTION/GUARD UNDER ENGINE - R.R.Remove the vehicle from the lift.