1016B12 SINGLE CYLINDER HEAD EXTENSION - R R WITH TIMING BELT REMOVED - REPLACE - Fiat - DUCATO - eLearn

244000650 - 1016B12 SINGLE CYLINDER HEAD EXTENSION - R R WITH TIMING BELT REMOVED - REPLACE

) 1. Disconnect the collar securing the air delivery sleeve to the turbocharger.2. Diconnect the vapour recovery pipe from the air delivery sleeve to the turbocharger.3. Disconnect the collar from turbocharger (3a) and remove the air delivery sleeve to turbocharger (3b).

1. Loosen the retaining bolts of the collar joining the intake pipe rigid section to the turbocharger.2. Unscrew nuts (2a) securing the pipe to the bracket on the cylinder head, and engine oil vapour pipe fitting retaining bolt (2b).3. Remove the rigid section of the air pipe from the turbocharger.

1. Undo the retaining bolts.2. Remove the engine oil vapour separator.

1. Disconnect the electrical connections:

	Description	Connector
1a	Injector	N070A

	Description	Connector
1a	Injector	N070B

	Description	Connector
1a	Injector	N070C

	Description	Connector
1a	Injector	N070D

	Description	Connector
1b	Fuel pressure sensor	K083

	Description	Connector
1c	Air pressure - temperature sensor	K044

	Description	Connector
.	Heater plugs	A040A

	Description	Connector
.	Heater plugs	A040B

	Description	Connector
.	Heater plugs	A040C

	Description	Connector
.	Heater plugs	A040D

	Description	Connector
1d	Timing sensor	K047

	Description	Connector
1e	Coolant temperature sending unit (for instrument panel)	K035

	Description	Connector
1f	Engine coolant temperature sensor/sender unit	K036

	Description	Connector
1g	Fuel pressure regulator	N077

1. Unscrew the fitting of the return pipe to the return manifold.2. Undo retaining bolt (1a), undo connector (1b) and disconnect delivery pipe (1c) from pump to fuel manifold.3. Undo the connectors for the supply pipes from the manifold to the injectors.4. Undo the bolts fixing the fuel manifold to the camshaft housing.5. Remove the fuel manifold complete with supply pipes to the injectors.

1. Press the fastening springs (1a) and disconnect the fuel recirculation pipe (1b) from the injectors.2. Undo the bolts fixing the brackets.3. Use the extractor and driver to remove the injectors from their seats on the cylinder head extension.

	Description	Code	Function
.	Mallet	1.840.206.001	Injector removal

	Description	Code	Function
.	Extractor	1.870.850.000	Injector removal

1. Undo the retaining bolts.2. Remove the cylinder head extension complete with camshafts.3. Remove the underlying gasket.

Refitting ( Removing

) - Fit a new gasket to the cylinder head.- Fit the cylinder head extension complete with camshafts and camshaft timing tools.

When fitting the cylinder head extension, take particular care to ensure that the tappet rockers do not move while fitting the cylinder head extension to the cylinder head.

- Tighten the bolts securing the cylinder head extension to the cylinder head to torque.

	Value - daNm	Fastening	Component	Ø
.	11,5	Bolt	CYLINDER HEAD EXTENSION	M12X1.25

	Value - daNm	Fastening	Component	Ø
.	1	Bolt	CYLINDER HEAD EXTENSION	M6

	Value - daNm	Fastening	Component	Ø
.	2.5	Bolt	CYLINDER HEAD EXTENSION	M8X1.25

- Lower the vehicle.- Fit the injectors in the seats in the camshaft housing.- Tighten the bolts fixing the brackets.

	Value - daNm	Fastening	Component	Ø
.	2.5	Bolt	INJECTORS(DIESEL)	M8

- Fasten the recirculation pipe on the injectors using securing bands.- Fit the fuel manifold complete with supply pipes to the injectors.

Whenever work is carried out on the fuel pipes from manifold to injector and from manifold to pressure pump, replace with new pipes to prevent oil leaks from the fittings.

- Tighten the bolts fixing the fuel manifold to torque.

	Value - daNm	Fastening	Component	Ø
.	2.5	Bolt	INJECTOR FUEL MANIFOLD (DIESEL)	M8

- Tighten the connectors for the pipes on the injectors to torque.

	Value - daNm	Fastening	Component	Ø
.	2.3	Connectors	INJECTOR FUEL MANIFOLD PIPE	M12X1.5

- Tighten the connector for the fuel supply pipe from the pressure pump to torque.- Tighten the bolt fixing the fuel supply pipe from the pressure pump to the bracket.- Screw in the connector for the return pipe from the single fuel manifold to the return manifold and tighten it to torque.

	Value - daNm	Fastening	Component	Ø
.	4	Connector	INJECTOR FUEL MANIFOLD (DIESEL)	M16

- Position the injection wiring and connect the electrical connections disconnected previously.

	Description	Connector
	Injector	N070A

	Description	Connector
	Injector	N070B

	Description	Connector
	Injector	N070C

	Description	Connector
	Injector	N070D

	Description	Connector
	Fuel pressure sensor	K083

	Description	Connector
	Air pressure - temperature sensor	K044

	Description	Connector
.	Heater plugs	A040A

	Description	Connector
.	Heater plugs	A040B

	Description	Connector
.	Heater plugs	A040C

	Description	Connector
.	Heater plugs	A040D

	Description	Connector
	Timing sensor	K047

	Description	Connector
	Coolant temperature sending unit (for instrument panel)	K035

	Description	Connector
	Engine coolant temperature sensor/sender unit	K036

	Description	Connector
	Fuel pressure regulator	N077

- Fit the rigid section of the air pipe from the turbocharger and tighten the bolt fixing the collar.- Tighten the bolts fixing it to the cylinder head.- Tighten the bolt fixing the engine oil vapour pipe.- Connect to the turbocharger and air cleaner case.- Connect the engine oil vapour separator pipe to the fitting.