1016C11 SINGLE CYLINDER HEAD-R R GASKET FOR VERSIONS WITH AIR CONDITIONER - Fiat - DUCATO - eLearn

244000642 - 1016C11 SINGLE CYLINDER HEAD-R R GASKET FOR VERSIONS WITH AIR CONDITIONER

) - Disconnect the negative battery terminal. Op. 0010T20 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY See in Op. 1088B10 Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE1. Open the retaining springs (1a) and disconnect the single-acting valve (1b) on the brake servo, then undo the nuts (1c).2. Remove the protective cover.

1. Undo the nuts (1a) and disconnect the electrical connections (1b) from the heat flange relay (1c).

	Description	Connector
1b	Heat-flange relay	J130A

	Description	Connector
1b	Heat-flange relay	J130B

	Description	Connector
1b	Heat-flange relay	J130C

1. Disconnect the electrical connection (1a) and the pipes (1b) from the EGR solenoid valve.

	Description	Connector
1a	EGR solenoid valve	L030

1. Undo the fixing nuts (1a) and remove the mounting bracket (1b).

See in Op. 1048B14 See in Op. 1048B22- Disconnect the vacuum pipe for the brake servo.1. Open the retaining band (1a) and release the hose (1b) from the thermostat.2. Undo the fixing nuts (2a) and remove the bracket (2b) complete with rigid pipe and hoses.

See in Op. 1016A101. Disconnect the electrical connections for the injector wiring from the injectors.

	Description	Connector
1	Injector	N070A

	Description	Connector
1	Injector	N070B

	Description	Connector
1	Injector	N070C

	Description	Connector
1	Injector	N070D

See in Op. 1060G221. Undo the nut (1a) fixing the injector wiring bracket (1b).

1. Undo the fixing bolts (1a) and remove the EGR pipe shield (1b).2. Open the retaiing bands (2a) and release the pipe (2b) on the heater and the pipe (2c) on the EGR pipe.3. Undo the fixing bolts (3a) and nuts (3b).

- Raise the lift. Op. 7055B54 UNDER-ENGINE GUARD - R R Op. 1080B62 CATALYTIC CONVERTER - R + R1. Undo the fixing nuts (1a) and remove the EGR assembly (1b).

1. Undo the bolts fixing the cold air intake.2. Open the band securing the hose to the air filter.3. Remove the hose complete with cold air intake.

See in Op. 1048A10 Op. 1060G10 FLOW METER - R R1. Open the retaining band (1a) for the hose (1b) from the flow meter to the turbocharger.2. Open the band (2a) securing the oil vapour recovery pipe (2b) to the oil vapour recovery reservoir.3. Undo the bolt (3a) fixing the mounting bracket (3b) for the oil vapour recovery pipe and remove it.

1. Undo the fixing bolts (1a) and move the mounting bracket (1 b) for the fuel pipes (1c) and the connection for the rpm sensor (1d) aside.2. Undo the nut (2a) fixing the earth (2b) to the heat flange.

	Description	Connector
2b	Heat flange earth	C090

See in Op. 1048B101. Undo the fixing nuts (1a) and remove the intake manifold (1b) complete with: Heat flange (1c), support (1d) and hose filler (1e).

1. Undo the connector for the fluid pipe on the turbine.2. Undo the bolt fixing the pipe mounting bracket.3. Undo the nuts securing the exhaust manifold to the cylinder head.

1. Disconnect the electrical connection (1a) for the oil pressure sensor (1b).2. Undo the connector (2a) for the turbocharger oil supply pipe (2b) and remove it.

	Description	Connector
1a	Engine oil pressure sensor	K028

1. Undo the bolts (1a) fixing the oil return pipe to the turbocharger (1b) and release it.

1. Undo the turbocharger (1b) fixing bolts (1a).

1. Remove the turbocharger (1a) complete with exhaust manifold (1b).

1. Open the retaining bands (1a) and release the radiator supply and return hoses (1b) and the additional heater pipe (1c).2. Disconnect the electrical connections for the sensors on the thermostat.

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

	Description	Connector
2	Engine coolant temperature sensor/sender unit	K036

1. Fit the flywheel lock on the bellhousing.

	Description	Code	Function
1	Flywheel lock	1.870.765.000	Engine flywheel lock

1. Working on the tensioner (1b) adjustment screw (1a), loosen the compressor drive belt (1c) and remove it.

1. Loosen the bolts (1a) fixing the alternator (1b) and, working on the adjustment screw (1c), loosen the alternator drive belt (1d) and remove it.

1. Undo the bolts (1a) and remove the crankshaft pulley (1b) complete with washer (1c).

1. Undo the air conditioning pipe (1b) fixing bolt (1a).2. Undo the nut (2a) fixing the air conditioning pipes mounting bracket (2b).3. Release the pipe.

1. Fit crossmember supporting tool 1870735000

	Description	Code	Function
1a	Engine mounting beam	1.870.735.000	Support power unit

1. Undo the nuts (1a) and the bolts (1b) fixing the timing side flexible mounting (1c) and remove it.

1. Undo the fixing bolts (1a) for the protective timing cover (1b) and remove it.

1. Undo the fixing bolts (1a) and remove the additional protective timing cover (1b).

1. Work on the tensioning piston.2. Fit the tool3. Remove the toothed timing belt.

	Description	Code	Function
2	Calibrated shim	1.860.638.000	Component for retaining lower timing belt tensioner spring

1. Open the retaining bands (1a) and release the hose (1b) between the thermostat and the rigid pipe and the two supply and return hoses (1c) to the water/oil heat exchanger.

1. Open the retaining bands (1a) for the pipes (1b).2. Undo the bolts fixing the oil vapour recovery reservoir.3. Remove the oil vapour recovery reservior.

1. Undo the fastenings (1a) and move the rigid water/oil heat exchanger pipes (1b) aside.

1. Undo one of the fixing bolts (1a) ande move the oil dipstick (1b) aside.

1. Undo the connectors (1a) and disconnect the rigid injector supply pipes from the single fuel supply pipe (1b).

1. Undo the connectors (1a) and remove the rigid fuel supply pipe for the single rigid fuel delivery pipe (1b).2. Working on the fasteners (2a), remove the fuel return pipe from the injectors (2b).

1. Undo the bolt (1a) fixing the fuel recovery manifold (1b) and move it out of the work area.

1. Undo the remaining fastenings (1a) and remove the protective cover for the single rigid fuel delivery pipe (1b).

1. Disconnect the electrical connection (1a) for the fuel pressure sensor (1b).2. Undo the nuts (2a) fixing the single rigid fuel delivery pipe (2b) and remove it.

	Description	Connector
1a	Fuel pressure sensor	K083

1. Undo the fixing bolts (1a) and remove the injectors (1b) from the cylinder head.2. Undo the bolt (2a) and release the injection wiring bracket (2b) and move it outside of the work area.3. Undo the nut (3a) and move the mounting bracket for the rigid cooling pipe to the EGR (3b) aside.

1. Undo the fixing nuts (1a) and remove the tappet cover (1b).2. Remove the tappet cover gasket.3. Undo the fixing bolts (3a) and remove the cylinder head (3b).

using a hydraulic lift, secure the cylinder head using the special support hooks.

1. - Remove the gasket underneath the single cylinder head.

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.

- Because the gasket is made out of special material, it undergoes a polymerisation process during engine operation and hardens considerably during service. Take the following precautions to ensure that gasket polymerisation takes place.- Keep the gasket sealed in its plastic bag and do not remove from its protection until ready to fit.- Do not lubricate the gasket or contaminate with oil or grease.

place the cylinder head in position using the hydraulic lift and release the support hooks.

1. Tighten the cylinder head fixing bolts checking the torque using the angular tightening tool.

	Description	Code	Function
.	Torque wrench	1.860.942.000	Cylinder head bolts angular tightening

	Value - daNm	Fastening	Component	Ø
.	6,0 + 6,0 + 180°	Bolt	CYLINDER HEAD	M12

Take care to tighten the fixing bolts which are different lengths.

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

- Position the tappet cover gasket.- Fit the tappet cover and tighten the nuts, checking the torque.

	Value - daNm	Fastening	Component	Ø
.	1,0	Nut	CAM COVER	-

- Fit the injector bracket support pads.- Fit the injectors, complete with seals and brackets, in the seats in the cylinder head and tighten the fixing bolts and check the torque.

	Value - daNm	Fastening	Component	Ø
.	2,6 - 3,2	Bolt	INJECTORS	M6

- Fit the injection wiring bracket and tighten the fixing bolt.- Tighten the nut fixing the rigid cooling pipe to the EGR.- Positin the single fuel manifold pipe and tighten the fixing nuts.- Connect the electrical connection for the fuel pressure sensor.

	Description	Connector
1a	Fuel pressure sensor	K083

- Fit the single fuel manifold pipe protection securing it using the nuts.- Reposition the fuel recovery manifold and secure it using the bolt.- Connect the fuel return pipe to the injectors and secure it using the fasteners.- Fit the rigid fuel supply pipe for the single fuel manifold pipe checking the torque of both connectors.

	Value - daNm	Fastening	Component	Ø
.	(Fuel manifold end) 2.6 - 3.2	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M14

	Value - daNm	Fastening	Component	Ø
.	(Pressure pump end) 1.9 - 2.3	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	M12

- Connect the rigid injector supply pipes.

	Value - daNm	Fastening	Component	Ø
.	(Manifold end) 2.6 - 3.2	Connector	PIPE FUEL MANIFOLD TO INJECTORS	M14

	Value - daNm	Fastening	Component	Ø
.	(Injector end) 1.9 -2.3	Connector	PIPE FUEL MANIFOLD TO INJECTORS	M12

- Fasten the oil dipstick pipe using the bolt.- Fasten the water/oil heat exchanger rigid pipes using the bolt.- Fit the oil vapour recovery reservoir and connect the pipes fastening them using the bands.- Fit the hose between the thermostat and the rigid pipe and secure it using the bands.- Connect the two supply and return pipes to the thermostat from the water/oil heat exchanger. See in Op. 1032B14- Fit the two supply and return hoses on the thermostat from the radiator and secure them using the bands.- Connect the electrical connections for the sensors on the thermostat.

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

	Description	Connector
2	Engine coolant temperature sensor/sender unit	K036

- Connect the additional heater pipe to the thermostat and secure it using the band.- Position the turbocharger complete with exhaust manifold and gaskets.- Tighten the bolts fixing the exhaust manifold and check the torque.- Tighten the bolts fixing the turbocharger to the crankcase.- Connect the oil return pipe to the turbocharger and fasten it using the bolts.- Connect the rigid oil supply pipe to the turbine complete with oil pressure sensor.- Connect the electrical connection for the engine oil pressure sensor.

	Description	Connector
1a	Engine oil pressure sensor	K028

- Tighten the bolt fixing the bracket for the rigid oil supply pipe to the turbine.- Tighten the nuts fixing the exhaust manifold to the cylinder head and check the torque.

	Value - daNm	Fastening	Component	Ø
.	(Cylinder head side) 2.1 -2.6	Nut	EXHAUST MANIFOLD/S	M8

- Fit the intake manifold complete with heat flange, support and hose filler plus the gaskets.- Tighten the nutss fixing the intake manifold and check the torque.

	Value - daNm	Fastening	Component	Ø
.	(Cylinder head side) 2.5	Nut	INLET MANIFOLD	M8

See in Op. 1048B10- Connect the earth to the heat flange and tighten the fixing nut.

	Description	Connector
2b	Heat flange earth	C090

- Fit the fuel pipe mounting bracket using the bolts.- Place the oil vapour recovery pipe mounting bracket and fastenings in position.- Connect the oil vapour recovery pipe to the reservoir and secure it using the band. Op. 1060G10 FLOW METER - R R See in Op. 1048A10- Connect the turbocharger hose to the air flow meter and secure it using the retaining band.- Tighten the cold air intake complete with hose to the front crossmember and connect it to the filter casing fastening it using a retaining band.- Fit the EGR assembly and fastenings and check the torque.

	Value - daNm	Fastening	Component	Ø
.	(Intake manifold side)	Bolt	(EGR)/INTAKE VALVE EXAUST GAS PIPE	-

	Value - daNm	Fastening	Component	Ø
.	(Heat-flange end)	Nut	EXHAUST GAS/WATER HEAT EXCHANGER for system	-

- Connect the pipe to the heater and secure it using a retaining band.- Connect the pipe to the EGR valve exhaust gas pipe using the band.- Fit the EGR pipe shield using the fixing bolts. Op. 1080B62 CATALYTIC CONVERTER - R + R Op. 7055B54 UNDER-ENGINE GUARD - R R See in Op. 1060G22- Secure the injector wiring mounting bracket using a nut.- Connect the electrical connections for the injector wiring to the injectors.

	Description	Connector
1	Injector	N070A

	Description	Connector
1	Injector	N070B

	Description	Connector
1	Injector	N070C

	Description	Connector
1	Injector	N070D

See in Op. 1016A10- Fit the bracket and nuts and connect a hose to the thermostat.- Connect the vacuum pipe for the brake servo. See in Op. 1048B22 See in Op. 1048B14- Fit the mounting bracket for the EGR solenoid valve and heat flange relay.- Connect the pipes to the EGR solenoid valve.- Connect the electrical connection to the solenoid valve.

	Description	Connector
1a	EGR solenoid valve	L030

- Connect the electrical connections to the heat flange relay.

	Description	Connector
1b	Heat-flange relay	J130A

	Description	Connector
1b	Heat-flange relay	J130B

	Description	Connector
1b	Heat-flange relay	J130C

- Fit the protective cover and secure it using the nuts and fasten the brake servo pipe to the retaining springs. Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE See in Op. 1088B10 Op. 0010T20 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY Op. 0010T11 ENGINE OIL CHECK LEVEL AND TOP UP- Connect the negative battery terminal.