1016C10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL - Fiat - DUCATO - eLearn

244000643 - 1016C10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

) Op. 7055B54 UNDER-ENGINE GUARD - R R- Arrange a container beneath the engine to recover the engine oil.1. Undo the plug on the oil sump and drain the oil.

Op. 4130B10 POWER STEERING FLUID RESEVOIR R RCharacteristic of working principle 1. Open the retaining band (1a) and disconnect the pipe (1b) joining the turbocharger to the ntake manifold.

- Arrange a container beneath the engine to recover the engine coolant.1. Disconnect band (1a) and disconnnect the lower radiator pipe from rigid section (1b).2. Disconnect the upper pipe from the thermostat.

1. Disconnect the band retaining the coolant pipe to the cylinder head.2. Undo the nuts securing the reservoir to the bodyshell.3. Disconnect sleeve (3a) from the rigid pipe and remove expansion tank (3b).

1. Undo bolts (1a) and remove the protective cover (1b) for the glow plug control unit.

1. Disconnect the electrical connection for the glow plug control unit.

	Description	Connector
1	Heater plugs control unit	M015C

2. Undo the nut securing the glow plug control unit to the bracket.- Release the wiring from the bands and replace the control unit on the engine.

1. Disconnect the electrical connections of the exhaust gas recirculation regulation solenoid (1a) and the throttle body solenoid (1b).

	Description	Connector
1a	EGR solenoid valve	L030

	Description	Connector
1b	Throttle body solenoid valve	L062

2. Remove vacuum pipes (2a), vacuum pipe to the EGR (2b) and the vacuum pipe to the pneumatic valve on the throttle body (2c) from the solenoids.3. Undo the retaining nuts.- . Remove the bracket from the engine compartment.

1. Open retaining clips (1a) and remove protective cover (1b) from the filter element.2. Remove the filter element from the filter casing.

1. Disconnect the electrical connection for the air flow meter.

	Description	Connector
1	Air flow meter	K041

2. Undo the nuts securing the filter casing to the bracket.3. Disconnect the band securing the air flow meter to the air delivery pipe to the turbo.4. Remove the air filter casing.

1. Press the retaining spring (1a) and disconnect the electrical connection (1b) for the engine oil vapour pipe.

	Description	Connector
1b	Oil vapour heating resistance	O007A

2. Disconnect the engine oil vapour pipe from the air intake pipe between the filter and the turbocharger.3. Remove the oil vapour pipe.

1. Undo the retaining nut (1a) and disconnect the supply lead from the glow plugs (1b).

	Description	Connector
1b	Heater plugs	A040

1. Disconnect the electrical connections:

	Description	Connector
1a	Injection pump third piston deactivation solenoid valve	L005

	Description	Connector
1b	Fuel pressure regulator	N077

	Description	Connector
.	Fuel pressure sensor	K083

	Description	Connector
1c	Injector	N070A

	Description	Connector
1c	Injector	N070B

	Description	Connector
1c	Injector	N070C

	Description	Connector
1c	Injector	N070D

	Description	Connector
1d	Timing sensor	K047

	Description	Connector
.	Engine oil pressure sensor	K028

	Description	Connector
1e	Alternator	A010A

	Description	Connector
1e	Alternator	A010B

	Description	Connector
1f	Rpm sensor	K046

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

	Description	Connector
.	Starter motor	A020A

	Description	Connector
.	Starter motor	A020B

- Release the wiring from the bands and move it to the side.

1. Disconnect the three quick-release connectors on the fuel lines from the fuel return manifold.2. Disconnect the quick-release connectors on both fuel lines from the pressure pump.3. Undo retaining bolt (I3a), disconnect injector recirculation pipe (3b) and remove return manifold (3c) complete with pipes.

1. Remove the water supply pipe from the heater.

1. Disconnect the quick-release connector from the vacuum pump.

1. Disconnect the recirculation hose from the thermostat.2. Undo the retaining bolt.3. Remove the rigid section of the water recirculation pipe from the cylinder head.

1. Use tool (1a) to open undo band (1b) and disconnect the water pipe (1c) to the thermostat.

	Description	Code	Function
.	Spanner	1.881.138.000	cylinder head - r + r and replace gasket

2. Open band (2a) and disconnect pipe (1b) from the EGR exhaust gas heat exchanger.

1. Use an appropriate wrench to open the bands and disconnect both coolant delivery and return pipes to the engine oil heat exchanger.

	Description	Code	Function
.	Spanner	1.881.138.000	cylinder head - r + r and replace gasket

2. Remove the rubber hose from the cam cover to the engine oil vapour separator.3. Remove the flexible section of the lower engine coolant pipe.

1. Undo retaining bolts (1a) and remove bracket (1b).

1. Undo the upper bolts securing the engine oil dipstick tube.2. Undo the lower bolt (2a) and remove the engine oil dipstick tube (2b).

1. Undo the connectors on the fuel manifold and pressure pump.2. Remove the fuel delivery pipe from pressure pump to fuel manifold.

1. Undo the retaining bolts.2. Remove the bracket on the thermostat.

- Raise the vehicle.Characteristic of working principle 1. Open the band securing the pipe to the turbocharger.2. Remove the rigid pipe from the upper part of the engine bay.

1. Open retaining band (1a) and remove rigid pipe (1b) from the upper part of the engine bay.

1. Remve the press-fitted EGR pipe heat shield.

1. Undo the bolt securing the lower reaction rod to the suspension crossmember.2. Undo the bolt securing the lower reaction rod to the mounting bracket on the gearbox.- Move the power unit slightly forward to make enough room to remove the reaction link.- Remove the lower reaction link.

1. Disconnect the band for the turbocharger sump oil return pipe.2. Undo the connector and disconnect the turbocharger rigid oil supply pipe.3. Undo retaining bolts (3a) and disconnect the EGR exhaust gas delivery pipe from the turbocharger (3B).4. Undo the nuts securing the exhaust manifold to the cylinder head.5. Undo the bolt securing the turbocharger to the mounting bracket.- Move the power unit forward.6. Remove the exhaust manifold complete with turbocharger from the lower part of the vehicle from the compartment between the suspension beam and body.

1. Unscrew the lower and upper bolts securing the intake manifold to the cylinder head.- Lower the lift.2. Remove the intake manifold from the upper part of the engine compartment.

- Refit the reaction link in its seat and screw in the retaining bolts without tightening.1. Undo the bolts securing the rigid water inlet pipe to the pump.2. Remove the rigid water intake pipe to the pump.

1. Position the tool for supporting the power unit fastened to the crossmember for the suspension and to the lower crossmember under the engine oil sump.

	Description	Code	Function
1	Crossmember	1.870.735.000	Lower engine mounting beam

Op. 1092G10 SINGLE ENGINE BELT R R- Disconnect the electrical connection for the rpm sensor.

	Description	Connector
.	Rpm sensor	K046

1. Undo the retaining bolt.2. Remove the rpm sensor.

1. Fit the flyhwheel lock into its seat on the rpm sensor.

	Description	Code	Function
1	Flywheel lock	1.870.765.001	Prevent flywheel rotation

1. Undo bolts (1a) and remove the auxiliary shaft drive pulley (1b).

- Remove the flywheel lock fitted previously.

	Description	Code	Function
.	Flywheel lock	1.870.765.001	Prevent flywheel rotation

1. Undo the nuts securing the block to the bodyshell.2. Undo the bolts securing the flexible block to the rigid mounting on the engine.3. Remove the flexible mounting from the engine compartment.

1. Undo the retaining bolts.2. Remove the timing belt upper guard.

1. Undo the retaining bolts.2. Remove the timing belt side guard.

- Raise the lift.1. Undo the retaining bolts.2. Remove the timing belt lower guard.

1. Slowly turn the crankshaft until the TDC positioning tool fits into the seat on the flywheel.

	Description	Code	Function
1	Pin	1.860.863.000	Positioning engine at TDC

- Lower the vehicle.1. Fit an 8 mm diameter camshaft timing adjustment pin nto its seat on the cylinder head.

The pin must be able to enter the hole on the head without the need to turn the crankshaft. If the pulley hole is in the diametrically opposite position, withdraw the TDC tool and turn the crankshaft through one revolution. Then re-fit the TDC tool and then insert the timing adjustment tool.

1. Loosen bolt (1a) and use a ¼" box wrench (1b) to slacken belt tension. Then tighten the nut unscrewed previously.2. Remove the timing belt.

1. Unscrew the power unit rigid lower mount bolts.

1. Undo the bolt (1a) and remove the timing sensor (1b)

1. Undo bolts (1a) in the order shown and remove cam cover (1b).

1. Undo the bolts securing the cylinder head to the crankase in the order shown.2. Remove the cylinder head assembly.3. Recover the underlying gasket.

Refitting ( Removing

) 1. Measure piston projection (1a) in two places 180° apart on the piston pin centre line using tool (1b) and take the average of the two values measured for each piston.

	Description	Code	Function
1b	Dial gauge support	1.870.404.000	Injector projection from cylinder head plane measurement

1. Select the correct size cylinder head gasket depending on the maximum average protrusions for each individual piston.

the difference between the minimum and maximum values should not be more than 0.07 mm.

	Subject	Value
1	CYLINDER HEAD GASKET	mm
-	Size	1,30
-	Average protrusion	0,470 - 0,605

	Subject	Value
1	CYLINDER HEAD GASKET	mm
-	Size	1,35
-	Average protrusion	0,605 - 0,655

	Subject	Value
1	CYLINDER HEAD GASKET	mm
-	Size	1,40
-	Average protrusion	0,655 - 0,705

	Subject	Value
1	CYLINDER HEAD GASKET	mm
-	Size	1,45
-	Average protrusion	0,705 - 0,755

	Subject	Value
1	CYLINDER HEAD GASKET	mm
-	Size	1,50
-	Average protrusion	0,755 - 0,830

- 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.- Position the cylinder head on the cylinder block/crankcase.- Undo the support clips and remove the bracket.1. Tighten the bolts fixing the cylinder head to the cylinder block to the recommended torque following the order illustrated and using the angular tightening tool.

	Value - daNm	Fastening	Component	Ø
.	2+6+220°	Bolts	CYLINDER HEAD	-

	Description	Code	Function
.	Torque wrench	1.860.942.000	Connecting rod cap bolt tightening

- Fit the tappet cover in its housing on the cylinder head.1. Tighten the bolts fixing the tappet cover to torque in the order given below.

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

- Fit the timing sensor into its housing in the cam cover.- Tighten the power unit rigid mount lower bolts.1. Loosen bolts (1a) securing the camshaft pulley (1b).2. Fit the timing belt over the pulleys in order.- Check that the engine is at TDC and the camshaft reference is aligned.3. Fit the C-TRONIC - 105.5 tool facing downward.4. Unscrew bolt (4a) securing tensioner (4b) and use a ¼" box wrench to tension the belt to the specified value.

	Subject	Value
.	Timing belt/s	unità seem
-	Timing belt tension	108

- Tighten the tensioner bolt and the pulley bolts.- Remove the C-TRONIC - 105.5 tool.- Fit the timing belt pulley bolt provisionally so that the crankshaft can be turned.- Crank the engine through 8 revolutions without going backward.

- Turn the engine clockwise without going back until the TDC reference tool fits into its seat on the flywheel.

	Description	Code	Function
.	Pin	1.860.863.000	Crankshaft TDC reference

1. Loosen bolts (1a) securing the pulley (1b), then position the 8 mm timing reference pin (1c) through the pulley into its seat on the cylinder head.2. Fit the C-TRONIC - 105.5 tool facing downward.3. Unscrew bolt (3a) securing tensioner (3b) and use a ¼" box wrench to tension the belt to the specified value.

	Subject	Value
.	Timing belt/s	unità seem
-	Timing belt tension	54

- Tighten the tensioner bolt and the timing pulley bolts.- Remove the C-TRONIC - 105.5 tool.- Refit the C-TRONIC - 105.5 too and check that the belt tension is within specified values.

	Subject	Value
.	Timing belt/s	unità seem
-	Timing belt tension	51 - 57

- Remove the C-TRONIC - 105.5 tool.- Remove the TDC reference tool.

	Description	Code	Function
.	Pin	1.860.863.000	Crankshaft TDC reference

- Remove the 8 mm diameter timing reference tool.- Turn the engine through two revolutions clockwise without going back until the TDC reference tool fits into its seat on the flywheel.

	Description	Code	Function
.	Pin	1.860.863.000	Crankshaft TDC reference

- Check that the 8 mm diameter timing reference pin fits through the pulley into its seat on the cylinder head extension.- If not, loosen the pulley bolts and turn the camshaft anticlockwise until the 8 mm diameter timing reference pin fits through the pulley into its seat on the cylinder head extension.- Tighten the pulley retaining bolts.- Repeat the check.- Remove the TDC reference tool.

	Description	Code	Function
.	Pin	1.860.863.000	Crankshaft TDC reference

- Remove the 8 mm diameter timing reference tool.- Tighten the bolts securing the pulley to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2,0	Bolt	TIMING DRIVEN PULLIES	-

- Tighten the tensioner retaining bolt to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2,3	Bolt	MOBILE TIMING TENSIONER	-

- Position the timing belt lower guard and tighten the retaining bolts.- Position the timing belt side guard and tighten the retaining bolts.- Position the timing belt upper guard and tighten the retaining bolts.- Fit the flexible mounting in the housing in the engine compartment.- Tighten the nuts securing the flexible mounting to the bodyshell.

	Value - daNm	Fastening	Component	Ø
.	(body block) 5	Nuts	FRONT FLEXIBLE MOUNTING BLOCKS, POWER UNIT	M10

- Tighten the nut and the two bolts fixing the flexible mounting to the timing side rigid power unit support to torque.

	Value - daNm	Fastening	Component	Ø
.	(Rigid mount on engine) 5	Bolt	FRONT FLEXIBLE MOUNTING BLOCKS, POWER UNIT	M10

	Value - daNm	Fastening	Component	Ø
.	(Rigid mount on engine) 8	Nut	FRONT FLEXIBLE MOUNTING BLOCKS, POWER UNIT	M12

- Fit the flywheel lock.

	Description	Code	Function
.	Flywheel lock	1.870.765.001	Prevent flywheel rotation

- Fit the auxiliary drivebelt pulley and tighten the retaining bolt to torque using the angular tightening tool.

	Value - daNm	Fastening	Component	Ø
.	4+51°	Bolt	CRANKSHAFT PULLEY	-

	Description	Code	Function
.	Torque wrench	1.860.942.000	Connecting rod cap bolt angular tightening

- Remove the flywheel lock fitted previously.

	Description	Code	Function
.	Counter-torque	1.860.765.001	Loosen/tighten toothed timing drive pulley bolt

- Fit the rpm sensor in its housing on the gearbox bell housing and tighten the retaining bolt.- Connect the electrical connection for the rpm sensor.

	Description	Connector
.	Rpm sensor	K046

Op. 1092G10 SINGLE ENGINE BELT R R- Remove the tool positioned previously under the engine oil sump for supporting the power unit

	Description	Code	Function
.	Crossmember	1.870.735.000	Lower engine mounting beam

- Fit the rigid inlet water pipe on the pump.- Remove the reaction link from its seat again.- Fit the intake manifold from the upper part of the engine compartment.- Raise the vehicle.- Tighten the lower nuts and upper bolts securing the intake manifold to the cylinder head to torque.

	Value - daNm	Fastening	Component	Ø
.	2,3	Bolt	INLET MANIFOLD	-

- Fit the exhaust manifold complete with turbocharger from the lower part of the vehicle from the compartment between the suspension beam and body.- Tighten the bolt securing the turbocharger to the mounting bracket.- Tighten the nuts securing the exhaust manifold to the cylinder head.

	Value - daNm	Fastening	Component	Ø
.	2,0	Nut	EXHAUST MANIFOLD/S	-

- Connect the EGR exhaust gas delivery pipe from the turbocharger and tighten the retaining bolts.- Connect the rigid oil supply pipe to the turbocharger and tighten the connector.- Connect the band for the turbocharger sump oil return pipe.- Fit the lower reaction rod in the housing and tighten the bolt fixing the suspension crossmember to torque.- Tighten the nut fixing the reaction rod to the gearbox to torque.- Fit the press-fitted EGR pipe heat shield.- Fit the rigid air intake pipe to the turbo from the upper part of the engine bay and do up the retaining band.- Fit the rigid air outlet pipe from the turbocharger from the upper part of the engine bay and do up the lower band on the turbocharger.Characteristic of working principle - Lower the vehicle.- Fit the bracket on the thermostat and tighten the fixing bolts.- Fit the new pipe from the pressure pump to the fuel manifold.

Each time work is carried out on the pipe from the pressure pump to the fuel manifold it must be replaced with a new one to prevent fuel leaks from the connectors.

- Tighten the connectors on the pressure pump and on the return manifold to torque.

	Value - daNm	Fastening	Component	Ø
.	2	Connector	PRESSURE PUMP LINE TO FUEL MANIFOLD	-

- Fit the engine oil dipstick tube and tighten the retaining bolts.- Fit the bracket located near the pressure pump mounting and tighten the bolts.- Fit the flexible section of the lower engine coolant pipe.- Fit the rubber hose from the cam cover to the engine oil vapour separator.- Connect the two supply and return pipes to the thermostat from the engine oil oil heat exchanger.- Connect the supplementary heater coolant pipe and the thermostat pipe to the EGR exhaust gas heat exchanger.- Fit the rigid section of the water recirculation pipe to the cylinder head and tighten the retaining bolts.- Connect the water recirculation hose from the thermostat.- Connect the quick-release connector of the vacuum pump pipe.- Fit the heater water supply pipe.- Fit the fuel return manifold and connect the fuel recirculation pipe from the injectors.- Tighten the retaining bolt and connect the quick release fittings of both fuel pipes from the pressure pump.- Connect the three quick-release connectors on the fuel lines to the fuel return manifold.- Position the injection wiring and connect the electrical connections.

	Description	Connector
.	Injection pump third piston deactivation solenoid valve	L005

	Description	Connector
.	Fuel pressure regulator	N077

	Description	Connector
.	Fuel pressure sensor	K083

	Description	Connector
.	Injector	N070A

	Description	Connector
.	Injector	N070B

	Description	Connector
.	Injector	N070C

	Description	Connector
.	Injector	N070D

	Description	Connector
.	Timing sensor	K047

	Description	Connector
.	Engine oil pressure sensor	K028

	Description	Connector
.	Alternator	A010A

	Description	Connector
.	Alternator	A010B

	Description	Connector

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