75534 - 1016C10 SINGLE CYLINDER HEAD - R.R. and Replace gasket

Removing ( Refitting )     See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.    See in Op. 1016A10 SOUND-PROOFING COVER - R.R.    See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.    See in Op. 4450B04 Right FRONT WHEEL (one) - R.R.    See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.    See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.    See in Op. 1092G10 Engine components single drive BELT - R.R.    See in Op. 1032D12 Timing system protective COVER(S) - R.R.    See in Op. 1032B10 TOOTHED timing BELT - R.R. for timing adjustment or replacement1. Undo the fixing nuts (1a) and remove the bonnet lock (1b) from its housing in the crossmember.2. Undo the lower nut (2a) and remove the lock reinforcement bracket (2b).
1. Undo the fixing bolts.2. Remove the upper front crossmember.
1. Remove the cold air intke pipe from the connector on the air filter.
1. Disconnect the heat exchanger pipe from the intake air pipe.2. Undo the fixing bolts.3. Remove the metal air intake pipe.4. Remove the vapour recirculation pipe disconnecting it from the tappet cover (4a) and from the air hose (4b).5. Disconnect the air vacuum pipe from the connector on the vacuum unit.
1. Undo the fixing bolts.2. Disconnect the flexible vacuum pipes from the actuator solenoid valve and the vacuum reservoir.3. Remove the rigid section of the EGR vacuum pipe.
1. Disconnect the engine coolant pipes.2. Undo the bolts fixing the rigid pipe to the cylinder head.3. Remove the rigid water pump inlet pipe.
1. Undo the bolts fixing the rigid EGR pipe to the exhaust manifold.2. Undo the turbocharger reinforcement bracket fastenings.3. Remove the bracket.4. Undo the fixing nuts (4a) and release the exhaust manifold/turbocharger assembly (4b) from the cylinder head pins.
1. Disconnect the electrical connection for the engine coolant temperature sensor.
DescriptionConnector
.I.E. engine temperature sensorK045
1. Disconnect the electrical connections (1a), (1b), (1c), (1d), (1e), (1f), (1g) and (1h).
DescriptionConnector
1a InjectorN070A
DescriptionConnector
1b Air conditioning compressor engagement electro-magnetL020
DescriptionConnector
1d Fuel pressure sensorK083
DescriptionConnector
1e EGR solenoid valveL030
DescriptionConnector
1f Supercharging sensorK082
DescriptionConnector
1g Timing sensorK047
DescriptionConnector
1h Heater plugs control unitM015A
DescriptionConnector
InjectorN070B
DescriptionConnector
InjectorN070C
DescriptionConnector
InjectorN070D
DescriptionConnector
InjectorN070E
DescriptionConnector
1h Heater plugs control unitM015B
DescriptionConnector
1h Heater plugs control unitM015C
DescriptionConnector
1c Turbocharger vane solenoid valveL036
2. Undo the fixing bolts (2a) and remove the injection wiring (2b) from the work area.
1. Disconnect the upper pipe from the connector on the radiator.2. Disconnect the oil radiator engine coolant pipe (Modine).3. Disconnect the two heater coolant supply and return pipes.
1. Undo the nuts fixing the return manifold to the intake manifold.2. Disconnect the recirculation pipe.3. Remove the rigid supply pipe from the pressure pump to the single fuel delivery manifold.
1. Undo the fixing bolts (1a) and remove the bracket (1b).2. Undo the bolt fixing the intake manifold to the pressure pump support.
1. Undo the fixing bolts.2. Remove the tappet cover.
- Draw off the engine oil from the chambers in the cylinder head.1. Loosen the bolts fixing the cylinder head.2. Position a bracket (2a) fastened to the exhaust manifold stud and secure the hook (2b) for manoeuvring the cylinder head later on safely to it.3. Position a second hook on the intake manifold.- Secure the chains to a hydraulic lift.4. Lift and remove the cylinder head, complete with intake manifold.- Keep the cylinder head gasket.
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 the ASTADUR type.
- On account of the special material from which these gaskets are made they undergo a polymerization process whilst the engine is working, becoming considerably harder during usage. In order to ensure that the polymerization process takes place, observe the precautions described below:- Keep the gasket sealed in its nylon container and only take it out shortly before fitting.- Do not lubricate the gasket or get oil or grease on it.- Position the cylinder head on the cylinder block/crankcase.- Release the supporting hooks and remove the mounting 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 - daNmFasteningComponentØ  
.2 + 6.5 + 90° + 90° + 90°BoltsCYLINDER HEADM12
The figure of 2 daNm in the table below is a tightening value for all the bolts following the order illustrated in the diagram.
- Remove the brackets, chains and hooks positioned previously for lifting the cylinder head.- Fit the tappet cover on the cylinder head.- Tighten the bolts fixing the tappet cover to torque.
Value - daNmFasteningComponentØ  
.1BoltsCAM COVERM6
- Tighten the bolt fixing the intake manifold to the pressure pump support to torque.
Value - daNmFasteningComponentØ  
.2.5BoltINLET MANIFOLDM8
- Fit the bracket joining the intake manifold - pump support.- 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 has to be replaced with a new pipe to prevent fuel leaking from the connectors.
- Tighten the connectors on the pressure pump and the single fuel delivery manifold to torque.
Value - daNmFasteningComponentØ  
.2.3ConnectorPRESSURE PUMP LINE TO FUEL MANIFOLDM14 X 1.5
- Position the return manifold in the special housing in the intake manifold and tighten the fixing nuts.- Connect the fuel recirculation pipe to the injectors.- Connect the two heater coolant supply and return pipes to the heater.- Connect the oil radiator engine coolant pipe (Modine) to the thermostat.- Connect the upper pipe to the connector on the radiator.- Connect the electrical connections for the injection wiring disconnected previously.
DescriptionConnector
.InjectorN070A
DescriptionConnector
.Air conditioning compressor engagement electro-magnetL020
DescriptionConnector
.Fuel pressure sensorK083
DescriptionConnector
.EGR solenoid valveL030
DescriptionConnector
.Supercharging sensorK082
DescriptionConnector
.Timing sensorK047
DescriptionConnector
.Heater plugs control unitM015A
DescriptionConnector
.InjectorN070B
DescriptionConnector
.InjectorN070C
DescriptionConnector
.InjectorN070D
DescriptionConnector
.InjectorN070E
DescriptionConnector
.Heater plugs control unitM015B
DescriptionConnector
.Heater plugs control unitM015C
- Tighten the bolts fixing the cable loom to the intake manifold.- Connect the engine coolant temperature sensor electrical connection.
DescriptionConnector
.I.E. engine temperature sensorK045
- Position the exhaust manifold in the special housing on the cylinder head pins.- Tighten the nuts fixing the manifold to the cylinder head to torque.
Value - daNmFasteningComponentØ  
.(Cylinder head) 2.5NutEXHAUST MANIFOLD/SM8
- Fit the exhaust manifold reinforcement bracket on the cylinder head.- Tighten the nuts and the bolt fixing the bracket to the head and themanifold to torque.
Value - daNmFasteningComponentØ  
.(Cylinder head) 2.5NutTURBOCHARGER SUPPORTM8
Value - daNmFasteningComponentØ  
.(Exhaust manifold)BoltsTURBOCHARGER SUPPORTM8
- Position the EGR exhaust gas supply pipe and tighten the bolts fixing it to the exhaust manifold.- Position the new gasket for the rigid water pump inlet pipe.- Fit the rigid inlet water pipe on the pump.- Tighten the bolts fixing the rigid pipe to the cylinder head to torque.
Value - daNmFasteningComponentØ  
.(Cylinder head) 0.9BoltCOOLANT PUMP RIGID INLET PIPEM6
- Connect the engine coolant pipes to the pump rigid water inlet pipe.- Fit the pipe assembly.- Connect the flexible pipe to the actuator solenoid valve.- Connect the flexible pipe from the vacuum reservoir.- Tighten the bolts fixing the rigid section of the pipe.- Connect the air vacuum pipe to the connector on the vacuum unit.- Fit the vapour recirculation pipe connecting it to the tappet cover and to the turbocharger air hose.- Fit the metal air intake pipe on the throttle casing and tighten the fixing bolts.- Connect the air/air heat exchanger flexible pipe to the rigid section.- Fit the cold air intake pipe to the connector on the air filter.- Fit the upper front crossmember and tighten the fixing bolts to torque.
Value - daNmFasteningComponentØ  
.0.6BoltsFRONT WING CROSSMEMBER HEADLAMP HOUSINGSM6
- Fit the bonnet lock complete with bracket and tighten the nuts fixing it to the upper crossmember and to the lower crossmember.    See in Op. 1032B10 TOOTHED timing BELT - R.R. for timing adjustment or replacement    See in Op. 1032D12 Timing system protective COVER(S) - R.R.    See in Op. 1092G10 Engine components single drive BELT - R.R.    See in Op. 7055B64 Engine compartment DUST SEAL in front wheel arch (one), left or right - R.R.    See in Op. 7055B42 FRONT WHEEL ARCH LINER (one), left or right - R.R.    See in Op. 4450B04 Right FRONT WHEEL (one) - R.R.    See in Op. 7055B54 PROTECTION/GUARD under engine - R.R.    See in Op. 0010T20 Engine REFRIGERANT FLUID - Change    See in Op. 0010T21 ENGINE COOLANT - Check density and top up if necessary- [0010T21]    See in Op. 1016A10 SOUND-PROOFING COVER - R.R.    See in Op. 7040D50 ENGINE COMPARTMENT UPPER SOUND INSULATION SHIELD - R.R.- Close the bonnet and remove the vehicle from the lift.