939010419 - 1016C10 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET

Removing ( Refitting ) - Position the vehicle on a lift.- Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).

	Description	Connector
-	Battery	See A001 BATTERY

    Op. 1048A34 SLEEVE(S) FROM FLOW METER TO AIR SUPPLY CAPACITY CASE - R + R     Op. 1056F17 THROTTLE BODY WITH DVL R R     Op. 1072B50 AIR CHAMBER - R.R.    Op. 1072B54 HOSES CONNECTING AIR INTAKE CHAMBER TO INTAKE MANIFOLD(S) - R.R.    Op. 1072B21 AIR INTAKE FUEL MANIFOLD INTERGRATED DUCT R R AND REPLACE GASKET     Op. 1048A28 VACUUM AIR CIRCUIT RESONATOR PIPE - R+R     Op. 1072C43 EXHAUST MANIFOLD UPPER BULKHEAD R R     Op. 1072C42 EXHAUST MANIFOLD LOWER BULKHEAD R R - Undo the radiator coolant drain plug.

Collect the coolant in a suitable container.

- Loosen the band and disconnect the radiator lower coolant outlet hose, cylinder head side.- Using a suitable syringe, draw off the power assisted steering fluid from the reservoir.1. Undo the connector (1a) and disconnect the supply pipe from the pump to the power assisted steering box (1b), power assisted steering pump side.2. Loosen the band and disconnect the power assisted steering fluid pipe from the reservoir to the pump, power assisted steering pump side.3. Loosen the band and disconnect the power assisted steering fluid return pipe from the heat exchanger to the reservoir, reservoir side.4. Undo the bolts (4a) and remove the power assisted steering fluid reservoir (4b) complete with pipe (4c).5. Loosen the band and disconnect the coolant return pipe, cylinder head side. 1. Disconnect the electrical connections (1a) and (1b) from the phase transformer electromagnets.

	Description	Connector
1a	Exhaust side phase transformer solenoid valve	See N093 PHASE SHIFTER SOLENOID VALVE ON EXHAUST SIDE

	Description	Connector
1b	Inlet side phase transformer solenoid valve	See N092 PHASE SHIFTER SOLENOID VALVE ON INTAKE SIDE

1. Disconnect the electrical connections (1a) and (1b) from the cam angle sensors.

	Description	Connector
1a	Exhaust side timing sensor	See K107 EXHAUST SIDE TIMING SENSOR

	Description	Connector
1b	Inlet side timing sensor	See K106 INTAKE SIDE TIMING SENSOR

2. Disconnect the electrical connections from the electronic power module.

	Description	Connector
2	Ignition coil	See A030 IGNITION COIL

1. Disconnect the electrical connection from the engine coolant temperature sensor.

	Description	Connector
1	Engine coolant temperature sensor/sender unit	See K036 ENGINE COOLANT TEMPERATURE SENSOR/SENDER UNIT

- Release the engine electrical wiring from the securing bands and move it aside.- Discharge the fuel supply system pressure.1. Disconnect the rapid connector for the fuel supply pipe, multiple connector side. 1. Undo the bolts (1a) and remove the electronic power module (1b). 1. Undo the bolts (1a) and remove the tappet cover (1b) complete with gaskets.2. Unscrew the timing system hydraulic tensioner and remove. 1. If no mark (1b) is present on the fixed timing chain hydraulic tensioner (1a), replace the tensioner with a new unit including a new mobile chain tensioner pad. 1. Undo the bolts (1a) and disconnect the intermediate exhaust pipe (1b), exhaust manifold side with the catalytic converter.2. Undo the bolts fixing the exhaust manifold and the catalytic converter to the mounting bracket. 1. Undo the nuts (1a) and release the exhaust manifold and catalytic converter (1b) from the studs on the cylinder head.- Remove the exhaust manifold and catalytic converter gasket. 1. Undo the bolts (1a) and remove the phase transformer electromagnets (1b). 1. Undo the bolts (1a) and remove the upper timing chain tensioner pad (1b). 1. Support the engine using a hydraulic hoist fitted with suitable chains attached to the brackets on the actual engine. 1. Undo the bolts (1a), (1b) and remove the flexible mounting for the power unit timing side front support (1c) complete with power assisted steering fluid reservoir mounting bracket (1d). - Raise the engine as necessary using the hydraulic hoist.1. Undo the access cap to the belt tensioner pad upper fixing bolt.- Undo the upper fixed belt tensioner fixed pad fixing bolt.2. Undo the bolt fixing the power assisted steering pump bracket to the cylinder head. 1. Undo the camshaft phase transformer fixing bolts.

Turn the hexagonal bolts on the camshafts to provide countertorque.

2. Remove the phase transformers.- Secure the timing chain appropriately. 1. Place the timing side power unit front support flexible mounting (1a) in its housing complete with power assisted steering fluid reservoir mounting bracket (1b) and secure it tightening the bolts (1c) and (1d). 1. Undo the bolts securing the cylinder head to the engine crankcase.

The bolts are firstly loosened by 1/4 turn and then by 1/2 in the order illustrated in the diagram.

- Remove the cylinder head.

Two mechanics are needed for this operation.Take care to release the timing chain.

- Remove the cylinder head gasket. Refitting ( Removing ) - Clean any residues of gasket from the the cylinder head - engine block matching surfaces.- Carry out a visual inspection of the components.- The lower cylinder head plane can be refaced if the flatness is betweeb 0.05 and 0.15 mm.- The refacing does not have to be carried out for lower flatness values.- The refacing is not permitted for higher flatness values.- Before refacing it is necessary to check that the minimum depth for each combustion chamber is 12.75 mm (at the point shown in the diagram) in order to guarantee the minimum combustion chamber volume. - Place the cylinder head gasket in position.

The gasket should be positioned with the word "TOP" facing upwards.

- Place the cylinder head in position.

Two mechanics are needed for this operation.- Check that the centering bushes are correctly positioned.Take care to raise the timing chain.

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

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

Component	Fastening	dia	Value (daNm)	Validity
Cylinder head	Bolt	M11	(engine block side) 2.7 - 3.3 + 100° + 65°	1.9 JTS2.2 JTS

Tool	Description	Function	Validity
1860942000	Torque wrench	Tighten bolts to torque plus angle

- Support the engine using a hydraulic hoist fitted with suitable chains attached to the brackets on the actual engine.1. Undo the bolts (1a), (1b) and remove the flexible mounting for the power unit timing side front support (1c) complete with power assisted steering fluid reservoir mounting bracket (1d). 1. Tighten the bolt fixing the power assisted steering pump bracket to the cylinder head to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Power assisted steering pump	Bolt	M8	(cylinder head side) 1.9 - 2.1	1.9 JTS2.2 JTS3.2 JTS

- Tighten the upper bolt fixing the fixed belt tensioner pad to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing fixed chain tensioner pad	Upper bolt	M6	(cylinder head side) 0.8	1.9 JTS2.2 JTS

2. Tighten the access cap to the belt tensioner pad upper fixing bolt to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Cap for timing fixed chain tensioner pad upper bolt	-	M22	6.5	1.9 JTS2.2 JTS

1. Place the timing side power unit front support flexible mounting (1a) in its housing complete with power assisted steering fluid reservoir mounting bracket (1b) and secure it tightening the bolts (1c) and (1d) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support flexible mounting	Bolt (to be replaced)	M12	(rigid support side) 6.3 - 7.7 + 90°

Component	Fastening	dia	Value (daNm)	Validity
Timing side power unit rigid support flexible mounting	Bolt (to be replaced)	M12	(bodyshell side) 6.3 - 7.7 + 90°

1. Place the inlet side camshaft phase transformer (1a) in its housing and secure it using a new bolt (1b) without tightening it.2. If necessary, rotate the crankshaft until cylinder no. 4 is at T.D.C. in the explosion stroke; in this condition the reference (2a) on the inner part of the crankshaft pulley should be in line with the reference (2b) on the timing chain cover.

Rotate the crankshaft slowly and evenly (in the direction of rotation).

Ensure the timing chain is not stuck.

3. Fit the timing chain on the inlet side camshaft phase transformer.

The light blue mesh (3a) should be in line with the reference (3b) on the inlet side camshaft phase transformer.

4. Place the exhaust side camshaft phase transformer (4a) in its housing and secure it using a new bolt (4b) without tightening it.

Rotate the exhaust side camshaft using the hexagon until the pink mesh (4c) is in line with the reference (4d) on the exhaust side camshaft phase transformer.

Check that the timing chain is correctly fitted on the drive gear (on the crankshaft) checking that there are three chain links between the head support surface and the timing references on the phase transformers.

- Remove the hydraulic hoist fitted with suitable chains for supporting the engine.1. Place the phase transformer electromagnets (1a) in their housings and secure them tightening the bolts (1b) to the recommended torque.

The white phase transformer electromagnet is the inlet side one and the black phase transformer electromagnet is the exhaust side one.

Component	Fastening	dia	Value (daNm)	Validity
Phase transformer solenoids	Bolt	M6	(cylinder head side) 1.0	1.9 JTS2.2 JTS3.2 JTS

- The following drawing shows the fixed timing chain hydraulic tensioner disassembled.

Replace the seals.

1. Tighten the bolts fixing the exhaust manifold and the catalytic converter to the mounting bracket.2. Connect the intermediate exhaust pipe (2b), exhaust manifold side with the catalytic converter and tighten the bolts (2b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Intermediate exhaust pipe with flexible section	Bolt	M8	(exhaust manifold side with catalytic converter) 2.2 - 2.6	1.9 JTS2.2 JTS

- Before it is possible to refit the timing fixed hydraulic tensioner it must be pre-loaded as described below.1. Position the piston in a vice with protective jaws, holding it by the square end.2. Insert the piston into the tensioner case by pressing and turning as shown in the figure until the pin (2a) fits into the groove (2b).3. Press and simultaneously turn the piston until the pin (3a) fits into the groove (3b).- Insert the assembled piston into the tensioner body. - Refit the timing chain hydraulic tensioner into its seat and tighten to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing fixed hydraulic tensioner	-	M27	7.5	1.9 JTS2.2 JTS

1. Place the tappet cover (1a) complete with gaskets in its housing and secure it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Tappet cover	Bolt	M6	(cylinder head side) 0.7 - 0.9	1.9 JTS2.2 JTS

1. Move the timing chain hydraulic tensioner to operating position by exercising overall pressure by hand on the chain in the area shown in the figure. This puts the chain under tension, which in turn acts on the mobile pad to release the mobile tensioner piston.

When the piston is activated the spring will make a noise.

1. Place the electronic power module (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Ignition coil module	Bolt	M6	(tappet cover side) 2.2	1.9 JTS2.2 JTS

If the chain remains slack, the tensioner is not in the operating position.

- Rotate the crankshaft through 720°, then place cylinder no. 4 at T.D.C. during the explosion stroke; in this condition the reference on the inner part of the crankshaft pulley should be aligned with the reference on the timing chain cover.

When the crankshaft is rotated the tensioner piston should follow the chain during the rotation stage.

- Check the timing making sure that the timing references correspond.1. Place the upper timing chain pad (1a) in its housing and fasten it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Timing upper chain tensioner pad	Bolt	M6	(cylinder head side) 1.0	1.9 JTS2.2 JTS

- Connect the rapid connector for the fuel supply pipe, multiple connector side.- Place the engine electrical wiring in position and fasten it with the bands.- Connect the electrical connection to the engine coolant temperature sensor.- Connect the electrical connections to the electronic power module.- Connect the electrical connections to the cam angle sensors.- Connect the electrical connections to the phase transformer electromagnets.- Connect the coolant return pipe, cylinder head side, and tighten the band.- Place the power assisted steering fluid reservoir complete with pipe in its housing and secure it using the bolts.- Connect the return pipe from the heat exchanger to the power assisted steering fluid reservoir, reservoir side and tighten the band.- Connect the supply pipe from the fluid reservoir to the power assisted steering pump, power assisted steering pump side, and tighten the band.- Connect the supply pipe from the pump to the power assisted steering box, power assisted steering pump side and tighten the connector to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Supply pipe from pump to power assisted steering box	Connector	M16	(power assisted steering pump side) 3.6 - 4.4

- Connect the radiator lower coolant inlet hose, cylinder head side, and tighten the band.- Tighten the radiator coolant drain plug.    Op. 1072C42 EXHAUST MANIFOLD LOWER BULKHEAD R R     Op. 1072C43 EXHAUST MANIFOLD UPPER BULKHEAD R R     Op. 1048A28 VACUUM AIR CIRCUIT RESONATOR PIPE - R+R     Op. 1072B21 AIR INTAKE FUEL MANIFOLD INTERGRATED DUCT R R AND REPLACE GASKET     Op. 1072B54 HOSES CONNECTING AIR INTAKE CHAMBER TO INTAKE MANIFOLD(S) - R.R.    Op. 1072B50 AIR CHAMBER - R.R.    Op. 1056F17 THROTTLE BODY WITH DVL R R     Op. 1048A34 SLEEVE(S) FROM FLOW METER TO AIR SUPPLY CAPACITY CASE - R + R     Op. 0010T20 ENGINE COOLANT - CHANGE     Op. 0010T71 POWER STEERING FLUID CHECK LEVEL AND TOP UP IF NECESSARY     Op. 0010T75 HYDRAULIC POWER STEERING SYSTEM BLEED AIR - Connect the negative battery terminal.- Remove the vehicle from the lift.