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

Removing ( Refitting ) - Position the vehicle on a lift.    Op. 1016A10 SOUND-PROOFING COVER - R.R     Op. 5530B10 BATTERY - R+R     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.     Op. 4450B04 RIGHT FRONT WHEEL - R.R     Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.     Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.     Op. 1092G10 SINGLE ENGINE BELT - R.R     Op. 1092A10 CRANKSHAFT PULLEY - R + R

Collect the coolant in a suitable container.

1. Unscrew bolts (1a), loosen collar (1b) and remove the sleeve (1c) and rigid air intake pipe (1d) to the throttle body.2. Disconnect the rapid connector for the vacuum intake pipe from the vacuum pump.3.Loosen the band and disconnect the radiator upper coolant inlet hose, thermostat side. 1. Disconnect the vacuum pipes from the vacuum reservoir.2. Disconnect the vacuum pipe from the turbocharger vane position actuator control solenoid valve.3. Disconnect the vacuum pipe from the vacuum pump.4. Undo the fastenings (4a) and remove the vacuum pipes (4b). 1. Disconnect the electrical connection from the throttle casing.

	Description	Connector
1	Integrated throttle casing actuator	See N075 THROTTLE BODY ACTUATOR

2. Disconnect the electrical connection from the fuel pressure sensor on the fuel manifold.

	Description	Connector
2	Fuel pressure sensor	See K083 FUEL PRESSURE SENSOR

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

2. Loosen the band and disconnect the coolant return pipe to the engine coolant reservoir, thermostat side. 1. Loosen the bands (1a), undo the bolts (1b) and remove the coolant return pipe to the engine coolant supply reservoir (1c). 1. Disconnect the electrical connection from the EGR system solenoid valve

	Description	Connector
1	E.G.R. solenoid	See L030 EGR SOLENOID VALVE

2. Disconnect the electrical connection from the pressure relief sensor.

	Description	Connector
2	Supercharging sensor	See K082 SUPERCHARGING SENSOR

1. Disconnect the electrical connections from the injectors.

	Description	Connector
1	Injector	See N070 INJECTOR

2. Undo the bolts (2a) and rmove the electrical wiring (2b) aside. 1. Disconnect the pipes (1a), undo the bolts (1b) and remove the fuel return manifold (1c).2. Disconnect the electrical connection from the fuel pressure regulator on the pressure pump.

	Description	Connector
2	Pressure regulator on pressure pump	See N077 FUEL PRESSURE REGULATOR

3. Disconnect the electrical connection from the fuel pressure regulator on the injector single manifold.

	Description	Connector
3	Fuel pressure regulator on rail	See N087 FUEL PRESSURE REGULATOR ON RAIL

1. Manually push the clips (1a) and disconnect the pipe from the injectors to the fuel recovery manifold (1b), injector side and remove it.2. Undo the connectors securing the pipes from the fuel manifold to the injectors, injector side. 1. Unscrew the connectors (1a) and remove the pipes from the fuel manifold to the injectors (1b).2. undo the connectors (2a), (2b) and remove the pipe from the pressure pump to the fuel manifold (2c).3. Undo the nuts (3a) and remove the single fuel manifold pipe assembly (3b). 1. Undo the nuts fixing the injector mounting brackets.2. Position the tool (2a) for extracting the injectors, taking care to position the lifting bracket (2b) under the polygonal area (2c) of the injector.

Tool	Description	Function	Validity
1870739000	Extractor	Removing injectors	1.9 JTD 8V1.9 JTD 16V

3. Position the second lifting bracket for the tool (3a) under the injector securing bracket (3b).4. Tighten the nut for the tool (4a) and remove the injector assembly (4b).- Repeat the operation for the remaining injectors. 1. Loosen the bands (1a), undo the fastenings (1b) and remove the engine cooling system supply pipe (1c).2. Loosen the band and disconnect the coolant outlet pipe from the coolant/exhaust gas heat exchanger for the EGR system.3. Loosen the band and disconnect the coolant return pipe from the engine oil heat exchanger on the water pump rigid inlet pipe side. 1.Loosen the band and disconnect the lower coolant inlet hose from the radiator, water pump rigid coolant inlet pipe side.2. Undo the upper bolt securing the engine oil dipstick tube. 1. Undo the bolts (1a) and remove the side guard (1b) for the timing belt. 1. Undo the bolts (1a) and remove the water pump inlet pipe (1b).- Remove the gasket. 1. Undo the two upper bolts fixing the exhaust manifold heat shield. 1. Undo the lower bolt securing the engine oil dipstick tube. 1. Undo the nuts (1a) and the bolt (1b) securing the exhaust manifold heat shield. - Working via the engine compartment, remove the pipe for the engine oil dipstick and the exhaust manifold heat shield.1. Undo the bolts securing the engine oil return pipe from the turbocharger, engine block side.2. Undo the connector fastening the engine oil supply pipe to the turbocharger, engine block side. 1. Undo the nuts fixing the intermediate exhaust pipe mounting bracket.2. Undo the nuts (2a) and disconnect the intermediate exhaust pipe (2b) from the catalytic converter.- Remove the gasket. 1. Undo the bolts (1a), loosen the collar (1b) and remove the exhaust gas intake pipe from the exhaust manifold to the E.G.R. heat exchanger (1c).2. Remove the relative seals. 1. Undo the nuts (1a) and move the turbocharger and exhaust manifold assembly (1b) away from the cylinder head. 1. Undo the bolts fixing the exhaust gas outlet hose from the E.G.R. solenoid valve, E.G.R. solenoid valve side.2. Undo the bolts (2a) and remove the throttle body (2b).- Remove the gasket. 1. Undo the bolts (1a) and remove the vacuum unit (1b).- Remove the gasket. 1. Loosen the bands and disconnect the pipes from the thermostat.2. Undo the bolts (2a) and remove the thermostat (2b).- Remove the gasket. 1. Loosen the collar (1a) and disconnect the exhaust gas outlet hose from the exhaust gas/water heat exchanger for the E.G.R. system (1b), heat exchanger side.2. Undo the fixing bolts (2a) and remove the E.G.R. system solenoid valve (2b) complete with hose.- Remove the gasket. 1. Undo the fastenings (1a) and remove the water/exhaust gas heat exchanger for the E.G.R. system (1b).2. Loosen the band and disconnect the oil vapour pipe from the tappet cover to the crankcase, tappet cover side. 1. Undo the nuts (1a) and remove the vacuum reservoir for the engine air intake management (1b). 1. Undo the fastenings (1a) and remove the vacuum reservoir mounting (1b).2. Disconnect the electrical connections from the heater plugs.

	Description	Connector
2	Heater plugs	See A040 HEATER PLUGS

1. Undo the bolts (1a) and remove the cam cover (1b) complete with gasket.     Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE     Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R     Op. 1092G20 ENGINE COMPONENT SINGLE BELT FIXED TENSIONER - ONE - R + R     Op. 1008A46 POWER UNIT RIGID SUPPORT - TIMING SIDE - R.R.     Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT 1. Fit the timing side power unit rigid support (1a) temporarily in its housing and secure it using the bolts (1b). 1. Place the flexible mounting for the timing side power unit front support (1a) in its housing temporarily and secure it using the bolts (1b), (1c).- Remove the hydraulic jack from underneath the engine. 1. Undo the bolts (1a), (1b) and remove the cylinder head (1c).2. Remove 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.- Position the cylinder head on the cylinder block/crankcase.1. Tighten the bolts securing the cylinder head to the cylinder block to the recommended torque following the order illustrated and using the angular tightening tool.

Component	Fastening	dia	Value (daNm)	Validity
Cylinder head	Bolt	M12	(engine crankcase side) 6.2 - 6.8 + 90° + 90° + 90°	1.9 JTD 8v

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

- Tighten the bolt fixing the pressure pump mounting to the cylinder head to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Pressure pump mounting	Bolt	M10	(cylinder head side) 4.5 - 5.5	1.9 JTD 8v

- Position a hydraulic jack underneath the engine.- Remove the flexible mounting for the timing side power unit front support fitted provisionally.- Remove the timing side rigid power unit support fitted provisionally.    Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT     Op. 1008A46 POWER UNIT RIGID SUPPORT - TIMING SIDE - R.R.     Op. 1092G20 ENGINE COMPONENT SINGLE BELT FIXED TENSIONER - ONE - R + R     Op. 1032D12 TIMING SYSTEM PROTECTIVE COVER(S) - R + R     Op. 1008B10 POWER UNIT FRONT SUPPORT FLEXIBLE MOUNTING (TIMING SIDE) - REPLACE - Place the tappet cover in position and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Tappet cover	Bolt	M6	(cylinder head side) 0.8 - 1.0	1.9 JTD 8v

- Connect the electrical connections to the heater plugs.-- Place the vacuum reservoir mounting back in its housing and secure it.- Place the vacuum reservoir for the engine air intake management back in its housing and secure it using the nuts.- Connect the oil vapour pipe from the tappet cover to the crankcase, tappet cover side and tighten the band.- Place the exhaust gas/water heat exchanger for the E.G.R. system back in its housing and secure it.- Place the gasket for the E.G.R. system solenoid valve in its housing.1. Place the E.G.R. system solenoid valve (1a) complete with hose in its housing and fasten it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
E.G.R. system solenoid valve	Bolt	M8	(intake manifold side) 2.3 - 2.8	1.9 JTD 8v

2. Connect the exhaust gas outlet hose from the exhaust gas/water heat exchanger for the E.G.R. system (2a), heat exchanger side and tighten the collar (2b). - Place the gasket for the thermostat back in its housing.1. Place the thermostat (1a) in its housing and fasten it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Thermostat	Bolt	M8	(cylinder head side) 2.3 - 2.8	1.9 JTD 8v

2. Connect the pipes to the thermostat and tighten the bands. - Place the gasket for the vacuum unit back in its housing.1. Place the vacuum unit (1a) in its housing and fasten it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Vacuum unit	Bolt	M8	(cylinder head side) 2.7 - 3.3	1.9 JTD 8v

- Place the gasket for the throttle body back in its housing.1. Place the throttle body (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Throttle body	Bolt	-	(intake manifold side)	1.9 JTD 8v

2. Tighten the bolts fixing the exhaust gas outlet hose from the E.G.R. solenoid valve, E.G.R. solenoid valve side. 1. Place the turbocharger and exhaust manifold assembly (1a) in its housing and tighten the nuts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Turbocharger and exhaust manifold assembly	Nut	M8	(cylinder head side) 2.2 - 2.7	1.9 JTD 8v

1. Place the exhaust gas intake pipe from the exhaust manifold to the E.G.R. heat exchanger (1a) back in its housing complete with gaskets (1b), then secure it tightening the collar (1c) and the bolts (1d) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Exhaust gas/water heat exchanger for E.G.R. system	Bolt	M8	(exhaust manifold side) 2.3 - 2.8	1.9 JTD 8v

- Place the exhaust pipe gasket in its housing.1. Connect the intermediate exhaust pipe (1a) to the catalytic converter and tighten the nuts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Intermediate exhaust pipe with flexible section	Nut	M8	(catalytic converter side) 2.2 - 2.6	1.9 JTD 16v1.9 JTD 8v2.4 JTD 20v

2. Tighten the nuts securing the intermediate exhaust pipe mounting bracket. 1. Tighten the connector securing the engine oil delivery pipe to the turbocharger, crankcase side to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil supply pipe to turbocharger	Connector	M12	(engine crankcase side) 2.2 - 2.7	1.9 JTD 16v1.9 JTD 8v

2. Tighten the bolts securing the engine oil return pipe from the turbocharger, crankcase side, to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil supply pipe from turbocharger	Bolt	M8	(engine crankcase side) 2.2 - 2.7	1.9 JTD 16v1.9 JTD 8v

- Working via the engine compartment, place the pipe for the engine oil dipstick and the exhaust manifold heat shield in their housings.- Tighten the lower nuts and the bolt securing the exhaust manifold heat shield.- Tighten the lower bolt securing the engine oil dipstick tube.- Tighten the two upper bolts fixing the exhaust manifold heat shield.- Place the water pump rigid inlet pipe gasket in its housing.1. Place the water pump rigid inlet pipe (1a) in position and secure it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Water pump rigid inlet pipe	Bolt	M6	(cylinder head side) 0.8 - 1.0	1.9 JTD 16v1.9 JTD 8v

- Fit the timing belt side protective cover and secure it using the bolts.- Tighten the upper bolt securing the engine oil dipstick tube.- Connect the lower coolant inlet hose from the radiator, water pump rigid coolant inlet pipe side and tighten the band.- Connect the return pipe from the engine oil heat exchanger, water pump rigid inlet pipe and tighten the band.- Connect the coolant oulet pipe from the coolant/exhaust gas heat exchanger for the EGR system and tighten the band.- Place the engine cooling system supply pipe in its housing, secure it and tighten the bands.- Place the injectors in their seats complete with brackets and fasten them tightening the nuts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Injector brackets	Nut	M8	(cylinder head side) 2.7 - 3.3	1.9 JTD 8v

1. Place the single fuel manifold pipe (1a) in its housing and secure it tightening the nuts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Single fuel manifold pipe (rail)	Nut	M8	(intake manifold side) 2.3 - 2.8	1.9 JTD 8v

2. Place the pipe from the pressure pump to the fuel manifold pipe (2a) back in its housing and secure it tightening the connectors (2b) and (2c) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Pipe from pressure pump to fuel manifold	Connector	M12	(pressure pump side) 2.2 - 2.4	1.9 JTD 8v

Component	Fastening	dia	Value (daNm)	Validity
Pipe from pressure pump to fuel manifold	Connector	M14	(fuel manifold side) 2.2 - 2.4	1.9 JTD 8v

3. Place the pipes from the fuel manifold to the injectors (3a) in their housings and secure them tightening the connectors (3b) and (3c) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Pipes from fuel manifold to injectors	Connector	M14	(fuel manifold side) 2.2 - 2.4	1.9 JTD 8v

Component	Fastening	dia	Value (daNm)	Validity
Pipes from fuel manifold to injectors	Connector	M12	(injector side) 2.2 - 2.4	1.9 JTD 8v

- Place the pipe from the injectors to the fuel recovery manifold in its housing and connect it to the injectors and push home until the clips click into place.- Connect the electrical connection to the fuel pressure regulator on the injector single manifold.- Connect the electrical connection to the fuel pressure regulator on the pressure pump.- Place the fuel return manifold in its housing, secure it using the bolts and connect the pipes.- Place the electrical wiring in position and fasten it using the bolts.- Connect the electrical connections to the injectors.- Connect the electrical connection for the pressure relief sensor.- Connect the electrical connection to the EGR system solenoid valve- Place the coolant return pipe to the engine coolant reservoir in position and secure it using the bolts and tighten the bands.- Connect the electrical connection to the engine coolant temperature sensor.- Connect the electrical connection to the fuel pressure sensor on the fuel manifold.- Connect the electrical connection to the throttle casing.- Place the vacuum pipes in their housings and secure them.- Connect the vacuum pipe to the vacuum unit.- Connect the vacuum pipe to the turbocharger vane position actuator control solenoid valve.- Connect the vacuum pipes to the vacuum reservoir.- Connect the radiator upper coolant inlet hose, thermostat side, and tighten the band.- Connect the vacuum pipe rapid connector to the vacuum pump.- Place the hose and the throttle body rigid air inlet pipe in their housings, then fasten them using the band and the bolts.- Tighten the coolant drain plug to the radiator.    Op. 1092A10 CRANKSHAFT PULLEY - R + R     Op. 1092G10 SINGLE ENGINE BELT - R.R     Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.     Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.     Op. 4450B04 RIGHT FRONT WHEEL - R.R     Op. 1048A10 AIR FILTER ASSEMBLY - R.R.     Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R     Op. 5530B10 BATTERY - R+R     Op. 1016A10 SOUND-PROOFING COVER - R.R     Op. 0010T20 ENGINE COOLANT - CHANGE     Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R. - Remove the vehicle from the lift.