Cylinder head - r + r and replace gasket

Operation 1016C10 · Cylinder head - remove + re-fit

1.6 TS · 103 CV

Removing

Position the vehicle on the ramp.

Ensure that the ignition key is in the OFF position, then disconnect the negative battery terminal (-).

Proceed with the removal - 4450B10 Front WHEEL (one) - R.R. (Right side).

Proceed with the removal - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. (Right side).

1. Disconnect the lower coolant outlet hose from the radiator and drain the engine coolant.

Manually press the springs and remove the rapid attachment for the hose.

Recover the coolant using a suitable container.

Proceed with removal - 1016A40 ignition coil cover on cylinder head- r+r.

Proceed with removal - 5510C14 ignition coil/s - r+r.

Proceed with removal - 1016A20 single cam cover - r + r and replace gasket.

Proceed with removal - 1056B60 single fuel manifold pipe, with injectors - r + r.

Proceed with removal - 1072B50 sleeves connecting air capacity box to inlet manifold is - r+r.

1. Undo the bolts (1a) and release the mounting bracket (1b) for the power assisted steering fluid reservoir from the intake manifold.

Proceed with removal - 1072C44 exhaust manifold heat shield on bulkhead - r+r.

1. Undo the nut securing the engine oil dipstick to the exhaust manifold.

2. Undo the nuts fixing the catalytic converter to the manifold.

3. Disconnect the engine coolant system supply pipe from the water pump rigid inlet pipe.

1. Disconnect the upper coolant inlet hose to the radiator, thermostat side.

2. Disconnect the coolant supply pipe to the air conditioning system heater, thermostat side.

3. Disconnect the coolant return pipe from the climate control system heater, on the side of the rigid fluid intake to the coolant pump.

Proceed with removal - 1092G10 single engine belt r r.

Proceed with removal - 1092G20 engine component single belt fixed tensioner - one - r + r.

Proceed with removal - 1092A10 Crankshaft services PULLEY - R.R..

Proceed with removal - 1032D12 timing system protective cover(s) - r + r.

Proceed with removal - 1032B10 toothed timing belt - r + r for timing adjustment or replacement.

1. Undo the bolts (1a) and remove the cylinder head (1b).

To undo/tighten the cylinder head bolts, use the ordinary spanner USAG 233 1/2 S.

2. Remove the cylinder head gasket.

Refitting

Place the cylinder head gasket back in its housing.

Position the cylinder head on the cylinder block, taking care that the camshafts are positioned with the front cams facing outwards (valves closed).

1. Tighten the bolts (1a) fixing the cylinder head to the recommended torque using the angular tightening tool (1b).

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

To undo/tighten the cylinder head bolts, use the ordinary spanner USAG 233 1/2 S.

The value of 4.0 daNm should be implemented by tightening to 2.0 daNm and then increased by a torque of 2.0 daNm until the nominal value of 4.0 daNm is reached.

Proceed with refitting - 1032B10 toothed timing belt - r + r for timing adjustment or replacement.

Proceed with refitting - 1032D12 timing system protective cover(s) - r + r.

Proceed with refitting - 1092A10 Crankshaft services PULLEY - R.R..

Proceed with refitting - 1092G20 engine component single belt fixed tensioner - one - r + r.

Proceed with refitting - 1092G10 single engine belt r r.

Connect the coolant return hose from the climate control system heater on the side of the rigid inlet pipe to the water pump.

Connect the engine coolant supply pipe from the climate control system heater, thermostat side.

Connect the upper coolant inlet hose to the radiator, thermostat side.

Connect the engine cooling system supply pipe to the water pump rigid outlet pipe.

1. Tighten the nuts fixing the catalytic converter to the manifold to the recommended torque.

Tighten the nut securing the tube for the oil dipstick to the exhaust manifold.

Proceed with refitting - 1072C44 exhaust manifold heat shield on bulkhead - r+r.

Place the power assisted steering reservoir mounting bracket back in its housing and secure it using the bolts.

Proceed with refitting - 1072B50 sleeves connecting air capacity box to inlet manifold is - r+r.

Proceed with refitting - 1056B60 single fuel manifold pipe, with injectors - r + r.

Proceed with refitting - 1016A20 single cam cover - r + r and replace gasket.

Proceed with refitting - 5510C14 ignition coil/s - r+r.

Proceed with refitting - 1016A40 ignition coil cover on cylinder head- r+r.

Connect the lower coolant outlet hose from the radiator.

Proceed with the refitting - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. (Right side).

Proceed with the refitting - 4450B10 Front WHEEL (one) - R.R. (Right side).

Refill the cooling system - 0010T20 coolant change.

Connect the negative (-) battery terminal.

Remove the car from the ramps.

1.6 TS · 120 CV

Removing

Position the vehicle on the ramp.

Proceed with removal - 5530B10 battery - r+r.

Proceed with the removal - 4450B10 Front WHEEL (one) - R.R. (Right side).

Proceed with the removal - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. (Right side).

1. Disconnect the lower coolant outlet hose from the radiator and drain the engine coolant.

Manually press the springs and remove the rapid attachment for the hose.

Recover the coolant using a suitable container.

Proceed with removal - 1016A40 ignition coil cover on cylinder head- r+r.

Proceed with removal - 5510C14 ignition coil/s - r+r.

Proceed with removal - 1016A20 single cam cover - r + r and replace gasket.

Proceed with removal - 1056B60 single fuel manifold pipe, with injectors - r + r.

Proceed with removal - 1072B50 sleeves connecting air capacity box to inlet manifold is - r+r.

1. Undo the bolts (1a) and remove the bracket (1b) connecting the intake manifold to the bracket on the engine for the reaction rod.

1. Disconnect the coolant supply pipe to the air conditioning system heater, thermostat side.

2. Disconnect the coolant return pipe from the air conditioning system heater, on the side of the rigid fluid intake to the coolant pump.

3. Disconnect the flexible coolant supply pipe from the rigid pipe to the engine oil heat exchanger.

4. Disconnect the lower coolant outlet sleeve from the radiator.

Proceed with removal - 1072C44 exhaust manifold heat shield on bulkhead - r+r.

1. Undo the bolt fixing the engine oil dipstick tube.

2. Remove the tube for the engine oil dipstick.

1. Unscrew the nuts securing the catalytic preconverter to the exhaust manifold.

2. Undo the nuts fixing the catalytic pre-converter to the mounting bracket.

1. Undo the plug and drain the engine oil.

Collect the engine oil in a suitable container.

1. Release and remove the engine oil filter using a suitable tool.

2. Undo the pin (2a) and disconnect the engine oil heat exchanger (2b) from the crankshaft oil seal front cover.

1. Disconnect the engine coolant system supply pipe from the water pump rigid inlet pipe.

Proceed with removal - 1092G10 single engine belt r r.

Proceed with removal - 1092A10 Crankshaft services PULLEY - R.R..

Proceed with removal - 1092G20 engine component single belt fixed tensioner - one - r + r.

Proceed with removal - 1032D12 timing system protective cover(s) - r + r.

Proceed with removal - 1032B10 toothed timing belt - r + r for timing adjustment or replacement.

1. Undo the bolts (1a) and remove the cylinder head (1b).

To undo/tighten the cylinder head bolts, use the ordinary spanner USAG 233 1/2 S.

2. Remove the cylinder head gasket.

Refitting

Place the cylinder head gasket back in its housing.

Position the cylinder head on the cylinder block, taking care that the camshafts are positioned with the front cams facing outwards (valves closed).

1. Tighten the bolts (1a) fixing the cylinder head to the recommended torque using the angular tightening tool (1b).

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

To undo/tighten the cylinder head bolts, use the ordinary spanner USAG 233 1/2 S.

The value of 4.0 daNm should be implemented by tightening to 2.0 daNm and then increased by a torque of 2.0 daNm until the nominal value of 4.0 daNm is reached.

Proceed with refitting - 1032B10 toothed timing belt - r + r for timing adjustment or replacement.

Proceed with refitting - 1032D12 timing system protective cover(s) - r + r.

Proceed with refitting - 1092G20 engine component single belt fixed tensioner - one - r + r.

Proceed with refitting - 1092A10 Crankshaft services PULLEY - R.R..

Proceed with refitting - 1092G10 single engine belt r r.

Connect the engine cooling system supply pipe to the water pump rigid outlet pipe.

Place the engine oil heat exchanger back in its housing and fix it to the crankshaft front oil seal cover using the pin.

Refit the engine oil filter in its seating and tighten it fully by hand.

1. Tighten the engine oil drain plug to the crankcase sump to the recommended torque.

Tighten the nuts fixing the front section of the exhaust pipe to the mounting bracket.

Tighten the nuts fixing the catalytic pre-converter to the exhaust manifold to the recommended torque.

Place the engine oil dipstick tube in its seating and fix it using the bolt.

Proceed with refitting - 1072C44 exhaust manifold heat shield on bulkhead - r+r.

Connect the lower coolant outlet hose to the radiator.

Connect the flexible coolant supply pipe to the rigid pipe to the engine oil heat exchanger.

Connect the coolant return hose from the air conditioning system heater on the side of the rigid inlet pipe to the water pump.

Connect the coolant supply pipe to the air conditioning system heater, thermostat side.

Place the bracket connecting the intake manifold to the bracket on the engine for the reaction rod back in its housing and fix it using the bolts.

Proceed with refitting - 1072B50 sleeves connecting air capacity box to inlet manifold is - r+r.

Proceed with refitting - 1056B60 single fuel manifold pipe, with injectors - r + r.

Proceed with refitting - 1016A20 single cam cover - r + r and replace gasket.

Proceed with refitting - 5510C14 ignition coil/s - r+r.

Proceed with refitting - 1016A40 ignition coil cover on cylinder head- r+r.

Connect the lower coolant outlet hose from the radiator.

Proceed with the refitting - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. (Right side).

Proceed with the refitting - 4450B10 Front WHEEL (one) - R.R. (Right side).

Proceed with refitting - 5530B10 battery - r+r.

Refill the engine oil lubrication system - 1084A10 ENGINE OIL - Check level and top up, if necessary.

Refill the cooling system - 0010T20 coolant change.

Remove the car from the ramps.

2.0 TS

Removing

Position the vehicle on the ramp.

Proceed with removal - 5530B10 battery - r+r.

Proceed with the removal - 4450B10 Front WHEEL (one) - R.R. (Right side).

Proceed with the removal - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. (Right side).

Proceed with removal - 7055B54 under-engine guard - r r.

1. Disconnect the lower coolant outlet hose from the radiator and drain the engine coolant.

Manually press the springs and remove the rapid attachment for the hose.

Recover the coolant using a suitable container.

Proceed with removal - 1016A40 ignition coil cover on cylinder head- r+r.

Proceed with removal - 5510C14 ignition coil/s - r+r.

Proceed with removal - 1016A20 single cam cover - r + r and replace gasket.

Proceed with removal - 1056B60 single fuel manifold pipe, with injectors - r + r.

Proceed with removal - 1072D10 modular inlet manifold - r+r.

1. Undo the bolts (1a) and remove the bracket (1b) connecting the intake manifold to the bracket on the engine for the reaction rod.

1. Disconnect the coolant supply pipe to the air conditioning system heater, thermostat side.

2. Disconnect the coolant return pipe from the air conditioning system heater, on the side of the rigid fluid intake to the coolant pump.

3. Disconnect the flexible coolant supply pipe from the rigid pipe to the engine oil heat exchanger.

4. Disconnect the upper coolant inlet hose to the radiator, thermostat side.

Proceed with removal - 1072C44 exhaust manifold heat shield on bulkhead - r+r.

1. Undo the bolt fixing the engine oil dipstick tube.

2. Remove the tube for the engine oil dipstick.

1. Unscrew the nuts securing the catalytic preconverter to the exhaust manifold.

2. Undo the nuts fixing the catalytic pre-converter to the mounting bracket.

1. Undo the plug and drain the engine oil.

Collect the engine oil in a suitable container.

1. Release and remove the engine oil filter using a suitable tool.

2. Undo the pin (2a) and disconnect the engine oil heat exchanger (2b) from the crankshaft oil seal front cover.

1. Disconnect the engine coolant system supply pipe from the water pump rigid inlet pipe.

Proceed with removal - 1092G10 single engine belt r r.

Proceed with removal - 1092A10 Crankshaft services PULLEY - R.R..

Proceed with removal - 1092G20 engine component single belt fixed tensioner - one - r + r.

Proceed with removal - 1092G14 engine component single belt mobile tensioner - r + r.

Proceed with removal - 1032D12 timing system protective cover(s) - r + r.

Proceed with removal - 1092E10 counter-rotating shaft drive toothed belt - r + r.

Proceed with removal - 1032B10 toothed timing belt - r + r for timing adjustment or replacement.

1. Undo the bolts (1a) and remove the cylinder head (1b).

To undo/tighten the cylinder head bolts, use the ordinary spanner USAG 233 1/2 S.

2. Remove the cylinder head gasket.

Refitting

Place the cylinder head gasket back in its housing.

Position the cylinder head on the cylinder block, taking care that the camshafts are positioned with the front cams facing outwards (valves closed).

1. Tighten the bolts (1a) fixing the cylinder head to the recommended torque using the angular tightening tool (1b).

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

To undo/tighten the cylinder head bolts, use the ordinary spanner USAG 233 1/2 S.

The value of 4.0 daNm should be implemented by tightening to 2.0 daNm and then increased by a torque of 2.0 daNm until the nominal value of 4.0 daNm is reached.

Proceed with refitting - 1032B10 toothed timing belt - r + r for timing adjustment or replacement.

Proceed with refitting - 1092E10 counter-rotating shaft drive toothed belt - r + r.

Proceed with refitting - 1032D12 timing system protective cover(s) - r + r.

Proceed with refitting - 1092G14 engine component single belt mobile tensioner - r + r.

Proceed with refitting - 1092G20 engine component single belt fixed tensioner - one - r + r.

Proceed with refitting - 1092A10 Crankshaft services PULLEY - R.R..

Proceed with refitting - 1092G10 single engine belt r r.

Connect the engine cooling system supply pipe to the water pump rigid outlet pipe.

Place the engine oil heat exchanger back in its housing and fix it to the crankshaft front oil seal cover using the pin.

Refit the engine oil filter in its seating and tighten it fully by hand.

1. Tighten the engine oil drain plug to the crankcase sump to the recommended torque.

Tighten the nuts fixing the catalytic pre-converter to the mounting bracket to the recommended torque.

Tighten the nuts fixing the front section of the exhaust pipe to the mounting bracket.

Place the engine oil dipstick tube in its seating and fix it using the bolt.

Proceed with refitting - 1072C44 exhaust manifold heat shield on bulkhead - r+r.

Connect the upper coolant inlet hose to the radiator, thermostat side.

Connect the flexible coolant supply pipe to the rigid pipe to the engine oil heat exchanger.

Connect the coolant return hose from the air conditioning system heater on the side of the rigid inlet pipe to the water pump.

Connect the coolant supply pipe to the air conditioning system heater, thermostat side.

Place the bracket connecting the intake manifold to the bracket on the engine for the reaction rod back in its housing and fix it using the bolts.

Proceed with refitting - 1072D10 modular inlet manifold - r+r.

Proceed with refitting - 1056B60 single fuel manifold pipe, with injectors - r + r.

Proceed with refitting - 1016A20 single cam cover - r + r and replace gasket.

Proceed with refitting - 5510C14 ignition coil/s - r+r.

Proceed with refitting - 1016A40 ignition coil cover on cylinder head- r+r.

Connect the lower coolant outlet hose from the radiator.

Proceed with refitting - 7055B54 under-engine guard - r r.

Proceed with the refitting - 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R. (Right side).

Proceed with the refitting - 4450B10 Front WHEEL (one) - R.R. (Right side).

Proceed with refitting - 5530B10 battery - r+r.

Refill the engine oil lubrication system - 1084A10 ENGINE OIL - Check level and top up, if necessary.

Refill the cooling system - 0010T20 coolant change.

Remove the car from the ramps.

1.9 JTD 8V

Removing

- 1008C10 power unit upper reaction link r r

- 1016A10 sound-proofing cover - r + r

- 1008C14 engine link bracket - r r

- 4450B04 right front wheel r r

- 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R.

- 1092G10 single engine belt r r

- 1092A10 Crankshaft services PULLEY - R.R.

- 1060G80 ds electric injection control unit - r r

- 1032B10 toothed timing belt - r + r for timing adjustment or replacement

- 5530B10 battery - r+r

Position a suitable container for collecting the coolant fluid.

Disconnect the lower radiator pipe and completely drain the engine coolant into the special container.

1. Disconnect the recirculation pipe (1a) and the water supply pipe (1b) to the rigid water supply pipe to the pump from the engine coolant reservoir.

1. Disconnect the engine oil vapour recovery pipes (1a) and (1b) from the tappet cover.

2. Disconnect the upper radiator pipe from the thermostat.

3. Disconnect the vacuum pipe from the vacuum unit.

1. Disconnect the upper flexible coolant pipe (1a) and the lower flexible coolant pipe (1b) from the rigid supply section to the engine oil heat exchanger.

2. Undo the fixing bolts (2a) and remove the rigid section of the supply pipe to the heat exchanger.

1. Disconnect the engine coolant pipes connected to the rigid pipe.

2. Undo the bolts fixing the pump rigid water inlet pipe.

3. Remove the rigid pump coolant inlet pipe, recovering the gasket underneath.

1. Undo the retaining bolts.

2. Remove the heat shield for the exhaust manifold.

1. Undo the bolt (1a) fixing the turbocharger reinforcement bracket (1b) to the cylinder block/crankcase.

2. Undo the bolts (2a) fixing the turbocharger rigid oil return pipe (2b).

1. Undo the bolts (1a) fixing the rigid EGR pipe (1b) to the exhaust manifold.

2. Undo the fixing nuts (2a) and release the exhaust manifold/turbocharger assembly (2b) from the cylinder head pins.

1. Open the band and disconnect the air pipe from the throttle body.

1. Disconnect the two supply and return pipes to the heater from the thermostat.

2. Disconnect the electrical connection for the engine coolant temperature sensor.

3. Disconnect the vacuum pipe (3a) to the vacuum reservoir and the pipe (3b) to the variable geometry turbocharger from the connectors on the vacuum pipe.

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 supply manifold.

Fit a new high pressure pipe from the pressure pump to the fuel manifold upon reassembly.

1. Disconnect the electrical connections (1a), (1b), (1c), (1d), (1e) and (1f).

2. Undo the retaining bolts (2a) and remove the injection wiring (2b).

1. Undo the bolts fixing the tappet cover to the cylinder head.

2. Remove the tappet cover with vapour separator incorporated.

3. Undo the fixing bolts (3a) and remove the timing belt side shield (3b).

Remove the oil present in the cylinder head.

1. Undo the bolts fixing the cylinder head.

2. Position a bracket (2a) fixed to the exhaust manifold stud and fasten the hook (2b) to it for moving the cylinder head later on in safety.

3. Position a second hook at the intake manifold.

Secure the chains to a hydraulic lift.

4. Lift and remove the cylinder head, complete with intake manifold.

Recover the cylinder head gasket.

Refitting

Fit a new cylinder head gasket to the cylinder block/crankcase, taking care that it is the same thickness as the old one.

ASTADUR type cylinder head gaskets are fitted.

The material from which these gaskets are made undergoes a polymerisation process during the operation of the engine so that they become considerably harder during usage. In order for the polymerization of the gasket to take place it is necessary to follow the precautions listed below.

Keep the gasket sealed in its nylon container and only take it out shortly before fitting.

Do not lubricate it 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 securing the cylinder head to the cylinder block/crankcase to the recommended torque following the order shown in the diagram and using the angular tightening tool.

The value of 6.5 daNm should be implemented by tightening to 2.0 daNm and then increased by a torque of 4.5 daNm until the nominal value of 6.5 daNm is reached.

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.

Connect the electrical connections disconnected previously.

Tighten the bolts fixing the injection wiring to the intake manifold.

Fit a new rigid supply pipe from the pressure pump to the single fuel supply manifold and tighten the connectors to the recommended torque.

Clean the threaded seats for the above mentioned pipe on the manifold and the pressure pump using heptane.

Tighten the nuts fixing the return manifold to the intake manifold.

Connect the fuel recirculation pipe to the injectors.

Connect the vacuum pipe to the vacuum reservoir and the pipe to the variable geometry turbocharger to the connectors on the vacuum pipe.

Connect the electrical connection for the engine coolant temperature sensor.

Connect the two heater supply and return pipes to the thermostat.

Connect the throttle casing air pipe.

Fit the exhaust manifold/turbocharger assembly on the cylinder head pins.

Tighten the nuts securing the manifold to the cylinder head to the recommended torque.

Position the EGR exhaust gas supply pipe and tighten the bolts fixing it to the exhaust manifold.

Fit the exhaust manifold heat shield.

Fit the pump rigid water inlet pipe with a new gasket underneath.

Tighten the bolts fixing the water inlet rigid pipe to torque.

Connect the engine coolant pipes to the rigid pipe.

Fit the rigid section of the supply pipe to the heat exchanger and tighten the fixing bolts.

Connect the upper and lower flexible coolant pipes to the rigid section of the supply pipe to the engine oil heat exchanger.

Connect the vacuum pipe to the vacuum unit.

Connect the upper radiator hose to the thermostat.

Connect the engine oil vapour recovery pipes to the tappet cover.

Connect the recirculation pipe and the coolant supply pipe to the rigid supply pipe to the pump to the engine coolant reservoir.

Connect the lower radiator hose.

- 5530B10 battery - r+r

- 1032B10 toothed timing belt - r + r for timing adjustment or replacement

- 1060G80 ds electric injection control unit - r r

- 1092A10 Crankshaft services PULLEY - R.R.

- 1092G10 single engine belt r r

- 7055B64 Engine compartment DUST shield in front wheel arch (one), left or right - R.R.

- 4450B04 right front wheel r r

- 1008C14 engine link bracket - r r

- 1016A10 sound-proofing cover - r + r

- 1008C10 power unit upper reaction link r r

- 0010T20 coolant change

- 0010T21 coolant check density and top up if necessary

1.9 JTD 16V

Removing

Position the vehicle on the ramp

Proceed with removal - 1016A10 sound-proofing cover - r + r.

Ensure that the ignition key is in the OFF position, then disconnect the negative battery terminal (-).

Proceed with removal - 1008C10 power unit upper reaction link r r.

Proceed with removal - 1060G80 ds electric injection control unit - r r.

Proceed with removal - 4450B04 right front wheel r r.

Proceed with removal - 7055B54 under-engine guard - r r.

Proceed with removal - 7055B91 Right front WHEEL ARCH LINER - R.R..

Proceed with removal - 1092G10 single engine belt r r.

Proceed with removal - 1092A10 Crankshaft services PULLEY - R.R..

Proceed with removal - 1092G20 engine component single belt fixed tensioner - one - r + r.

Proceed with removal - 1032D12 timing system protective cover(s) - r + r.

1. Undo the bolts (1a) and (1b), then remove the bracket on the engine for the reaction rod (1c).

1. Loosen the nut securing the timing belt mobile tensioner

2. Prise off and remove the timing belt.

1. Loosen the band and disconnect the lower radiator coolant outlet hose from the radiator, water pump rigid inlet pipe end.

Collect the coolant which comes out in a suitable container.

1. Disconnect the electrical connections from the injectors.

2. Disconnect the electrical connection from the cam angle sensor.

3. Disconnect the electrical connection for the air conditioning compressor.

Release the electrical wiring from the band on the timing cover.

4. Undo the bolts fastening the cable duct and move the electrical wiring aside.

1. Push clips (1a) by hand and disconnect the pipe from the injectors to the fuel recovery manifold (1b), injectors side and move it aside.

2. Undo the connectors (2a), (2b) and remove the pipe from the fuel manifold to the injectors (2c).

Use new pipes from from fuel manifold to injectors upon reassembly.

1. Undo the nuts fixing the injector brackets.

2. Remove the injectors (2a) complete with brackets using the tool (2b).

Start the removal beginning with the injector for cylinder no. 1 and continuing with the injectors for cylinders 2, 3 and 4.

1. Undo the connectors (1a), (1b) and remove the pipe from the pressure pump to the fuel manifold (1c).

When refitting, fit a new pipe from the pressure pump to the fuel manifold.

1. Disconnect the electrical connection from the fuel pressure sensor.

2. Undo the bolts (2a) and remove the single fuel manifold pipe (2b) complete with fuel pressure sensor (2c).

Proceed with removal - 5530B10 battery - r+r.

1. Loosen the band and disconnect the vacuum pipe from the brake servo.

2. Loosen the band and disconnect the engine oil vapour recovery pipe from the engine oil filler.

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

1. Undo the bolts (1a) and remove the engine oil filler (1b).

2. Remove the gasket.

1. Undo bolts (1a) and remove vacuum unit (1b).

2. Remove the gasket.

1. Undo the bolts (1a), (1b), and remove the camshaft housing assembly (1c).

2. Remove the gasket.

1. Remove the valve rocker arms.

2. Remove the hydraulic tappets.

1. Disconnect the electrical connections from the heater plugs.

2. Undo and remove the heater plugs.

1. Disconnect the electrical connection from the turbocharger vane actuator solenoid.

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

1. Disconnect the electrical connection from the E.G.R. valve.

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

Release the wiring from the bands near the thermostat.

1. Loosen the band and disconnect the coolant return pipe from the engine coolant reservoir, thermostat side.

2. Loosen the band and disconnect the coolant outlet pipe from the cylinder head, engine coolant return pipe to the coolant reservoir side.

3. Loosen the band and disconnect the flexible coolant return pipe from the rigid coolant return pipe to the engine coolant reservoir.

4. Undo the bolts (4a) and remove hose (4b) carrying coolant to the coolant supply reservoir.

1. Loosen the band and disconnect the air intake hose from the connector on the throttle casing.

1. Undo the bolts (1a) and remove the connector on the throttle body (1b) complete with gasket (1c).

1. Disconnect the vacuum pipe from the pneumatic valve on the throttle body.

2. Undo the bolts (2a) and remove the electropneumatically controlled throttle body (2b) complete with gasket (2c).

Disconnect the vacuum pipe from the three-way connector on the brake servo vacuum intake pipe.

Disconnect the intermediate coupling for the vacuum pipe for the turbocharger vane position control actuator solenoid valve.

1. Loosen the band and disconnect the upper coolant inlet hose to the radiator, thermostat side.

2. Loosen the band and disconnect the coolant return pipe to the climate control heater, thermostat side.

3. Loosen the band and disconnect the coolant supply pipe to the water/exhaust gas heat exchanger for the E.G.R. system, thermostat side.

4. Loosen the band and disconnect the coolant outlet pipe from the water/exhaust gas heat exchanger for the E.G.R. system, heat exchanger side.

1. Undo the bolts (1a) and remove the thermostat (1b) complete with O-Ring (1c).

1. Loosen the collar fastening the E.G.R. system water/exhaust gas heat exchanger, exhaust gas inlet pipe side.

2. Undo the bolts fixing the exhaust gas outlet pipe to the water/exhaust gas heat exchanger for the E.G.R. system, E.G.R. system solenoid valve side.

3. Undo the bolts (3a) and remove the E.G.R. system water/exhaust gas heat exchanger (3b) complete with exhaust gas pipe (3c).

1. Undo the nuts (1a) and move the oil vapour recovery pipe mounting bracket (1b) aside.

2. Undo the bolts (2a) and remove the E.G.R. system solenoid valve (2b).

3. Remove the gasket.

1. Disconnect the rapid attachment for the fuel return pipe from the fuel filter, return manifold pipe side.

2. Disconnect the rapid attachment for the fuel return pipe to the tank, return manifold pipe side.

3. Loosen the band and disconnect the fuel return pipe from the pressure pump, fuel return manifold pipe side.

1. Undo the bolts (1a) and remove the fuel return manifold pipe (1b) complete with the pipe from the injectors to the fuel recovery manifold (1c).

1. Undo the bolt fixing the guide pipe for the engine oil dipstick to the pressure pump mounting.

2. Disconnect the electrical connection from the fuel pressure regulator.

Release the electrical wiring from the band and move it to the side.

1. Loosen the band and disconnect the condensation oil recovery pipe from the crankcase sump.

1. Loosen the band and disconnect the oil vapour recovery pipe from the separator.

2. Loosen the band and disconnect the oil vapour recirculation pipe from separator.

Disconnect the electrical connection from the solenoid on the vacuum tank.

1. Undo the bolts (1a) and remove the mounting bracket (1b) complete with oil vapour separator (1c) and vacuum reservoir (1d).

1. Stop the pressure pump pulley from rotating using two bolts.

2. Undo the pressure pump pulley nut.

Undo the two bolts fitted previously to stop the rotation of the pressure pump pulley.

1. Remove the pressure pump pulley (1a) using the tool (1b).

1. Undo nuts (1a) and remove pressure pump (1b) from its mount.

1. Disconnect the electrical connection from the engine oil pressure warning light switch.

2. Disconnect the electrical connection for the engine oil level sensor.

3. Disconnect the electrical connection for the rpm sensor.

1. Disconnect the earth lead from the alternator.

2. Disconnect the earth lead from the starter motor.

1. Disconnect the electrical connection from the pre-heating control unit.

1. Undo the bolts (1a) and remove the power steering pump drive pulley (1b).

1. Undo the bolts securing the power steering pump to its mounting.

Remove the guide tube complete with engine oil dipstick.

1. Undo the bolts (1a) and remove the pressure pump mounting (1b).

1. Undo the nuts (1a) and remove the air chamber assembly (1b) complete with gasket (1c).

1. Loosen the band and disconnect the system supply pipe from the water pump rigid inlet pipe.

2. Loosen the band and disconnect the coolant outlet pipe from the climate control heater, water pump rigid inlet pipe side.

3. Undo the bolts (3a) and remove the coolant inlet rigid pipe to the water pump (3b).

Remove the gasket.

1. Undo the bolts (1a) and remove the exhaust manifold heat shield (1b).

1. Undo the nuts (1a) and remove the upper exhaust manifold heat shield (1b).

1. Undo the nuts fixing the front section of the exhaust pipe to the catalytic pre-converter.

2. Undo the nuts fixing the front section of the exhaust pipe to the catalytic converter.

3. Remove the front exhaust pipe section complete with seals.

1. Disconnect the vacuum pipe from the turbocharger variable geometry control actuator.

2. Loosen the band and disconnect the air supply hose between the turbocharger and the heat exchanger, turbocharger side.

3. Loosen the band and disconnect the corrugated air intake sleeve to the turbocharger, turbocharger side.

1. Undo the bolts (1a) and the nuts (1b) fixing the catalytic preconverter mounting bracket.

2. Undo the bolts securing the engine oil return pipe from the turbocharger, engine crankcase side.

1. Undo the connector (1a) and disconnect engine oil supply pipe to the turbocharger (1b), crankcase side.

1. Loosen the collar (1a) and remove the catalytic preconverter (1b).

2. Keep the catalytic preconverter mounting bracket.

1. Undo the nuts (1a) and remove the exhaust manifold (1b) complete with turbocharger (1c).

2. Remove the exhaust manifold gasket.

1. Undo the bolts (1a) and remove the lower cylinder head assembly (1b).

2. Remove the cylinder head gasket.

3. Remove the locating bushes.

Refitting

Position the cylinder head centring bushes on the cylinder block/crankcase.

Fit a new cylinder head gasket, taking care that it is the same thickness as the old one.

Position cylinder no. 1 at T.D.C.; rotate the crankshaft through two further teeth on the toothed drive pulley in order to lower the pistons preventing any interference with the valves when fitting the cylinder head.

Position the cylinder head on the crankcase.

1. Tighten the cylinder head bolts (1a) to the recommended torque using the angular tightening tool (1b).

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

1. Place the exhaust manifold gasket in the housing.

2. Place the exhaust manifold (2a) complete with turbocharger (2b), back in its housing and fix it tightening the nuts (2c) to the recommended torque.

Place the catalytic preconverter complete with mounting back in its housing and fasten it to the turbocharger using the collar.

1. Connect the engine oil delivery pipe to the turbocharger (1a), crankcase side, and tighten the connector (1b) to the recommended torque.

Tighten the bolt fixing the enigne oil return pipe from the turbocharger, engine crankcase side.

Tighten the bolts and the nuts fixing the catalytic preconverter mounting bracket.

Connect the corrugated air intake sleeve to the turbocharger, turbocharger side, and tighten the band.

Connect the air supply hose between the turbocharger and the heat exchanger, turbocharger side, and secure with a band.

Connect the vacuum pipe from the turbocharger variable geometry control actuator.

1. Place the front section of the exhaust pipe with gaskets back in its housing.

2. Tighten the nuts securing the exhaust pipe front section to the catalytic converter to the specified torque.

3. Tighten the nuts fixing the front section of the exhaust pipe to the catalytic preconverter to the recommended torque.

Place the upper exhaust manifold heat shield back in its housing and fix it using the nuts.

Place the lower exhaust manifold heat shield back in its housing and fix it using the bolts.

Place the water pump rigid inlet pipe, complete with gasket, back in its housing and secure it with the bolts.

Connect the coolant return hose from the climate control heater on the side of the rigid inlet pipe to the water pump and do up the band.

Connect the system supply pipe to the water pump rigid inlet pipe and tighten the band.

1. Refit air chamber (1a) complete with gasket (1b) and secure it by tightening nuts (1c) to the recommended torque.

1. Place the pressure pump support (1a) back in its housing and secure it tightening the bolts (1b).

Refit the guide tube and engine oil dipstick.

1. Place the power assisted steering pump back in its housing and fix it tightening the bolts to the recommended torque.

1. Place the power assisted steering pump pulley (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

Connect the electrical connection to the pre-heating control unit.

Connect the earth lead to the starter motor.

Connect the earth lead to the alternator.

Connect the electrical connection for the rpm sensor.

Connect the electrical connection for the engine oil level sensor.

Connect the electrical connection to the engine oil pressure warning light switch.

1. Fit the clutch pump (1a) back in its housing and tighten the nuts (1b) to the specified torque.

1. Replace the pressure pump pulley in its housing.

2. Stop the pressure pump pulley from rotating using two bolts.

3. Tighten the pressure pump pulley nut to torque.

Undo the two bolts fitted previously to stop the rotation of the pressure pump pulley.

Place the mounting bracket complete with oil vapour separator and vacuum reservoir back in its housing and secure it using the bolts.

Connect the electrical connection to the solenoid on the vacuum tank.

Connect the oil vapour recirculation pipe to the separator and tighten the band.

Connect the oil vapour recovery pipe to the separator and tighten the band.

Connect the condensation oil recovery pipe to the crankcase sump and tighten the band.

Place the electrical wiring back in its housing and fix it to the band.

Connect the electrical connection to the fuel pressure regulator.

Tighten the bolt fixing the engine oil dipstick guide pipe to the pressure pump mounting.

Place the fuel return manifold pipe complete with the pipe from the injectors to the fuel recovery manifold back in its housing and secure it using the bolts.

Connect the fuel return pipe to the pressure pump, fuel return manifold pipe side and tighten the band.

Connect the rapid attachment for the fuel return pipe to the tank, fuel return manifold pipe side.

Connect the rapid attachment for the fuel return pipe from the fuel filter, return manifold pipe side.

1. Place the E.G.R. system solenoid valve (1a) complete with gasket (1b) back in its housing and fasten it tightening the bolts (1c) to the recommended torque.

2. Place the oil vapour recovery pipe mounting bracket (2a) back in its housing and secure it using the nuts (2b).

1. Place the water/exhaust gas heat exchanger for the E.G.R. system (1a), complete with exhaust gas outlet pipe (1b) back in its housing.

2. Tighten the bolts fixing the exhaust gas outlet pipe to the water/exhaust gas heat exchanger for the E.G.R. system, E.G.R. system solenoid valve side to the recommended torque.

3. Tighten the collar fixing the water/exhaust gas heat exchanger for the E.G.R. system.

1. Refit thermostat (1a), complete with O-ring (1b) and secure by tightening the bolts (1c) to the recommended torque.

Connect the coolant outlet pipe from the E.G.R. water/exhaust gas heat exchanger, heat exchanger side, and tighten the band.

Connect the engine coolant supply pipe to the EGR system water/exhaust gas heat exchanger, thermostat side and tighten the band.

Connect the engine coolant return pipe from the climate control system heater, thermostat side, and tighten the band.

Connect the upper coolant inlet hose to the radiator, thermostat side, and tighten the band.

Connect the intermediate coupling for the vacuum pipe for the turbocharger vane position control actuator solenoid valve.

Connect the vacuum pipe to the three-way connector on the brake servo vacuum intake pipe.

1. Replace the pneumatically-controlled throttle body (1a), complete with gasket (1b), back in its housing and secure by tightening bolts (1c) to the recommended torque.

2. Connect the vacuum pipe to the pneumatic valve on the throttle body.

1. Replace the connector on the throttle body (1a), complete with gasket (1b), back in its housing and secure by tightening bolts (1c) to the recommended torque.

Connect the air inlet hose to the connector on the throttle casing and tighten the band.

Place the coolant return pipe to the engine cooling system reservoir back in its housing and fix it using the bolts.

Connect the flexible pipe to the coolant return pipe to the engine coolant reservoir and tighten the band.

Connect the coolant oulet pipe from the cylinder head, engine coolant return pipe to the supply reservoir side and tighten the band.

Connect the engine coolant return pipe to the supply reservoir, thermostat side and tighten the band.

Fasten the electrical wiring to the bands near the thermostat.

Connect the electrical connection to the excess pressure sensor.

Connect the electrical connection to the EGR solenoid.

Connect the electrical connection to the air flow meter.

Connect the electrical connection to the turbocharger vane actuator solenoid.

1. Place the heater plugs back in their housings and tighten them to the recommended torque.

2. Connect the electrical connections to the heater plugs.

Place the hydraulic tappets in their housings.

Place the valve rocker arms back in their housings.

Place the upper cylinder head gasket back in its housing.

1. Remove the plugs (1a) and fit the camshaft timing tools (1b) in the upper cylinder head.

Check that the tools are correctly inserted in the housings in the camshafts.

Remove the inlet side camshaft timing tool and tighten the plug.

1. Place the complete upper cylinder head (1a) back in its housing and secure it tightening the bolts (1b) to the recommended torque.

2. Loosen the exhaust side camshaft toothed drive pulley fixing bolt.

1. Undo the bolt for the crankcase front cover shown in the diagram.

Temporarily fit the timing drive belt on the drive pulley.

2. Fit the tool (2a) and secure it using the calibrated screw (2b)

To allow the engagement of the locating dowel on the timing drive belt drive pulley in the opening in the tool, rotate the crankshaft using small movements.

1. Completely fit the timing belt.

2. Use a screwdriver to lever in the hole (2a) until the reference on the tensioner (2b) lines up with the reference hole (2c) and, in this position, tighten the tensioner nut (2d) to torque.

3. Tighten the exhaust side camshaft toothed drive pulley fixing bolt to the recommended torque.

Remove the timing tools.

Remove the exhaust camshaft template, as the inlet camshaft has already been removed.

Rotate the crankshaft through two revolutions.

Check once again that the timing is correct by refitting the timing tools.

Only fit the exhaust camshaft side template because the inlet side one is not accessible.

Check that the tensioning references on the timing belt tensioner are aligned.

Tighten the bolt for the crankcase front cover previously removed.

Tighten the plug in the camshaft housing for fitting the exhaust side timing tool.

1. Place the vacuum unit (1a), complete with gasket (1b), back in its housing and secure it tightening the bolts (1c) to the recommended torque.

1. Place the engine oil filler (1a), complete with gasket (1b), back in its housing and secure it tightening the bolts (1c) to the recommended torque.

Connect the electrical connection to the engine coolant temperature sensor.

Connect the oil vapour recovery pipe to the engine oil filler and tighten the band.

Connect the vacuum pipe to the brake servo and tighten the band.

.Proceed with refitting - 5530B10 battery - r+r.

1. Place the single fuel manifold pipe (1a), complete with fuel pressure sensor (1b), back in its housing and secure it tightening the bolts (1c) to the recommended torque.

2. Connect the electrical connection to the fuel pressure sensor.

1. Place the pipe from the pressure pump to the single fuel manifold back in its housing and fix it using the connectors without tightening them.

2. Tighten the connector for the pipe from the pressure pump to the single fuel manifold, pump side, to the recommended torque using a suitable spanner.

3. Tighten the connector for the pipe from the pressure pump to the single fuel manifold, fuel manifold side, to the recommended torque using a suitable spanner.

1. Refit the injectors (1a) complete with brackets and secure by tightening the nuts (1b) to the specified torque.

Start the refitting beginning with the injector for cylinder no. 4 and continuing with the injectors for cylinders 3, 2 and 1.

1. Fit the new pipes from the fuel manifold to the injectors and secure them using the connectors without tightening them.

2. Tighten the connectors for the pipes from the fuel manifold to the injectors, injector side, to the recommended torque using a suitable spanner.

3. Tighten the connectors for the pipes between the fuel manifold and the injectors, fuel manifold side, to the recommended torque using a suitable spanner.

Clean the threaded seats for the above-mentioned pipe on the manifold and the injectors using heptane.

4. Connect the pipe from the injectors to the fuel recovery manifold (4a) to the injectors pushing it until the clips (4b) can be heard clicking into place.

Place the electrical wiring back in its housing and tighten the cable duct fixing bolts.

Fasten the electrical wiring using the band on the timing cover.

Connect the electrical connection to the air conditioner compressor.

Connect the electrical connection to the cam angle sensor

Connect the electrical connections to the injectors.

1. Fit the bracket on the engine for the reaction rod (1a) and fix it tightening the bolts (1b) and (1c) to the recommended torque.

Proceed with refitting - 1032D12 timing system protective cover(s) - r + r

Proceed with refitting - 1092G20 engine component single belt fixed tensioner - one - r + r

Proceed with refitting - 1092A10 Crankshaft services PULLEY - R.R.

Proceed with refitting - 1092G10 single engine belt r r

Proceed with refitting - 7055B91 Right front WHEEL ARCH LINER - R.R.

Proceed with refitting - 7055B54 under-engine guard - r r

Proceed with refitting - 4450B04 right front wheel r r

Proceed with refitting - 1060G80 ds electric injection control unit - r r

Proceed with refitting - 1008C10 power unit upper reaction link r r

Refill the engine cooling system with coolant - 0010T20 coolant change.

Connect the negative (-) battery terminal

Proceed with refitting - 1016A10 sound-proofing cover - r + r

Proceed with refitting - 7025A14 Bonnet LID - R.R.

Proceed with refitting - 7025A12 Engine front sound insulation COVER - R.R.

Remove the car from the ramps.