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Home >> Alfa Romeo >> 2019 >> Giulia Base, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 2.0L - Engine (Service Information) >> Cylinder Head >> Removal And Installation >> Cylinder Head

Cylinder Head

REMOVAL 

  1. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  2. Disconnect and isolate the negative battery cable.
  3. Drain the engine coolant system. Refer to DRAINING AND FILLING THE ENGINE COOLING SYSTEM .
  4. Drain the turbocharger coolant system. Refer to DRAINING AND FILLING THE TURBOCHARGER COOLING SYSTEM .
  5. Recover the A/C refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
  6. Remove the cam chain. Refer to CHAIN AND SPROCKETS, TIMING, REMOVAL AND INSTALLATION .
  7. Remove the variable valve actuation assembly. Refer to ASSEMBLY, VARIABLE VALVE ACTUATION, REMOVAL AND INSTALLATION .
  8. Remove the generator. Refer to GENERATOR, REMOVAL AND INSTALLATION .
  9. Remove the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL AND INSTALLATION .
  10. Remove the turbocharger. Refer to TURBOCHARGER, REMOVAL AND INSTALLATION .
  11. Remove the A/C discharge line. Refer to LINE, A/C DISCHARGE, REMOVAL AND INSTALLATIONLINE, A/C DISCHARGE JUMPER, REMOVAL AND INSTALLATION .
  12. Remove the A/C compressor. Refer to COMPRESSOR, A/C, REMOVAL AND INSTALLATION .
    GC0194203Courtesy of CHRYSLER GROUP, LLC
  13. Disconnect the quick coupling (1) of the water supply pipe from the heater core.
  14. Disconnect the quick coupling (2) of the water return pipe from the heater core.
    GC0194165Courtesy of CHRYSLER GROUP, LLC
  15. Loosen the clamp (1a) and remove the water return pipe (1b).
    GC0194475Courtesy of CHRYSLER GROUP, LLC
  16. Loosen the clamp (1a) and disconnect the degassing pipe (1b).
    GC0193553Courtesy of CHRYSLER GROUP, LLC
  17. Disconnect the camshaft position sensor electrical connection (1).
    GC0194196Courtesy of CHRYSLER GROUP, LLC
  18. Release the wiring retaining clip (1).
  19. Remove the bolt (2) and disconnect the ground cable.
    GC0180976Courtesy of CHRYSLER GROUP, LLC
  20. Disconnect the electrical connection (1) for the fuel pressure regulator.
    GC0193942Courtesy of CHRYSLER GROUP, LLC
  21. Disconnect the front fuel supply pipe quick coupling (1) to the high pressure pump.
    GC0194613Courtesy of CHRYSLER GROUP, LLC
  22. Release the wiring retaining clip (1) and move it aside.
  23. Open the retaining clip (2) for the high pressure pump front fuel supply pipe.
    GC0193369Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    To avoid bending the camshaft, partially loosen each cam cap bolt, one turn at a time, to remove the camshaft caps.

  24. Remove the bolts (1a) and remove camshaft caps (1b).
    GC0194661Courtesy of CHRYSLER GROUP, LLC
  25. Remove the camshaft (1) with the camshaft sprocket attached.
    GC0194595Courtesy of CHRYSLER GROUP, LLC
  26. Remove the side bolt (1) securing the cylinder head to the crankcase.
  27. Remove the inner bolts (2a) and remove the cylinder head assembly (2b).
    GC0181027Courtesy of CHRYSLER GROUP, LLC
  28. Remove the head gasket from the locating pins.
  29. Using suitable pliers (1a), remove the VVAA oil supply filter (1b).
    GC0180993Courtesy of CHRYSLER GROUP, LLC
  30. Check the locating pins (1).

INSTALLATION 

  1. Clean and prepare all engine gasket surfaces. Refer to ENGINE GASKET SURFACE PREPARATION  .
  2. Install the VVAA oil supply filter in the cylinder head.
  3. Install a new cylinder head gasket.
    GC0195169Courtesy of CHRYSLER GROUP, LLC
  4. Place the complete cylinder head (1) in position.
  5. Install ten inner head bolts (2a) hand tight.
  6. Install one outer head bolt (2b) hand tight.
    Fig 1: Cylinder Head Tightening Sequence
    GC0196173Courtesy of CHRYSLER GROUP, LLC
  7. Tighten the ten inner cylinder head bolts (1 - 10) in the sequence shown, following this 4 step torque plus angle method. Tighten according to the following torque values:
    • Step 1: All to 20 N.m (15 ft. lbs.)
    • Step 2: All to 55 N.m (40 ft. lbs.)
    • Step 3: All again to 55 N.m (41 ft. lbs.)
    • Step 4: All an additional 180° Turn Do not use a torque wrench for this step. 
  8. Tighten the one outer cylinder head bolt (11) to 28 N.m (21 ft. lbs.).
    GC0195354Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    To avoid bending the camshaft, partially tighten each cam cap bolt, one turn at a time, to seat the camshaft to the head. Do not torque to specification until the cam caps are in full contact with the cylinder head.

  9. Position the camshaft in the cylinder head, install the camshaft bearing caps (1a) and bolts (1b).
    GC0193209Courtesy of CHRYSLER GROUP, LLC
  10. Tighten the bolts in the sequence shown to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  11. Close the front fuel supply pipe retaining clip to the high pressure pump.
  12. Refit the wiring and engage it in the retaining clips.
  13. Connect the front fuel supply pipe quick coupling to the high pressure pump.
  14. Connect the electrical connection for the fuel pressure regulator.
  15. Connect the ground cable and tighten the bolt.
  16. Engage the wiring in the respective retaining clip.
  17. Connect the camshaft position sensor electrical connection.
  18. Connect the degassing pipe and close the clamp.
  19. Install the water return pipe and close the retaining clamp.
  20. Connect the quick coupling of the water return pipe to the heater core.
  21. Connect the quick coupling of the water supply pipe to the heater core.
  22. Install the A/C compressor. Refer to COMPRESSOR, A/C, REMOVAL AND INSTALLATION .
  23. Install the A/C discharge line. Refer to LINE, A/C DISCHARGE, REMOVAL AND INSTALLATIONLINE, A/C DISCHARGE JUMPER, REMOVAL AND INSTALLATION .
  24. Install the turbocharger. Refer to TURBOCHARGER, REMOVAL AND INSTALLATION .
  25. Install the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL AND INSTALLATION .
  26. Install the generator. Refer to GENERATOR, REMOVAL AND INSTALLATION .
  27. Install the variable valve actuation assembly. Refer to ASSEMBLY, VARIABLE VALVE ACTUATION, REMOVAL AND INSTALLATION .
  28. Install the cam chain. Refer to CHAIN AND SPROCKETS, TIMING, REMOVAL AND INSTALLATION .
  29. Evacuate and charge the A/C refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
  30. Fill the turbocharger coolant system. Refer to DRAINING AND FILLING THE TURBOCHARGER COOLING SYSTEM .
  31. Fill the engine coolant system. Refer to DRAINING AND FILLING THE ENGINE COOLING SYSTEM .
  32. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
  33. Connect the negative battery cable.
  34. Remove the support and lower the vehicle.
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