Removal
1 Disconnect the battery negative terminal of Fiat Punto car.
2 Drain the cooling system.
3 Remove the inlet and exhaust mainfolds.
4 Remove the timing belt.
5 Remove the camshaft cover.
6 Disconnect the radiator hose from the thermostat housing on the left-hand end of the cylinder head of Fiat Punto.
7 If not already done, disconnect the LT wiring connectors at the ignition coils.
6 Unscrew the cylinder head bolts halt a turn at a time in the reverse order to that specified for tightening (see illustration 105). When the bolts are free, remove them with their washers.
9 Lift the cylinder head from the block. If it is stuck tight Insert pieces of wood into the exhaust or inlet ports, and use them as levers to rock the head off the block. On no account drive levers into the gasket joint, nor attempt to tap the head sideways, as it is located on positioning dowels.
10 Remove and discard the cylinder head gasket.
11 The cylinder head can be dismantled after removing the camshaft and cam followers.

Preparation for refitting
12 The mating faces of the cylinder head and cylinder block of Fiat Punto must be perfectly clean before refitting the head. Use a hard plastic or wooden scraper to remove all traces of gasket and carbon; also clean the piston crowns. Take particular care when cleaning the piston crowns as the soft aluminium alloy is easily damaged. Make sure that the carbon is not allowed to enter the oil and water passages - this is particularly important for the lubrication system, as carbon could block the oil supply to the engine's components. Using adhesive tape and paper, seal the water, oil and bolt holes in the cylinder block. To prevent carbon entering the gap between the pistons and bores, smear a little grease in the gap. After cleaning each piston of Fiat Punto engine, use a small brush to remove all traces of grease and carbon from the gap, then wipe away the remainder with a clean rag. Clean all the pistons in the same way.
13 Check the mating surfaces of the cylinder block and the cylinder head for nicks, deep scratches and other damage. If slight, they may be removed carefully with a file, but if excessive, machining may be the only alternative to renewal. If warpage of the cylinder head gasket surface is suspected, use a straight-edge to check it for distortion.
14 Check the condition of the cylinder head bolts of Fiat Punto engine, and particularly their threads, whenever they are removed. Wash the bolts in a suitable solvent, and wipe them dry. Check each bolt for any sign of visible wear or damage, renewing them if necessary. Although Fiat do not specify that the bolts must be renewed, it is strongly recommended that the bolts should be renewed as a complete set whenever they are disturbed.
15 Refit the camshaft and followers of Fiat Punto engine, then adjust the valve clearances before refitting the cylinder head to the block.

Refitting
16 Before refitting the assembled cylinder head, make sure that the head and block mating surfaces are perfectly clean, and that the bolt holes in the cylinder block have been I mopped out to clear any oil.
17 Make sure that the crankshaft and camshaft are still set at their correct TDC positions and, where applicable, the camshaft is locked in the correct position using the special tool.
18 The new gasket should not be removed from its nylon cover until required for use. Fit the gasket dry, and make sure that the mating surfaces on the head and block are perfectly clean.
19 Place the gasket on the cylinder block of Fiat Punto engine so that the word ALTO can be read from above (see illustration).



Place the cylinder head gasket on the block so that the word ALTO can be read from above


20 Lower the cylinder head onto the block so that it locates on the positioning dowels.
21 The cylinder head bolt threads must be clean and lightly lubricated. Screw the bolts in finger-tight then working progressively and in the sequence shown, tighten all the cylinder head bolts of Fiat Punto engine to the Stage 1 torque setting given in the Specifications, using a torque wrench and 8 suitable socket (see illustration). With all the bolts tightened to their Stage 1 setting, working again in the specified sequence, first angle-tighten the bolts through the specified Stage 2 angle, then again through the Stage 3 angle, using a socket and extension bar. It is recommended that an angle-measuring gauge is used during this stage of tightening, to ensure accuracy.



Cylinder head bolt tightening sequence


22 Refit the inlet and exhaust manifolds.
23 Refit the camshaft cover.
24 Refit the timing belt.
25 Reconnect the LT wiring connectors at the ignition coils.
26 Reconnect the battery then fill and bleed the cooling system.