1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL - Fiat - IDEA - eLearn

2400992 - 1016E10 single cylinder head, removed - overhaul

) CAMSHAFT HOUSING1. Position the upper cylinder head (1a) in the vice using the tool (1b).

	Name	Country
1b	Mount	1.860.470.001

1. Undo bolts (1a) and remove vacuum unit (1b).2. Remove the gasket.3. Undo the bolts (3a) and remove the pressure pump (3b) complette with O-Ring.4. Remove the coupling.

1. Undo the bolts (1a) and remove the cam angle sensor (1b).

Temporarily remove the tool fitted previously on the exhaust side camshaft.

	Name	Country
-	Gauge	1.870.896.900

Check that the end float of the camshaft is within the recommended values using a dial gauge.

	Measurement		Value
-	End float (mm)		0.15 ÷ 0.34

If the end float of the camshaft is not within the recommended values, when reassembling the cylinder head, replace the worn components. 1. Remove the plug (1a) and fit the tool (1b) on the inlet side camshaft.

Fit the tool positioning it with the references in a horizontal direction and checking that it is correctly inserted in the housing in the camshaft.

	Name	Country
1b	Gauge	1.870.896.900

2. Undo the camshaft sprocket fixing bolts.

1. Remove the camshaft timing tools from the camshaft housing.

	Name	Country
1	Gauge	1.870.896.900

2. Release the camshafts (2a) as necessary and remove the camshaft gears (2b).Remove the camshafts completely.

Remove the support tool, complete with upper cylinder head from the vice and separate them. CYLINDER HEAD1. Undo the nuts (1a) and remove the exhaust manifold (1b).2. Remove the exhaust manifold gasket.3. Undo and remove the heater plugs.

1. Position the cylinder head (1a) in the vice using the tool (1b).

	Name	Country
1b	Mount	1.860.470.001

2. Remove the valve rocker arms.3. Remove the hydraulic tappets.4. Remove the camshaft housing centering bushes.

1. Loosen the bands and remove the coolant supply hose from the thermostat to the E.G.R. system exhaust gas/water heat exchanger. 2. Undo the bolts (2a) and remove the thermostat (2b) complete with O-Ring.3. Undo and remove the engine oil pressure warning light switch.

1. Loosen the collar fixing the E.G.R. system exhaust gas/coolant heat exchanger, air chamber side.2. Undo the bolt (2a) and remove the E.G.R. system exhaust gas/heat exchanger assembly (2b).3. Remove the gaskets (3a) and (3b).

1. Release the engine oil vapour recirculation pipe from the fastening band on the air chamber.2. Undo the bolts (2a) and remove the engine oil vapour separator (2b) complete with engine oil vapour recirculation pipe (2c).

1. Undo the bolts (1a) and remove the air chamber (1b) complete with excess pressure sensor.2. Remove the gasket.

1. Place a wooden board on the cylinder head surface to support the valves and bolt in place.

	Name	Country
1	Stand	1.860.749.000

1. Remove the cotters (1a) using tools (1b) and (1c).

	Name	Country
1b	Lever	1.860.644.001

	Name	Country
1c	Chamber	1.870.881.000

2. Remove the upper valve shim.3. Remove the valve spring.

Work in the same way on the remaining valves.Remove the wooden board and recover the valves.

	Name	Country
-	Stand	1.860.749.000

1. Remove the valve guide oil seals (1a) using the tool (1b).

	Name	Country
1b	Pliers	1.870.894.000

2. Remove the lower valve shims.

Remove the cylinder head from the support tool.

	Name	Country
-	Support	1.860.470.000

Replace the valve guides - 1016E14 single cylinder head valve guides - replace during operation 1016e10 .

Reassembling ( Dismantling

) Clean the residues of the old gasket from the lower surface of the cylinder head.Clean the residues of the old gasket from the matching surfaces between the cylinder head and the camshaft housing.Check that the planarity of the lower cylinder head surface is within the recommended values.

	Measurement		Value
-	Flatness of bottom surface (mm)		0.1

If the planarity of the lower cylinder head surface is not within the recommended values, regrind it starting from the nominal height of the head and, at the end of the operation, positioning a new gasket with the number of references indicated below.The head can be reground by 0.1 mm if starting with a gasket with 0 references and using a new gasket with 1 reference.The head can be reground by 0.2 mm if starting with a gasket with 0 references and using a new gasket with 2 references.The head can be reground by 0.1 mm if starting with a gasket with 1 reference and using a new gasket with 2 references.

If the limit condition is reached (head gasket with 2 references before regrinding), the cylinder head lower plane cannot be reground.

	Measurement		Value
-	Nominal lift (mm)		105.5 ± 0.05

Check that the valves do not show signs of scoring or seizing.Check that the diameter of the valve stems is within the recommended values; if this is not the case, replace the worn valves.

	Measurement		Value
-	Stem diameter, Inlet/Exhaust (mm)		5.90 ÷ 5.94

Check that the length of the uncompressed valve springs is within the recommended values.

	Measurement		Value
-	Free length (mm)		37.9

Use a torque wrench to check that the valve spring specifications are within specified values; if this is not the case, replace parts that have yielded.

	Measurement		Value
-	Length (mm)		31.0
	under load (daN)	16.2 ÷ 18.0

	Measurement		Value
-	Length (mm)		23.5
	under load (daN)	36.1 ÷ 39.5

Check that the cam journal diameters are within the recommended values; if this is not the case, replace the worn camshaft(s).

	Measurement		Value
-	Journal diameter (mm)	First pin	38.500 ÷ 38.515
Second pin	38.000 ÷ 38.015
Third pin	30.000 ÷ 30.015

Check that the nominal lift of the camshaft cams is within the recommended values; if this is not the case, replace the worn camshaft(s).

	Measurement		Value
-	Nominal cam lift (mm)	Exhaust	7.5
Inlet	6.4

1. Check the diameter of the camshaft mounts is within specified values; If this is not the case, replace the cylinder head.

	Measurement		Value
1	Support diameter (mm)	First support	38.545 ÷ 38.570
Second support	38.045 ÷ 38.070
Third support	30.045 ÷ 30.070

1. Regrind the valve seats to the recommended dimension.

	Measurement		Value
1	Contact band angle with valve (-)		45° ± 20?

Grind the valve seats using a suitable tool.CYLINDER HEADPosition the cylinder head in the vice using the tool.

	Name	Country
-	Mount	1.860.470.001

Fit the valves in their seats, then support them using the wooden board and secure them using bolts.

	Name	Country
-	Stand	1.860.749.000

Fit the lower valve shims back in their housings.1. Fit the valve guide oil seals (1a) in their seats manually using the tool (1b).

	Name	Country
1b	Drift	1.870.900.800

1. Place the valve spring back in its housing.2. Place the upper valve shim back in its housing.3. Place the split cotters (3a) back in their housings using the tools (3b) and (3c).

	Name	Country
3b	Lever	1.860.644.001

	Name	Country
3c	Chamber	1.870.881.000

Work in the same way on the remaining valves.Remove the wooden board for supporting the valves from the cylinder head plane.

	Name	Country
-	Stand	1.860.749.000

1. Place the air chamber (1a), complete with gasket (1b) and excess pressure sensor, back in its housing and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	INLET AIR DUCT	M8	(Cylinder head side) 2.3 ÷ 2.8

Place the engine oil vapour separator, complete with engine oil recirculation pips, back in its housing and fix it using the bolts.Fasten the engine oil vapour recirculation pipe to the band on the air chamber.1. Place the E.G.R. system exhaust gas/water heat exchanger (1a) back in its housing complete with gaskets (1b) and (1c), then secure it tightening the bolts (1d) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1d	Bolt	E.G.R EXHAUST GAS HEAT EXCHANGER.	M8	(Cylinder head side) 2.0 ÷ 2.4

2. Tighten the collar fixing the E.G.R. system exhaust gas/water heat exchanger, air chamber side.

1. Fit the engine oil pressure warning light switch in its seating and tighten it to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	-	OIL PRESSURE W/L	M14	(Cylinder head side) 2.9 ÷ 3.5

2. Refit the thermostat (2a), complete with O-ring, back in its housing and tighten the bolts (2b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	THERMOSTAT	M8	(Cylinder head side) 2.3 ÷ 2.8

3. Refit the coolant supply hose beetween the thermostat and the E.G.R. system exhaust gas/water heat exchanger and secure it using the bands.

Place the camshaft housing centering bushes back in their seats.Place the hydraulic tappets in their housings.

Position the hydraulic tappets with the oil port facing the outside of the cylinder head: this position places the above mentioned port in contact with the oil duct in the lower cylinder head.

Place the valve rocker arms back in their housings.Remove the cylinder head from the support tool.

	Name	Country
-	Mount	1.860.470.001

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

	Fastening	Component	Ø	Value(daNm)
1	-	GLOW PLUGS	M8	(Cylinder head side) 0.9 ÷ 1.0

2. Place an exhaust manifold gasket in the housing.3. Place the exhaust manifold (3a) back in its housing and fix it tightening the nuts (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	Nut	EXHAUST MANIFOLD/S	M8	(Cylinder head side) 2.1 ÷ 2.5

CAMSHAFT HOUSINGPositino the camshaft housing in the vice using the tool.

	Name	Country
-	Mount	1.860.470.001

Place the camshafts back in their housings.Place the camshaft gears back in their housings and secure them without tightening the bolts. 1. Fit the camshaft timing tools.

Fit the tool positioning it with the millings in a horizontal position and checking that it is correctly inserted in the housings in the camshafts.

	Name	Country
1	Gauge	1.870.896.900

2. Tighten the camshaft sprocket fixing bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	CYLINDER HEAD EXTENSION	M12	(Camshaft side) 10.8 ÷ 13.2

1. Place the cam angle sensor (1a) back in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CAM ANGLE SENSOR	M6	(Camshaft housing side) 0.6 ÷ 0.8

1. Place the pressure pump (1a), complete with coupling (1b) and new O-ring, back in its housing and fix it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	PRESSURE PUMP	M7	(Camshaft housing side) 1.4 ÷ 1.7

2. Place the vacuum unit (2a), complete with gasket (2b), back in its housing and secure it tightening the bolts (1c) to the recommended torque.

Follow the order shown in the diagram for each tightening sequence. Tighten to 2.0 daNm in two stages: an initial stage of 0.5 daNm following tightening to 1.8 - 2.2 daNm.

	Fastening	Component	Ø	Value(daNm)
2c	Bolt	BRAKE SERVO VACUUM PUMP	M8	(Cylinder head side) 1.8 ÷ 2.2

Remove the support tool, complete with upper cylinder head from the vice and separate them.