3315371 - 1016E22 r cylinder head - overhaul (Automatic transmission)

Dismantling ( Reassembling ) 1. Position the tool in the vice.

NameCountry
1Mount1.820.012.000
2. Fit the tool (2a) complete with tool (2b).

NameCountry
2aMount1.820.050.000

NameCountry
2b-1.860.952.000
3. Position the cylinder head (3a) on the supporting tools and fix it using the nuts (3b).
1. Undo the bolts (1a) and remove the intake pipes (1b).2. Undo the bolts (2a) and remove the fuel distribution manifold (2b) complete with fuel injectors (2c).3. Remove the air intake manifold (3a) complete with gasket (3b).
1. Undo the bolts (1a) and remove the automatic timing belt tensioner (1b).2. Undo the bolt (2a) and remove the fixed timing belt tensioner (2b).
1. Slacken the bolts (1a) on the camshaft pullies using the tools (1b) for counter-torque.

NameCountry
1bCounter-torque1.822.146.000
1. Remove the camshaft pullies (1a) using the tool (1b).

NameCountry
1bTiming pullies extractor1.860.954.000
1. Undo the bolts (1a) and remove the timing belt cover (1b).2. Undo the nuts (2a) and remove the reaction rod support (2b).
1. Undo the bolt (1a) and remove the coolant outlet connector (1b) from the right cylinder head (1b).2. Undo the bolt (2a) and remove the cam angle sensor (2b) complete with O-ring (2c).
Check that the camshaft end float is within the recommended values using a dial gauge on a magnetic base.

MeasurementValue
-End float (mm)0.060 - 0.201
If the value of the camshaft end float is not within the recommended values, when reassembling, replace the worn components.1. Undo the bolts (1a) and remove the camshaft caps (1b).2. Remove the camshafts.3. Remove the front camshaft oil seals.4. Remove the hydraulic tappets.5. Remove the spark plug housing gaskets.
1. Remove the split collars (1a) using tools (1b), (1c), (1d), (1e) and (1f).

NameCountry
1bValve supports1.820.011.000

NameCountry
1cSpecial nut1.820.049.000

NameCountry
1dMount1.821.124.000

NameCountry
1eChamber1.821.205.000

NameCountry
1fLever1.821.058.000
2. Remove the upper valve shim.3. Remove the valve springs.Remove the tools used for dismantling the valves.4. Remove the valve.Work in the same way to remove the remaining valves.
1. Remove the valve guide oil seal (1a) using the tool (1b).

NameCountry
1bExtractor1.821.208.000
2. Remove the lower spring washer (2a) and the lower valve shim (2b).
Remove the cylinder head from the supporting tools and position it on an appropriate workbench.1. Screw the special extraction tool (1b) in the valve seat (1a).Turn the cylinder head upside down on the workbench.Remove the valve seat using the extraction tool.
1. Remove the valve guides (1a) using the tool (1b).

NameCountry
1bExtractor1.821.176.000
Reassembling ( Dismantling ) Clean the residues of the old gasket from the lower surface of the cylinder head.1. Check that the planarity of the lower cylinder head surface is within the recommended values.

MeasurementValue
1Flatness of bottom surface (mm)0.05
1. If the planarity of the lower cylinder head surface is not within the recommended values, reface the lower cylinder head surface without exceeding the minimum permissible height.

MeasurementValue
1Minimum permissible height after refacing (mm)134.85 - 135.15
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.

MeasurementValue
-Stem diameter (mm)6.965 - 6.980
Check that the outer diameter of the hydraulic tappets is within the recommended values; if this is not the case, replace the worn hydraulic tappets.

MeasurementValue
-Outer diameter (mm)32.959 - 32.975
Check that the diameter of the hydraulic tappet seats is within the recommended values; if this is not the case, replace the cylinder head.

MeasurementValue
-Diameter of hydraulic tappet seats (mm)33.000 - 33.025
Check that the length of the valve springs is within the recommended values.

MeasurementValue
-Free length- Exterior (mm)45

MeasurementValue
-Free length - Interior (mm)42
Using the dynamometer, check that the characteristics of the springs are within the recommended values; if this is not the case, replace the worn components.

MeasurementValue
-Laden (daN)21.9 - 23.1
Length (mm)32.5

MeasurementValue
-Laden (daN)43.1 - 45.0
Length (mm)23

MeasurementValue
-Laden (daN)12.4 - 13.1
Length (mm)30.5

MeasurementValue
-Laden (daN)24.0 - 26.0
Length (mm)21
Check that the diameter of the camshaft journals is within the recommended values; if this is not the case, replace the worn components.

MeasurementValue
-Journal diameter (mm)25.959 - 26.980
Check that the nominal lift of the camshaft cams is within the recommended values; if this is not the case, replace the worn components.

MeasurementValue
-Nominal cam lift (mm)9.30
1. Fit the camshaft caps to the right cylinder head in accordance with the sequence indicated in the figure.
1. Tighten the camshaft cap bolts to torque.

FasteningComponentØValue(daNm)
1BoltCAMSHAFT CAPSM81.8 - 2.0
2. Check that the diameter of the camshaft bearings is within the recommended values; if this is not the case, replace the cylinder head.

MeasurementValue
2Camshaft bearing diameter (mm)27.010 - 27.036
Check that the outer diameter of the valve guides to be fitted is within the recommended values.

MeasurementValue
-Inlet outer diameter (mm)12.040 - 12.051 (*)
Oversize (mm)0.20

MeasurementValue
-Exhaust outer diameter (mm)12.050 - 12.068 (*)
Oversize (mm)0.20
1. Fit the valve guides (1a) using the tool (1b).

NameCountry
1bFitting tool1.821.207.000
Ream the inner diameter of the valve guides to the recommended diameter.

MeasurementValue
-Inner diameter (mm)7.000 - 7.015
Check that the outer diameter of the valve seats to be fitted is within the recommended values.

MeasurementValue
-Inlet outer diameter (mm)34.600 - 34.616
Oversize (mm)0.3

MeasurementValue
-Exhaust outer diameter (mm)30.100 - 30.110
Oversize (mm)0.3
1. Heat up the cylinder head to 100-120° C, then fit the valve seats (1a) using a suitable tool (1b).
1. Regrind the valve seats to the recommended dimensions.

MeasurementValue
1Valve contact band taper (mm)90° ± 20?
Grind the valve seats using a suitable tool.
Fit the cylinder head on the supporting tools and fix it using the nuts.Fit the lower valve shim and lower spring washer.1. Fit the valve guide oil seal (1a) using the tool (1b).

NameCountry
1bFitting tool1.821.206.000
1. Fit the valves (1a) for the cylinder head in question and support them using the tools (1b) and (1c).

NameCountry
1bValve supports1.820.011.000

NameCountry
1cSpecial nut1.820.049.000
2. Fit the valve springs.3. Fit the upper valve shims.4. Fit the split collars (4a) using the tools (4b), (4c) and (4d).

NameCountry
4bMount1.821.124.000

NameCountry
4cChamber1.821.205.000

NameCountry
4dLever1.821.058.000
Work in the same way when fitting the remaining valves.Remove the tools used for fitting valves.
1. Fit the spark plug housing gaskets.2. Fit the hydraulic tappets.3. Fit the camshafts.
1. Fit the camshaft caps on the right cylinder head in accordance with the sequence indicated in the figure.
Tighten the camshaft cap bolts to torque.

FasteningComponentØValue(daNm)
-BoltCAMSHAFT CAPSM81.8 - 2.0
1. Fit the camshaft front oil seals (1a) using the tool (1b).

NameCountry
1bFitting tool1.860.948.000
Fit the cam angle sensor complete with O-ring and fix it using the bolt.Fit the coolant outlet connector on the cylinder head and fix it using the bolt.Fit the reaction rod mounting and fix it using the nuts.Fit the timing belt cover and fix it using the bolts.1. Fit the camshaft pullies.2. Tighten the bolts (2a) on the camshaft pullies to torque using the tools (2b).

NameCountry
2bCounter-torque1.822.146.000

FasteningComponentØValue(daNm)
2aBoltTIMING GEAR DRIVEN PULLEYSM106.8 ÷ 8.4
Fit the timing belt fixed tensioner and fix it using the bolt.Fit the automatic timing belt tensioner and fix it using the bolts, without tightening them.Fit the inlet manifold complete with gasket.Fit the fuel distribution manifold complete with fuel injectors and fix it using the bolts.Fit the inlet ducts and fix them using the bolts.Remove the cylinder head from the supporting tools.Remove the cylinder head support tools from the vice and return them.