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

2892339 - 1016E10 single cylinder head, removed - overhaul

) 1. Position the cylinder head in the vice, supporting it with a suitable tool.

	Name	Country
1	Support	1.860.470.000

2. Using the tool, remove the spark plugs.

	Name	Country
2	Key	1.850.184.000

1. Using the tools (1a), (1b), (1c), (1d) and (1e) as illustrated in the diagram, compress the valve springs.2. Remove the cotters (2a), caps (2b) and springs (2c), then remove the tool to remove the inlet and exhaust valves (2d) from the head.

	Name	Country
1a	Lever	1.860.790.000

	Name	Country
1b	Lever hook	1.860.788.000

	Name	Country
1c	Extension	1.860.787.000

	Name	Country
1d	Valve retaining base	1.860.786.000

	Name	Country
1e	Chamber	1.860.789.000

1. Using suitable pliers (1a), remove the oil seals (1b) from the valve guides.

Reassembling ( Dismantling

) De-carbonize and clean the valve seats and ducts.Clean the residues of the old gasket from the lower surface of the cylinder head.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 cylinder head surface is not within the recommended values, regrind the head surface.1. After regriding the cylinder head, use a dial gauge (1a) and magnetic base (1b) to check that the minimum height between the reference plane inside the combustion chamber and the cylinder head surface is within the recommended value.

	Measurement		Value
-	Minimum height between combustion chamber plane/cylinder head (mm)		12.5 ÷ 13.0

The minimum permissible height after refacing is 12.5 mm.

	Name	Country
1b	Dial gauge mounting	1.870.404.000

According the planarity figure measured, the cylinder head can be refaced until the minimum permissible value is reached.If the value measured is within the tolerance, but close to the minimum permissible value, the operation of refacing the head could alter the functional characteristics of the actual cylinder head because it could cause an excessive increase in the compression ratio with consequent detonation.Also check the volume of all the combustion chambers following the procedure described below.1. Temporarily fit the valves and spark plugs and use a graduated test tube containing a known quantity of engine oil.2. Rest a glass sheet with four holes corresponding to the combustion chambers on the cylinder head.3. Complete the filling of the combustion chamber, taking care that no oil comes out of the combustion chamber.Wait for around 10 minutes to allow the decantation of the oil.Measure the quantity of oil remaining in the test tube and then calculate the difference between it and the quantity of oil used initially when the test tube was full; this value corresponds to the volume of the chamber.Check that this figure corresponds to the recommended values, or else the cylinder head has to be replaced.

	Measurement		Value
-	Volume of combustion chamber in cylinder head (cm)		33.35

Remove the combustion residues from the valves.Check that the valves do not show signs of scoring or seizing.Check that the thickness of the part in contact with the valve seat is within the recommended values.

	Measurement		Value
-	Valve thickness (mm)		/= 1

Check that the diameter of the valve stems is within the recommended values; if this is not the case, replace the valves.

	Measurement		Value
-	Inlet valve internal diameter (mm)		6.982 ÷ 7.000

	Measurement		Value
-	Exhaust valve internal diameter (mm)		6.974 ÷ 6.992

Check that the diameter of the valve head is within the recommended values; if this is not the case, replace the valves.

	Measurement		Value
-	Gudgeon pin oversizel (mm)		0.2

	Measurement		Value
-	Exhaust valve external diameter (mm)		29.750 ÷ 30.050

Check that the contact angle with the valve seat for both valves is within the recommended values or else the valve has to be replaced.

	Measurement		Value
-	Contact band angle with valve seat (-)	Inlet	45° 30' ± 5'

	Measurement		Value
-	Contact band angle with exhaust valve seat (-)		45° 30' ± 5'

Using a special instrument, check that the valve spring specifications in the various load conditions have not changed; otherwise they must be replaced.

	Measurement		Value
-	Internal spring height (mm)		27.5
	Under load (daN)	8.3 - 9.3

	Measurement		Value
-	Internal spring height (mm)		18.5
	Under load (daN)	17.6 - 19.6

	Measurement		Value
-	External spring height (mm)		33.5
	Under load (daN)	23.4 - 25.6

	Measurement		Value
-	External spring height (mm)		24.5
	Under load (daN)	46 - 50

Regrind the valve seats to the recommended dimensions for a length of around 2 mm.

	Measurement		Value
-	Contact band angle with valve (-)	Exhaust	45° ± 20°
Inlet	45° ± 20°

Ream the internal diameter of the valve guide, using a suitable reamer.Check that the value of the valve guide internal diameter after refacing and the clearance with the valve are within the recommended values or else the valve guide has to be replaced. If necessary, replace the valve guides referring to op. 1016E14 single cylinder head valve guides - replace during operation 1016e10

	Measurement		Value
-	Valve guide internal diameter (mm)		7.022 ÷ 7.040

	Measurement		Value
-	Clearance between inlet valve - inlet valve guide (mm)		0.022 ÷ 0.058

	Measurement		Value
-	Clearance between exhaust valve - exhaust valve guide (mm)		0.030 ÷ 0.066

1. Fit the oil seals (1a) on the valve guides, using the drift (1b) on the stem of the valve temporarily fitted in the seat, then fit the new oil seal on the drift.2. Remove the drift and, using a suitable tool, fit the oil seal in the housing.

	Name	Country
1b	Drift	1.860.813.000

	Name	Country
1b	Drift	1.860.813.000

Refit the valves, springs, caps and cotters using the same tools as used for the dismantling.

	Name	Country
-	Lever	1.860.790.000

	Name	Country
-	Lever hook	1.860.788.000

	Name	Country
-	Extension	1.860.787.000

	Name	Country
-	Valve retaining base	1.860.786.000

	Name	Country
-	Chamber	1.860.789.000

Carry out the valve leakage test, referring to operation 1016C04 cylinder head valves, removed - tightness test - Valve leakage test Remove the cylinder head from the vice.Remove the support tool fitted initially from the cylinder head.

	Name	Country
-	Support	1.860.470.000

1. Remove the hydraulic tappets from the camshaft housing, taking care to place them on a suitable surface, making a note of their position in the camshaft housing.

Do not turn the tappets upsidedown or else they fluid they contain will escape.

1. Fit the supporting tool (1a) on the camshaft housing (1b) and place it in the vice.

	Name	Country
1a	Support	1.860.470.000

1. Undo the nut (1a) and remove the rear cover (1b).Remove the camshaft, complete with oil seal, from the housing.

Measure the diameters of the camshaft housing supports, checking that the figures correspond to the recommended values; if this is not the case, replace the damaged camshaft housing.

	Measurement		Value
-	Diameter of 1st° camshaft bearing, inlet side, in camshaft housing (mm)		29.989 - 30.014

	Measurement		Value
-	Diameter of 2nd° camshaft support, inlet side in camshaft housing (mm)		52.445 - 52.470

	Measurement		Value
-	Diameter of 3rd° camshaft bearing, inlet side, in camshaft housing (mm)		52.845 - 52.870

	Measurement		Value
-	Diameter of 4th° camshaft bearing, inlet side, in camshaft housing (mm)		53.245 - 53.270

	Measurement		Value
-	Diameter of 5th° camshaft bearing, inlet side, in camshaft housing (mm)		53.645 - 53.670

Measure the camshaft bearings, checking that the values correspond to the recommended figures; if this is not the case, replace the damaged camshaft.

	Measurement		Value
-	Diameter of 1st° camshaft bearing, timing side (mm)		29.944 - 29.960

	Measurement		Value
-	Diameter of 2nd° camshaft bearing, timing side (mm)		52.400 - 52.415

	Measurement		Value
-	Diameter of 3rd° camshaft bearing, timing side (mm)		52.800 - 52.815

	Measurement		Value
-	Diameter of 4th° camshaft bearing, timing side (mm)		53.200 - 53.215

	Measurement		Value
-	Diameter of 5th° camshaft bearing, timing side (mm)		53.600 - 53.615

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

	Measurement		Value
-	Camshaft cam height (mm)	Exhaust	8
Inlet	8.5

Also check that the surfaces of the cams and the bearings do not show signs of wear, grooves or seizing.Fit the camshafts in the camshaft housings, taking into account that the recommended clearance should not be exceeded.

	Measurement		Value
-	Clearance between camshaft bearings- camshaft housing. supports (mm)		0.030 - 0.070

1. Fit the new oil seal (1a) on the camshaft housings, using the tool (1b).

	Name	Country
1b	Fitting tool	1.860.882.000

Measure the diameters of the tappet housings, checking that the values correspond to the recommended figures; if this is not the case, replace the camshaft housing.

	Measurement		Value
-	Diameter of tappet housings (mm)		33.000 - 33.025

1. Measure the diameters of the tappets, checking that the values are within the recommended figures; if this is not the case, replace the tappets.

	Measurement		Value
-	Tappet external diameter (mm)		32.959 - 32.975

Fit the hydraulic tappets in the special housings in the camshaft housing.Measure the tappet clearance with the housing in the camshaft housing, checking that the values correspond to the recommended figures.

	Measurement		Value
-	Clearance between housing in head - hydraulic tappet (mm)		0.025 - 0.066