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

3363555 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

) 1. Undo the bolts (1a) and remove the vacuum unit (1b) complete with O-ring.2. Undo the bolts (2a) and remove the thermostat (2b) complete with pipe and sensors.3. Remove the seal.

Place the head on the workbench.1. Undo the stud using the nut and locknut.2. Fit the tool (2a) on the cylinder head (2b) and secure it using the nuts (2c).

	Description	Code
2a	Drift	1.860.460.000

Place the tool in the vice.1. Loosen the manifold side connectors for the pipes from the fuel manifold to the injectors.2. Undo the injector side connectors for the pipes from the fuel manifold to the injectors.3. Undo the nuts (3a) and remove the fuel distribution manifold (3b) complete with fuel pressure sensor and pipes (3c).Completely undo the connectors loosened previously and separate the pipes from the fuel manifold to the injectors from the fuel manifold.

Use new pipes from the fuel manifold to the injectors when refitting.

4. Manually push the clips (4a) and disconnect the pipe from the injectors to the fuel recovery manifold (4b), injector side, and remove it.Undo the nuts and disconnect the supply wiring from the glow plugs.

	Description	Connector
-	Heater plug	A40

Disconnect the coolant return pipe to the expansion tank and de-aeration system from the thermostat.5. Undo the nuts (5a) and remove the air intake manifold assembly (5b).

Disconnect the supply pipe from the thermostat to the waer return manifold to the pump, manifold side.1. Undo the bolts (1a) and remove the water pump inlet pipe (1b).2. Remove the seal.

1. Undo the driven toothed pulley bolt (1a) using the tools (1b).

	Description	Code
1b	Support for counter-torque	1.860.831.000

	Description	Code
1b	Counter-torque	1.860.831.001

2. Remove the toothed driven pulley.3. Undo the bolts (3a) and remove the cam angle sensor (3b).4. Undo the bolts (4a) and remove the water pump (4b) complete with O-ring (4c).

1. Unscrew the glow plugs and remove.2. Undo the nuts for the brackets fastening the injectors and the washers.

1. Remove the injectors (1a), complete with gaskets and mounting brackets (1b), using the tool (1c).

	Description	Code
1c	Extractor	1.870.739.000

Remove the injector bracket support pads.

Check that the camshaft endfloat is within the recommended values using a dial gauge.

	Measurement		Value
-	End float (mm)		0.100 ÷ 0.230

If the camshaft endfloat is not within the recommended values, replace the worn components when reassembling the cylinder head.1. Undo the camshaft cap bolts.2. Remove the camshaft support lubrication pipe.3. Remove the camshaft caps.4. Remove the camshaft.5. Remove the camshaft front oil seal.6. Remove the cups complete with valve clearance adjustment pads.

Remove the cylinder head from the vice.Place a suitable wooden bench between the support tools and the cylinder head to support the valves.Refit the cylinder head in the vice.1. Remove the cotters (1a) using the tool (1b).

	Description	Code
1b	Tool	1.860.644.000

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

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

	Description	Code
1b	Extractor	1.860.989.000

2. Remove the lower shim.Carry out the same operations on the other valves.Remove the cylinder head from the support tools and recover the valves.

Position the cylinder head on the workbench.1. Thread the special extraction tool (1b) in the valve seat (1a).

Turn the cylinder head upsidedown on the workbench.1. Remove the valve seat (1a) using the extraction tool (1b).Carry out the same operations on the other valve seats.

For the replacement of the valve guides Op. 1016E14 VALVE GUIDES IN SINGLE CYLINDER HEAD - REPLACE DURING OP. 1016E10.

Refitting ( Removing

) Clean any residues of the old gasket from the lower cylinder head plane.Check that the flatness of the lower cylinder head plane corresponds to the recommended values.

	Measurement		Value
-	Lower plane planarity (mm)		0.1

1. If the planarity of the lower cylinder head plane does not correspond to the recommended figures, regrind it without exceeding the minimum permitted height.

	Measurement		Value
1	Minimum permitted height (mm)		140.85 ÷ 141.15

Check that the valves do not show signs of scoring or seizing.Check that the diameter of the valve stems corresponds to the recommended figures; if not, replace the worn valves.

	Measurement		Value
-	Stem diameter (mm)		7.890 ÷ 7.940

With the valve guides fitted in the head, check that the diameter is within the recommended values or, in the case of wear, replace the guides.

	Measurement		Value
-	Diameter (mm)		8.040 ÷ 8.022

Check that the outer diameter of the cups corresponds to the recommended figures; if not, replace the worn components.

	Measurement		Value
-	Outer diameter (mm)		36.975 ÷ 36.991

Check that the diameter of the cup seats corresponds to the recommended figures; if not, replace the cylinder head.

	Measurement		Value
-	Cup housing diameter (mm)		37.000 - 37.025

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

	Measurement		Value
-	Length of spring released (mm)		53.9

Using a torque wrench, check that the spring specifications correspond to the recommended figures; if not, replace the worn components.

	Measurement		Value
-	Length (mm)		43.12
	Under a load of (daN)	24.5 - 21.5

	Measurement		Value
-	Length (mm)		26.5
	Under a load of (daN)	56 - 61

Check that the diameter of the camshaft bearings corresponds to the recommended figures; if not, replace the worn camshaft.

	Measurement		Value
-	Journal diameter (mm)		26.000 - 26.015

Check that the nominal camshaft cam lift corresponds to the recommended figures; if not, replace the worn camshaft.

	Measurement		Value
-	Nominal cam height (mm)	Inlet	8.5
Exhaust	9.0

1. Fit the camshaft caps (1a) on the cylinder head and tighten the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CAMSHAFT CAPS	M7	(Cylinder head side) 1.4 - 2.0

2. Check that the diameter of the camshaft supports corresponds to the recommended figures; if not, replace the cylinder head.

	Measurement		Value
2	Diameter (mm)		26.045 - 26.070

Check that the outer diameter of the valve seats to be fitted corresponds to the recommended figures.

	Measurement		Value
-	Outer diameter (mm)	Inlet	36.135 - 36.150
Exhaust	35.142 - 35.157

1. Fit the valve seats (1a) using a suitable tool (1b).

1. Grind the valve seats to the recommended size.

	Measurement		Value
1	Angle of ring in contact with valve (-)		45°30'' ± 1?

Grind the valve seats using a suitable tool.Temporarily fit the valves.1. Check that the valve recess in relation to the cylinder head plane corresponds to the recommended figures using the tool fitted with a dial gauge.

	Measurement		Value
1	Cylinder head plane recess (mm)		0.1 - 0.5

	Description	Code
1	Dial gauge support	1.870.404.000

If the valve recess in relation to the cylinder head plane does not correspond to the recommended figures, regrind the valve seats once again.

Place a suitable wooden bench between the support tools and the cylinder head to support the valves.Fit the cylinder head, complete with valves, on the support tools and secure it using the nuts.Fit the lower shim.1. Fit the valve guide oil seals (1a) using the tools (1b) and (1c).

	Description	Code
1b	Drift	1.860.814.001

	Description	Code
1c	Fitting tool	1.860.313.000

	Description	Code
1d	Drift	1.867.019.000

Fit the valve spring.Fit the valve upper shim.

	Description	Code
se	Tool	1.860.644.000

Carry out the same operations on the other valves.

Remove the cylinder head from the support tools.Remove the wooden valve support bench from the support tools.Refit the cylinder head on the support tools.Fit the cups complete with valve clearance adjustment pads.Fit the camshaft.1. Fit the camshaft caps.Fit the camshaft bearing lubrication pipe.2. Tighten the camshaft cap bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	CAMSHAFT CAPS	M7	(Cylinder head side) 1.4 - 2.0

1. Fit the camshaft front oil seal (1a) using the tool (1b).

	Description	Code
1b	Fitting tool	1.821.824.000

2. Fit the spark plugs and tighten them to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2	-	GLOW PLUGS	M12	(Cylinder head side) 1.4 -1.8

1. Fit the injector bracket support pads.2. Fit the injectors (2a) complete with gasket (2b).3. Fit the injector brackets (3a) and tighten the nuts (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	Nut	INJECTORS(DIESEL)	M8	(Cylinder head side) 2.7 -4.0

4. Position the connectors for the pipe from the injectors to the fuel recovery manifold (4a) in the corresponding injector seats and insert them fully until the clip (4b) can be heard to click.

1. Fit the water pump (1a), complete with a new O-Ring (1b) and tighten the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	COOLANT PUMP	M8	(Engine crankcase side) 2.3 -3.3

2. Fit the cam angle sensor (2a) and tighten the bolts (2b).

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	ENGINE RPM AND TIMING SENSOR	-	0.9 - 1.2

3. Fit the toothed driven pulley.4. Tighten the toothed driven pulley bolt (4a) to the recommended torque using the tools (4b).

	Fastening	Component	Ø	Value(daNm)
4a	Bolt	TIMING DRIVEN PULLEY	M12	11.0 - 15.9

	Description	Code
4b	Support for counter-torque	1.860.831.000

	Description	Code
4b	Counter-torque	1.860.831.001

Check that the valve clearance, with the valves closed, corresponds to the recommended figures; if not, replace the valve clearance adjustment pads following the instructions given below.

	Measurement		Value
-	Inlet valve clearance in closed position (mm)	Inlet	0.30 - 0.40
Exhaust	0.30 - 0.40

1. Lower the tappet in question using the tool.

	Description	Code
1	Lever	1.860.443.000

2. Fit the tool.

	Description	Code
2	Lever	1.860.724.001

Remove the tool.

	Description	Code
-	Lever	1.860.443.000

Extract the valve clearance adjustment pad and replace it with another one of a suitable size (smaller for a smaller clearance, bigger for a bigger clearance).Remove the tool.

	Description	Code
-	Lever	1.860.724.001

1. Remove the seal.2. Fit the thermostat (2a) complete with pipes and sensors and tighten the bolts (2b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	THERMOSTAT	M8	1.4 ÷ 2.0

3. Fit the thermostat (3a) complete with O-Ring and tighten the bolts (3b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	VACUUM PUMP FOR BRAKES	M8	2.3 - 3.3

1. Remove the seal.2. Fit the water pump rigid inlet pipe (2a) and tighten the bolts (2b).Connect the supply pipe from the thermostat to the water return manifold to the pump, manifold side.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	COOLANT PUMP RIGID INLET PIPE	M6	0.9 - 1.2

1. Fit the intake air manifold assembly (1a) and tighten the nuts (1b).

	Fastening	Component	Ø	Value(daNm)
1b	Nut	INLET MANIFOLD	-	2.3 - 3.3

Connect the coolant return pipe to the expansion tank and de-aeration system to the thermostat.Position the heater plugs supply wiring and secure it using the nuts.2. Connect the fuel return pipe for lubricating the injectors to the fuel manifold.Assemble new pipes from the fuel manifold to the injectors on the fuel manifold without tightening the connectors.3. Fit the fuel distribution manifold (3a) complete with pipes and fuel pressure sensor and tighten the nuts (3b).

	Fastening	Component	Ø	Value(daNm)
4	Nut	INJECTOR FUEL MANIFOLD (DIESEL)	-	2.3 - 3.3

4. Tighten the injector side connectors to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
4	Connector	PIPE FUEL MANIFOLD TO INJECTORS	M12	(Injector side) 2.3 - 3.3

5. Tighten the connectors for the pipes from the fuel manifold to the manifold side injectors to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
5	Connector	PIPE FUEL MANIFOLD TO INJECTORS	M14	(Manifold end) 2.1 -2.8

Remove the cylinder head from the support tools.