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

3363555 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

) CYLINDER HEAD EXTENSION1. Position the cylinder head extension (1a) in a vice using the tool (1b).

	Description	Code
1b	Support	1.860.470.001

1. Undo the bolts (1a) and remove the engine oil filler (1b).2. Remove the gasket.

1. Undo the bolts (1a) and remove the vacuum unit (1b).2. Remove the gasket.

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

Check that the camshaft endfloat is within the recommended values using a dial gauge.If the camshaft endfloat is not within the recommended values, replace the worn components when reassembling the cylinder head.1. Remove plug (1a) and fit camshaft timing tools (1b) to the cylinder head extension.

Check that the tools are correctly fitted in the housings in the camshafts.

	Description	Code
1b	Templates	1.870.896.900

1. Undo the bolts fixing the camshaft gears.

1. Undo the bolt (1a) and remove the exhaust side camshaft toothed drive pulley (1b).

Remove the camshaft timing tools from the cylinder head extension.

	Description	Code
-	Templates	1.870.896.900

1. Wtihdraw the camshafts (1a), as far as necessary and remove the camshaft gears (1b).

1. Using a suitable drift, extract the inlet side camshaft (1a) and plug (1b).2. Using a suitable drift, extract the exhaust side camshaft (2a) and oil seal (2b).Remove the exhaust side camshaft oil seal.

1. Undo and remove the engine oil lubrication duct plugs.

Remove the support tool complete with cylinder head extension from the vice and separate them.LOWER CYLINDER HEAD1. Position the lower cylinder head (1a) in a vice using the tool (1b).

	Description	Code
1b	Support	1.860.470.001

2. Remove the hydraulic tappets.3. Undo the bolts (3a) and remove the thermostat (3b).Remove the gasket.

1. Undo the bolts (1a) and remove the water pump (1b).2. Remove the gasket.

1. Fit a wooden stand on the cylinder head plane to support the valves and secure it using bolts.

	Description	Code
1	Stand	1.860.804.001

1. Fit the half-cones (1a) using the tools (1b) and (1c).

	Description	Code
1b	Lever	1.860.644.001

	Description	Code
1c	Chamber	1.870.890.000

2. Remove the valve upper shim.3. Remove the valve spring.4. Remove the shim (for exhaust valves only).5. Remove the valve guide oil seal with integrated lower valve shim.Carry out the same operations on the other valves.

Remove the wooden stand and recover the valves.

	Description	Code
-	Stand	1.860.804.001

Remove the lower cylinder head from the support tool.

	Description	Code
-	Support	1.860.470.001

Replace the valve guide 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 ± 0.05

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
-	Minimum permitted height (mm)		107.0 ± 0.05

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)	Inlet	5.982 ÷ 6.000
Exhaust	5.972 ÷ 5.990

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

	Measurement		Value
-	Free length (mm)		43.1

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

	Measurement		Value
-	Length (mm)		34.0
	Under a load of (daN)	20.17 ÷ 21.42

	Measurement		Value
-	Length (mm)		24.5
	Under a load of (daN)	42.82 ÷ 45.47

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

	Measurement		Value
-	Journal diameter (mm)	First journal	43.600 ÷ 43.615
Fourth journal	43.000 ÷ 43.015
Fifth journal	30.000 ÷ 30.015
Second journal	43.400 ÷ 43.415
Third journal	43.200 ÷ 43.215

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

	Measurement		Value
-	Nominal cam height (mm)	Inlet	8.0
Exhaust	8.0

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

	Measurement		Value
-	Bearing diameter (mm)	First bearing	43.646 ÷ 43.671
Fourth bearing	43.046 ÷ 43.071
Fifth bearing	30.045 ÷ 30.070
Second bearing	43.446 ÷ 43.471
Third bearing	43.246 ÷ 43.271

The outer diameter of the valve seats is as follows.

	Measurement		Value
-	Outer diameter (mm)	Inlet	29.489 ÷ 29.514
Exhaust	27.491 ÷ 27.512

1. Grind the valve seats to the recommended size.

	Measurement		Value
-	Contact band angle with inlet valve ()		45° ± 20''

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

	Description	Code
-	Support	1.860.470.001

Fit the valves in the seats, then support them using the wooden stand and secure it using suitable bolts.

	Description	Code
-	Stand	1.860.804.001

1. Place the valve guide oil seal (1a) in position using the tool (1b).

	Description	Code
1b	Fitting tool	1.870.897.100

1. Place the shim in position (for exhaust valves only).2. Fit the valve spring in its seat.3. Refit the upper valve shim.4. Place the cotters (4a) in their housings using the tools (4b) and (4c).

	Description	Code
4b	Lever	1.860.644.001

	Description	Code
4c	Chamber	1.870.890.000

Carry out the same operations on the other valves.

Remove the wooden stand for supporting the valves from the cylinder head plane.

	Description	Code
-	Stand	1.860.804.001

1. Position the water pump (1a), complete with gasket (1b), in its housing and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	-	-	2.5

1. Place the thermostat (1a) complete with gasket back in its housing and secure it by tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	-	-	0.9

2. Place the hydraulic tappets in their housings.

Remove the lower cylinder head from the support tool.

	Description	Code
-	Support	1.860.470.001

CYLINDER HEAD EXTENSION1. Position the cylinder head extension (1a) in a vice using the tool (1b).

	Description	Code
1b	Support	1.860.470.001

Tighten the engine oil lubrication duct plugs.Place the camshafts in their housings.Place the camshaft gears in their housings and secure them without tightening the bolts.1. Fit the camshaft timing tools.

Check that the tools are correctly fitted in the housings in the camshafts.

	Description	Code
1	Templates	1.870.896.900

1. Tighten the camshaft gear fixing bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	-	-	30 + 40°

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

	Description	Code
1b	Fitting tool	1.870.896.800

Fit the intake side camshaft plug.Refit the exhaust side camshaft toothed pulley and secure by screwing in the bolt without tightening.1. Position the cam angle sensor (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	-	-	0.9

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

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	-	-	0.5 + 50°

1. Place the engine oil filler fitting (1a), complete with gasket (1b), back in its housing and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	-	-	-	-

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