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

3363555 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

) 1. Undo the bolt (1a) and remove the guide pipe complete with engine oil dipstick (1b).2. Undo the nuts (2a) and remove the exhaust manifold (2b).

1. Undo the bolts (1a) and the nut (1b) and remove the water pump rigid inlet pipe (1c) complete with gasket (1d).2. Remove the exhaust manifold gasket.

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

	Description	Code
1b	Support	1.860.470.000

1. Disconnect the electrical connection from the engine coolant temperature sensor.

	Description	Connector
1	Engine temperature sending unit	K36

1. Disconnect the electrical connection for the throttle position sensor.

	Description	Connector
1	Integrated throttle casing actuator	N75

2. Disconnect the electrical connection from the idle actuator.

	Description	Connector
2	Integrated throttle casing actuator	N75

3. Disconnect the electrical connection from the air flow meter.

	Description	Connector
3	Air flow meter	K41

1. Disconnect the electrical connection from the fuel vapour recovery solenoid valve.

	Description	Connector
1	Fuel vapour recovery solenoid valve	L10

2. Disconnect the electrical connections from the injectors.

	Description	Connector
2	Injector	N70

3. Disconnect the electrical connection from the phase transformer solenoid.

	Description	Connector
3	Variable valve timing actuator	N76

1. Disconnect the electrical connection for the timing sensor.

	Description	Connector
1	Timing sensor	K47

1. Remove the electrical wiring after having released it from the fastenings.

Disconnect the heating coolant outlet pipe for the throttle casing from the thermostat.1. Undo the nuts (1a), then remove the intake manifold (1b) complete with modular intake manifold (1c), throttle casing (1d) and fuel manifold pipe (1e).Remove the intake manifold gasket.

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

1. Undo the bolt (1a) for the exhaust side timing driven pulley using the tools (1b) and (1c) for counter-torque.

	Description	Code
1b	Support for counter-torque	1.860.831.000

	Description	Code
1c	Counter-torque	1.860.848.000

2. Remove the exhaust side timing driven pulley.3. Undo the inlet side timing driven pulley bolts (3a) using the tool (3b) for counter-torque.

	Description	Code
3b	Counter-torque	1.860.856.000

4. Remove the inlet side timing driven pulley.5. Undo the bolts (5a) and remove the side timing belt guards (5b).

1. Undo the bolt (1a) and remove the cam angle sensor (1b).2. Undo the bolts (2a) and remove the water pump (2b) complete with O-ring (2c).

Check that the camshaft endfloat corresponds to the recommended values using a dial gauge on a magnetic base.

	Measurement		Value
-	End float (mm)		0.10 - 0.23

If the endfloat for the camshafts does not correspond to the recommended values, replace the worn components when reassembling the cylinder head.

1. Undo the bolts (1a) and remove the camshaft caps (1b).2. Remove the inlet side camshaft front supper upper half-bearing.3. Remove the camshafts.4. Remove the camshaft front oil seals.5. Remove the inlet side camshaft front support lower half-bearing.6. Remove the hydraulic tappets.

1. Remove the cotters (1a) using the tools (1b), (1c), (1d), (1e) and (1f).

	Description	Code
1b	Valve retaining base	1.860.786.000

	Description	Code
1c	Extension	1.860.787.000

	Description	Code
1d	Lever hook	1.860.788.000

	Description	Code
1e	Chamber	1.860.840.000

	Description	Code
1f	Lever	1.860.790.000

2. Remove the valve upper shim.3. Remove the valve springsRemove the tools used for dismantling the valves.4. Remove the valve.Carry out the same operations for removing the remaining valves.

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

	Description	Code
1b	Extractor	1.860.989.000

2. Remove the lower valve shim.

1. Remove the valve guides (1a) using the tool (1b).

	Description	Code
1b	Drift	1.860.395.000

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

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

After the cylinder head has been refaced, check that the volume of the combustion chamber (with the valves and spark plugs fitted temporarily) is within the recommended values.

	Measurement		Value
-	Combustion chamber volume (cc)		38.5 - 39.5

If the volume of the combustion chamber does not correspond to the recommended values, remove material from inside the combustion chamber at the points shown by the arrows.

Decarbonize the valves and check that there are no signs of grooves on the stem.Check that the diameter of the valve stems corresponds to the recommended figures; if not, replace the worn valves.

	Measurement		Value
-	Stem diameter (mm)		6.975 - 6.990

	Measurement		Value
-	Stem diameter (mm)		6.960 - 6.975

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

	Measurement		Value
-	Outer diameter (mm)		32.959 - 32.975

Check that the diameter of the hydraulic tappet housings corresponds to the recommended figures; if not, replace the cylinder head.

	Measurement		Value
-	Hydraulic tappet housing diameter (mm)		33.000 - 33.025

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

	Measurement		Value
-	Inner spring length (mm)		29.5
	Test load (daN)	9.61 - 10.6

	Measurement		Value
-	Inner spring length (mm)		20.0
	Test load (daN)	20.11 - 22.07

	Measurement		Value
-	Outer spring length (mm)		34.0
	Test load (daN)	27.07 - 29.43

	Measurement		Value
-	Outer spring length (mm)		24.5
	Test load (daN)	48.46 - 52.38

Check that the surfaces of the camshaft bearings and cams do not show signs of wear, grooves or seizing; if this is not the case, replace the camshafts.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 inlet shaft cam lift (mm)		9.0

	Measurement		Value
-	Nominal cam height (mm)		8.5

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 SUPPORTS	M7	Cylinder head side 1.3 - 1.6

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

	Measurement		Value
2	Camshaft support diameter (mm)		26.045 - 26.070

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

	Measurement		Value
-	Outer diameter (mm)		13.010 ÷ 13.030
	Oversize (mm)	0.20

1. Fit the valve guides (1a) using the tool (1b).

	Description	Code
1b	Fitting tool	1.860.812.000

Before fitting the new valve guides, heat the cylinder head in the oven to a temperature of 80 - 100 °C.

In the case of slight distortions due to fitting, ream the inner diameter of the valve guides to the recommended value.

	Measurement		Value
-	Inner diameter (reaming) (mm)		7.022 - 7.040

Grind the valve seats each time the valves or the valve guides are replaced.

1. Grind the valve seat with the cutter at 44° 30''.Reduce the valve seat from above with the grinder at 20° and from below with the grinder at 75° until the correct valve contact band width is obtained.

	Measurement		Value
-	Width of band in contact with valve (mm)		~ 2

Check the valve seating; if it is not centered, make the appropriate reductions as described previously.1. Temporarily fit the valves and the spark plugs and carry out the valve compression leakage test using tools (1a) and (1b).

	Description	Code
1a	Lever	1.860.490.000

	Description	Code
1b	Test equipment	1.895.868.000

Place the lower valve shims in their housings.1. Fit the valve guide oil seal (1a) using the tools (1b) and (1c).

	Description	Code
1b	Drift	1.860.813.000

	Description	Code
1c	Fitting tool	1.860.454.000

1. Fit the valve (1a) and support it using the tools (1b) and (1c).

	Description	Code
1b	Valve retaining base	1.860.786.000

	Description	Code
1c	Extension	1.860.787.000

2. Place the valve springs in their housings.3. Refit the upper valve shim.4. Place the cotters (4a) in their housings using the tools (4b), (4c) and (4d).

	Description	Code
4b	Lever hook	1.860.788.000

	Description	Code
4c	Chamber	1.860.840.000

	Description	Code
4d	Lever	1.860.790.000

Carry out the same operations for refitting the remaining valves.Remove the tools used for refitting the valves.

Place the inlet side camshaft front support lower half-bearing in its housing.Place the camshafts in their housings.Place the inlet side camshaft front support upper half-bearing in its housing.1. - Place the camshaft caps (1a) in their housings and secure them tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CAMSHAFT SUPPORTS	M7	Cylinder head side 1.3 - 1.6

2. Position the water pump (2a) , complete with O-ring (2b), in its housing and secure it tightening the bolts (2c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2c	Bolt	COOLANT PUMP	M8	(Cylinder head side) 2.1 - 2.6

Fit the cam angle sensor in place and secure it using the bolts1. Fit the exhaust side camshaft front oil seal (1a) using the tool (1b).

	Description	Code
1b	Fitting tool	1.860.824.000

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

	Description	Code
1b	Fitting tool	1.860.844.000

Place the timing belt side guards in their housings and secure them using the bolts.1. Place the inlet side timing driven pulley in its housing.2. Tighten the bolts (2a) for the inlet side toothed timing driven pulley using tool (2b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	TIMING DRIVEN PULLIES	M6	(Inlet camshaft side) 0.8 - 1.0

	Description	Code
2b	Counter-torque	1.860.856.000

3. Place the exhaust side timing driven pulley in its housing.4. Tighten the bolt (4a) for the exhaust side toothed timing driven pulley using the tools (4b) and (4c) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
4a	Bolt	TIMING DRIVEN PULLIES	M12	(Exhaust camshaft side) 10.2 -12.6

	Description	Code
4b	Support for counter-torque	1.860.831.000

	Description	Code
4c	Counter-torque	1.860.848.000

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

	Fastening	Component	Ø	Value(daNm)
-	Bolt	THERMOSTAT	M8	(Cylinder head side) 2.1 -2.6

Place the intake manifold gasket in its housing.Place the intake manifold complete with modular intake manifold, throttle casing and fuel manifold pipe back in its housing, then secure it tightening the nuts and bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	INLET MANIFOLD	M8	(Cylinder head side) 2.1 -2.6

Connect the heating coolant outlet pipe for the throttle casing to the thermostat.Place the electrical wiring in position and fasten it to the bands.Connect the electrical connection for the timing sensor.Connect the electrical connection to the phase transformer solenoid.Connect the electrical connections to the injectors.Connect the electrical connection to the fuel vapour recovery solenoid valve.Connect the electrical connection to the air flow meter.Connect the electrical connection to the idle actuator.Connect the electrical connection to the throttle position sensor.Connect the electrical connection to the engine coolant temperature sensor.Remove the cylinder head from the vice and place it in the housing on the support tool.

	Description	Code
-	Support	1.860.470.000

Place the exhaust manifold gasket in its housing.Place the water pump rigid inlet pipe, complete with gasket, in position and secure it using the nut and the bolts.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	COOLANT PUMP RIGID INLET PIPE	M6	Cylinder head side 0.8 - 1.0

	Fastening	Component	Ø	Value(daNm)
-	Nut	COOLANT PUMP RIGID INLET PIPE	M8	Cylinder head side 2.1 -2.6

Place the air conditioning compressor mounting in its housing and secure it by tightening the nuts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	EXHAUST MANIFOLD/S	M8	(Cylinder head side) 2.5

Place the guide pipe complete with engine oil dipstick in position and fasten it using the bolt.