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

194002127 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

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

Tool	Description	Function	Validity
1860470001	Support	Overhaul cylinder head	1.82.21.9 JTD 8V1.9 JTD 16V

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).

1. Remove the plugs (1a) and fit camshaft timing tools (1b) on the camshaft housing.

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

Tool	Description	Function	Validity
1870896900	Template	Engine tuning	1.9 JTD 16V

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.

Tool	Description	Function	Validity
1870896900	Template	Engine tuning	1.9 JTD 16V

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).

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

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

Tool	Description	Function	Validity
1860470001	Support	Overhaul cylinder head	1.82.21.9 JTD 8V1.9 JTD 16V

1. Loosen collar (1a), unscrew nut (1b) and bolts (1c), then remove the rigid fluid inlet pipe to the water pump assembly (1d).- Remove the gasket.

1. Undo the bolts (1a) and (1b) and remove the water/exhaust gas heat exchanger for the E.G.R. system assembly (1c).

1. Loosen the collar and disconnect the degasing pipe from the thermostat.1. Undo the nuts (2a) and remove the intake manifold assembly (2b).- Remove the gasket.

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

Tool	Description	Function	Validity
1860804001	Stand	Removing/refitting valves	1.81.9 JTD 16V

1. Fit the cotters (1a) using the tools (1b) and (1c).

Tool	Description	Function	Validity
1860644001	Lever	Removing/refitting valves	1.81.9 JTD 16V

Tool	Description	Function	Validity
1870890000	Chamber	Removing/refitting valves	1.9 JTD 16V

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.

Tool	Description	Function	Validity
1860804001	Stand	Removing/refitting valves	1.81.9 JTD 16V

Remove the lower cylinder head from the support tool.

Tool	Description	Function	Validity
1860470001	Support	Overhaul cylinder head	1.82.21.9 JTD 8V1.9 JTD 16V

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		Validity
Cylinder head lower surface flatness (mm)	0.1 ± 0.05		1.9 JTD 16V

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		Validity
Minimum permitted cylinder head height (mm)	107.00 ± 0.05		1.9 JTD 16V

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	Validity
Inlet valve stem diameter (mm)	5.982 ÷ 6.000	1.9 JTD 16V

Measurement	Value	Validity
Exhaust valve stem diameter (mm)	5.972 ÷ 5.990	1.9 JTD 16V

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

Measurement	Value	Validity
Valve spring free length (mm)	43.1	1.9 JTD 16V

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

Measurement	Value	Validity
Length of valve springs under a load of 20.47 - 21.84 daN (mm)	34.0	1.9 JTD 16V

Measurement	Value	Validity
Length of valve springs under a load of 44.81 - 47.59 daN (mm)	24.5	1.9 JTD 16V

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

Measurement	Value	Validity
Camshaft first support diameter (mm)	43.600 ÷ 43.615	1.9 JTD 16V

Measurement	Value	Validity
Camshaft second support diameter (mm)	43.400 ÷ 43.415	1.9 JTD 16V

Measurement	Value	Validity
Camshaft third support diameter (mm)	43.200 ÷ 43.215	1.9 JTD 16V

Measurement	Value	Validity
Camshaft fourth support diameter (mm)	43.000 ÷ 43.015	1.9 JTD 16V

Measurement	Value	Validity
Camshaft fifth support diameter (mm)	30.000 ÷ 30.015	1.9 JTD 16V

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

Measurement	Value	Validity
Nominal inlet/exhaust cam lift (mm)	8.0	1.9 JTD 16V

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

Measurement	Value		Validity
Camshaft first support diameter (mm)	43.646 ÷ 43.671		1.9 JTD 16V

Measurement	Value		Validity
Camshaft second support diameter (mm)	43.446 ÷ 43.471		1.9 JTD 16V

Measurement	Value		Validity
Camshaft third support diameter (mm)	43.246 ÷ 43.271		1.9 JTD 16V

Measurement	Value		Validity
Camshaft fourth support diameter (mm)	43.046 ÷ 43.071		1.9 JTD 16V

Measurement	Value		Validity
Camshaft fifth support diameter (mm)	30.045 ÷ 30.070		1.9 JTD 16V

The outer diameter of the valve seats is as follows.

Measurement	Value	Validity
Inlet valve seat outer diameter (mm)	29.600 ÷ 29.611	1.9 JTD 16V

Measurement	Value	Validity
Exhaust valve seat outer diameter (mm)	27.600 ÷ 27.611	1.9 JTD 16V

1. Grind the valve seats to the recommended size.

Measurement	Value	Validity
Valve seat band angle in contact with valve	45° 30’ +/- 1°	1.9 JTD 16V

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

Tool	Description	Function	Validity
1860470001	Support	Overhaul cylinder head	1.82.21.9 JTD 8V1.9 JTD 16V

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

Tool	Description	Function	Validity
1860804001	Stand	Removing/refitting valves	1.81.9 JTD 16V

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

Tool	Description	Function	Validity
1870897100	Extractor/Fitting tool	Extracting/fitting valve guidesValve guide oil seal fitting	1.9 JTD 16V

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).

Tool	Description	Function	Validity
1860644001	Lever	Removing/refitting valves	1.81.9 JTD 16V

Tool	Description	Function	Validity
1870890000	Chamber	Removing/refitting valves	1.9 JTD 16V

Carry out the same operations on the other valves.

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

Tool	Description	Function	Validity
1860804001	Stand	Removing/refitting valves	1.81.9 JTD 16V

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

Component	Fastening	dia	Value (daNm)	Validity
Water pump	Bolt	M8	(cylinder head side) 2.3 - 2.8	1.9 JTD 8v1.9 JTD 16v

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

Component	Fastening	dia	Value (daNm)	Validity
Thermostat	Bolt	M8	(cylinder head side) 2.5	1.9 JTD 16v2.4 JTD 20v

2. Place the hydraulic tappets in their housings.

- Place the intake manifold gasket in its housing.- Replace the air conditioning compressor mounting in its housing and secure it by tightening the nuts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Intake manifold	Nut	M8	(cylinder head side) 2.3 - 2.8	1.9 JTD 16v

- Connect the degasing pipe to the thermostat and secure with the collar.- Place the exhaust gas/water heat exchanger for the E.G.R. system back in its housing and secure it by tightening the bolts to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Exhaust gas/water heat exchanger for E.G.R. system	Bolt	M8	(cylinder head side) 2.3 - 2.8	1.9 JTD 16v1.9 JTD 8v2.4 JTD 20v

Component	Fastening	dia	Value (daNm)	Validity
Exhaust gas/water heat exchanger for E.G.R. system	Bolt	M8	(EGR solenoid side) 2.3 - 2.8	1.9 JTD 16v1.9 JTD 8v2.4 JTD 20v

- Replace the water pump rigid inlet pipe, complete with gasket, in position and secure it using the bolts, the nut and the collar. Remove the lower cylinder head from the support tool.

Tool	Description	Function	Validity
1860470001	Support	Overhaul cylinder head	1.82.21.9 JTD 8V1.9 JTD 16V

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

Tool	Description	Function	Validity
1860470001	Support	Overhaul cylinder head	1.82.21.9 JTD 8V1.9 JTD 16V

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.

Tool	Description	Function	Validity
1870896900	Template	Engine tuning	1.9 JTD 16V

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

Component	Fastening	dia	Value (daNm)	Validity
Camshaft gears	Bolt	M12	(camshaft side) 2.9 - 3.2 + 40°	1.9 JTD 16v

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

Tool	Description	Function	Validity
1870896800	Fitting tool	Fitting exhaust camshaft oil seal	1.9 JTD 16V

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.

Component	Fastening	dia	Value (daNm)	Validity
Cam angle sensor	Bolt (pretreated to be replaced for 1.9 JTD 8v)	M6	(cylinder head extension side) 0.8 - 1.0	1.9 JTD 8V1.9 JTD 16v2.4 JTD 20v

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.

Component	Fastening	dia	Value (daNm)	Validity
Vacuum unit	Bolt (pretreated to be replaced)	M6	(cylinder head extension side) 0.5 + 50°	1.9 JTD 16v2.4 JTD 20v

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.

Component	Fastening	dia	Value (daNm)	Validity
Engine oil filler	Bolt	M6	(cylinder head extension side) 0.8 - 1.0	1.9 JTD 16v2.4 JTD 20v

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