1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL - Fiat - NUOVA BRAVO - eLearn

198002016 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

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

Tool	Description	Function	Validity
1860470000	Mount	Overhaul cylinder head

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

1. Unscrew the connectors (1a) and (1b) and remove the pipes from the fuel manifold to the injectors (1c).

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

2. Undo the nuts (2a) and remove the fuel distribution manifold (3b) complete with fuel pressure sensor and pipes (2c).3. Manually push the clips (3a) and disconnect the pipe from the injectors to the fuel recovery manifold (3b), injector side, and remove it.- Undo the nuts and disconnect the supply wiring from the heater plugs.- Disconnect the coolant return pipe to the expansion tank and de-aeration system from the thermostat.4. Undo the nuts (4a) and remove the air chamber (4b) complete with E.G.R. electrical valve (4c) and throttle body (4d).

1. Undo the bolts (1a) and remove the vacuum unit (1b) complete with O-ring.2. Loosen the retaining band (2a) and disconnect the pipe (2b) from the thermostat to the oil heat exchanger, heat exchanger side.3. Undo the bolts (3a) and remove the thermostat (3b) complete with pipe and sensor.4. Remove the gasket.5. Undo the bolt (5a) and the nut (5b) and remove the water/exhaust gas heat exchanger for the E.G.R. system (5c).

1. Undo the driven toothed pulley bolt.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. Undo the nuts (1a) and remove the brackets (1b) for the injectors.2. Remove the injectors (2a) complete with gasket (2b).3. Remove the injector bracket support pads.4. Remove the heater plugs.

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

Measurement	Value	Validity
Camshaft end float (mm)	0.100 ÷ 0.230	1.9 JTD

- 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.- Position a suitable wooden stand on the cylinder head plane to support the valves and secure it using bolts.- Refit the cylinder head in the vice.1. Remove the cotters (1a) using the tools (1b), (1c) and (1d).

Tool	Description	Function	Validity
1820257000	Mount	Valve mount	1.9 JTD 8v

Tool	Description	Function	Validity
1821058000	Lever	Removing/ refitting valves	1.9 JTD 8v

Tool	Description	Function	Validity
1821205000	Chamber	Removing/ refitting valves	1.9 JTD 8v

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

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

Tool	Description	Function	Validity
1870894000	Extractor	Valve guide oil seal extraction

2. Remove the lower shim.- Carry out the same operations on the other valves.- Remove the cylinder head from the vice.- Remove the wooden stand and keep the valves.- Remove the cylinder head from the support tools.

- 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 planarity of the lower cylinder head plane corresponds to the recommended values.

Measurement	Value	Validity
Engine cylinder head lower surface flatness (mm)	< 0.1

1. If the lower surface flatness of the lower cylinder head is not within specified values, grind from the nominal head height and then fit a new gasket with the number of notches determined as described below.a - The head may be levelled to 0.1 mm if starting with a gasket with no references and using a new gasket with one reference.b - The head may be levelled to 0.2 mm if starting with a gasket with no references and using a new gasket with two references.c - The head may be levelled to 0.1 mm if starting with a gasket with one reference and using a new gasket with two references.

When within limit conditions (head gasket with 2 references before levelling), the lower head surface cannot be levelled.

Measurement	Value	Validity
Cylinder head nominal height (mm)	140.85 ÷ 141.15	1.9 JTD 8v

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

Measurement	Value	Validity
Exhaust/inlet valve stem diameter (mm)	7.974 ÷ 7.992	1.9 JTD 8v

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

Measurement	Value	Validity
Tappet sleeve outer diameter (mm)	36.975 ÷ 36.991	1.9 JTD 8v

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

Measurement	Value	Validity
Tappet sleeve seat diameter (mm)	37.010 ÷ 37.030	1.9 JTD 8v

- Check that the length of the valve springs released corresponds to the recommended figures; if not, replace the weakened components.

Measurement	Value	Validity
Valve spring free length (mm)	53.9	1.9 JTD 8v

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

Measurement	Value	Validity
Length of valve springs under a load of 21.5 - 24.5 daN (mm)	43.12	1.9 JTD 8v

Measurement	Value	Validity
Length of valve springs under a load of 43.6 - 48.6 daN (mm)	32.34	1.9 JTD 8v

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

Measurement	Value	Validity
Camshaft journal diameter (mm)	26.000 ÷ 26.015	1.9 JTD 8v

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

Measurement	Value	Validity
Nominal inlet cam lift (mm)	8.5	1.9 JTD 8v

Measurement	Value	Validity
Nominal exhaust cam lift (mm)	9.0	1.9 JTD 8v

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

Component	Fastening	dia	Value (daNm)	Validity
Camshaft caps	Bolt	M7	1.3 ÷ 1.6	1.9 JTD

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

Measurement	Value	Validity
Camshaft support diameter (mm)	26.045 ÷ 26.070	1.9 JTD 8v

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

Measurement	Value	Validity
Inlet valve seat outer diameter (mm)	36.039 ÷ 36.064	1.9 JTD 8v

Measurement	Value	Validity
Exhaust valve seat outer diameter (mm)	35.039 ÷ 35.064	1.9 JTD 8v

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

1. Grind the valve seats to the recommended size.

Measurement	Value	Validity
Valve seat band angle in contact with valve	45° +/- 20’	1.9 JTD 8v

- 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 (1a) corresponds to the recommended figures using the tool (1b) fitted with a dial gauge.

Measurement	Value	Validity
Cylinder head plane valve inset (mm)	0.1 ÷ 0.5	1.9 JTD 8v

Tool	Description	Function	Validity
1820253000	Dial gauge mount	Measure the piston protrusion/valve recess in relation to the cylinder head plane	1.9 JTD 8v

- 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).

Tool	Description	Function	Validity
1860814001	Installing tool	Valve guide oil seal fitting	1.9 JTD 8v

Tool	Description	Function	Validity
1821178000	Fitting tool	Valve guide oil seal fitting	1.9 JTD 8v

- Fit the valve spring.- Fit the valve upper shim.1. Fit the cotters (1a) using the tools (1b), (1c) and (1d).

Tool	Description	Function	Validity
1820257000	Mount	Valve mount	1.9 JTD 8v

Tool	Description	Function	Validity
1821058000	Lever	Removing/ refitting valves	1.9 JTD 8v

Tool	Description	Function	Validity
1821205000	Chamber	Removing/ refitting valves	1.9 JTD 8v

- Carry out the same operations on the other valves.

- Remove the cylinder head from the vice.- Remove the wooden stand supporting the valves.- Refit the cylinder head in the vice.- Fit the cups complete with valve clearance adjustment pads.- Fit the camshaft.1. Fit the camshaft caps.

Apply LOCTITE to the contact surfaces with the head for the 1st and 5th camshaft caps.

- Fit the camshaft bearing lubrication pipe.2. Tighten the camshaft cap bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Camshaft caps	Bolt	M7	1.3 ÷ 1.6	1.9 JTD

1. Fit the camshaft front oil seal (1a) using the tool (1b).2. Fit the spark plugs and tighten them to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Glow heater plug	-	M12	1.3 ÷ 1.7	1.9 JTD 8v

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.

Component	Fastening	dia	Value (daNm)	Validity
Injector brackets	Nut	M8	2.7 ÷ 3.3	1.9 JTD 8v

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.

- Fit the water pump, complete with a new O-Ring and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Water pump	Bolt	M8	2.3 ÷ 2.8	1.9 JTD

- Fit the cam angle sensor and tighten the bolts.- Fit the driven toothed pulley and tighten the bolt to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Driven timing toothed pulley	Bolt	M12	2.8 ÷ 3.1 + 40°	1.9 JTD

- 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	Validity
Inlet valve clearance in closed position (mm)	0.30	1.9 JTD 8v

Measurement	Value	Validity
Exhaust valve clearance in closed position (mm)	0.35	1.9 JTD 8v

1. Lower the tappet in question using the tool.

Tool	Description	Function	Validity
1820262000	Lever	Lower tappets	1.9 JTD 8v

2. Fit the tool.

Tool	Description	Function	Validity
1860724001	Lever	Lower tappets

- Remove the tool.

Tool	Description	Function	Validity
1820262000	Lever	Lower tappets	1.9 JTD 8v

- Extract the valve clearanance adjustment plate and replace it with a one of a suitable thickness.- Remove the tool.

Tool	Description	Function	Validity
1860724001	Lever	Lower tappets

- Refit the water/exhaust gas heat exchanger for the E.G.R. system and secure it using the bolt and the nut.- Fit the thermostat complete with gasket, pipes and sensor then tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Thermostat	Bolt	M8	2.3 ÷ 2.8	1.9 JTD

- Connect the pipe from the thermostat to the heat exchanger and tighten the band.- Place the vacuum unit in its housing with the O-ring and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Vacuum pump	Bolt	M8	2.7 ÷ 3.3	1.9 JTD 8v

- Fit the air chamber assembly and tighten the nuts.- 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.- Place the pipe from the injectors to the fuel recovery manifold back in its housing and connect it to the injectors and push home until the clips click into place.- Fit the fuel distribution manifold complete with fuel pressure sensor and tighten the nuts.- Place the new pipes from the fuel manifold ot the injectors in their housings.- Tighten the connectors for the pipes from the fuel manifold to the injector side injectors to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Pipes from fuel manifold to injectors - injectors side	Connector	M12	2.2 ÷ 2.4	1.9 JTD

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

Component	Fastening	dia	Value (daNm)	Validity
Pipes from fuel manifold to injectors - fuel manifold side	Connector	M14	1.8 ÷ 2.0	1.9 JTD

- Fit the water pump rigid inlet pipe complete with gasket and tighten the bolts .- Remove the support tool.