198002016 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

Removing ( Refitting ) CAMSHAFT HOUSING1. Position the camshaft housing (1a) in a vice using the tool (1b).
ToolDescriptionFunctionValidity
1860470000MountOverhaul cylinder head
1. Undo the bolts (1a) and removethe engine oil filler (1b).2. Remove the gasket.
1. Undo bolts (1a) and remove vacuum pump (1b).2. Remove the gasket.
1. Undo bolt (1a) and remove cam angle sensor (1b).
1. Remove plugs (1a) and fit camshaft timing tools (1b) on the cylinder head extension.
Check that the tools are correctly fitted in the housings in the camshafts.
ToolDescriptionFunctionValidity
1870896900TemplatesEngine tuning1.9 JTD 16v
1. Undo the bolts securing the camshaft gears.
1. Undo bolt (1a) and remove exhaust side camshaft toothed drive pulley (1b).
- Remove the camshaft timing tools from the cylinder head extension.
ToolDescriptionFunctionValidity
1870896900TemplatesEngine tuning1.9 JTD 16v
1. Withdraw camshafts (1a) as far as necessary and remove camshaft gears (1b).
1. Using a suitable drift, extract inlet side camshaft (1a) and plug (1b).2. Using a suitable drift, extract 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).
ToolDescriptionFunctionValidity
1860470000MountOverhaul cylinder head
1. Loosen the band (1a), unscrew the nut (1b) and the bolts (1c), then remove rigid fluid inlet pipe to water pump assembly (1d).- Remove the gasket.
1. Undo bolts (1a) and (1b) and remove water/exhaust gas heat exchanger for E.G.R. system assembly (1c).
1. Loosen the collar and disconnect the degassing pipe from the thermostat.1. Undo nuts (2a) and remove intake manifold assembly (2b).- Remove the gasket.
1. Remove the hydraulic tappets.2. Undo bolts (2a) and remove thermostat (2b).- Remove the gasket.
1. Undo bolts (1a) and remove 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.
ToolDescriptionFunctionValidity
1860804001StandRemoving/ refitting valves1.9 JTD 16v
1. Remove half-cones (1a) using tools (1b) and (1c).
ToolDescriptionFunctionValidity
1860644000LeverDismantling valves
ToolDescriptionFunctionValidity
1870890000ChamberDismantling valves1.4 16v1.9 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 built-in lower valve shim.- Carry out the same operations on the other valves.
- Remove the wooden stand and keep the valves.
ToolDescriptionFunctionValidity
1860804001StandRemoving/ refitting valves1.9 JTD 16v
Remove the lower cylinder head from the support tool.
ToolDescriptionFunctionValidity
1860470000MountOverhaul cylinder head
- Replace 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 lower plane corresponds to the recommended values.
MeasurementValueValidity
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 m if starting from a gasket with no references and using a new gasket with one reference.b - The head may be levelled to 0.2 m if starting from a gasket with no references and using a new gasket with two references.c - The head may be levelled to 0.1 m if starting from a gasket with one reference and using a new gasket with two references.
When within limit conditions (head gasket with 2 notches before levelling), the lower cylinder head surface cannot be levelled.
MeasurementValueValidity
Cylinder head nominal height (mm)107 +/- 0.051.9 JTD 16v
- Check that the valves do not show signs of grooves or meshing.- Check that the diameter of the valve stems corresponds to the recommended figures; if not, replace the worn valves.
MeasurementValueValidity
Inlet valve stem diameter (mm)4.982 ÷ 5.0001.9 JTD 16v
MeasurementValueValidity
Exhaust valve stem diameter (mm)4.972 ÷ 4.9901.9 JTD 16v
- Check that the length of the valve springs released is within the recommended values.
MeasurementValueValidity
Valve spring free length (mm)44.11.9 JTD 16v
- Using a torque wrench, check that the valve spring specifications correspond to the recommended figures; if not, replace the worn components.
MeasurementValueValidity
Length of valve springs under a load of 22.80 - 25.20 daN (mm)34.01.9 JTD 16v
MeasurementValueValidity
Length of valve springs under a load of 43.90 - 48.10 daN (mm)25.51.9 JTD 16v
- Check that the diameter of the camshaft journals corresponds to the recommended figures; if not, replace the worn camshaft.
MeasurementValueValidity
Camshaft journal first diameter (mm)43.600 ÷ 43.6151.9 JTD 16v
MeasurementValueValidity
Camshaft journal second diameter (mm)43.400 ÷ 43.4151.9 JTD 16v
MeasurementValueValidity
Camshaft journal third diameter (mm)43.200 ÷ 43.2151.9 JTD 16v
MeasurementValueValidity
Camshaft journal fourth diameter (mm)43.000 ÷ 43.0151.9 JTD 16v
MeasurementValueValidity
Camshaft journal fifth diameter (mm)30.000 ÷ 30.0151.9 JTD 16v
- Check that the nominal camshaft cam lift corresponds to the recommended figures; if not, replace the worn camshaft.
MeasurementValueValidity
Nominal inlet/exhaust cam lift (mm)8.01.9 JTD 16v
1. Check that the diameter of the camshaft supports corresponds to the recommended figures; if not, replace the cylinder head.
MeasurementValueValidity
Camshaft journal first diameter (mm)43.646 ÷ 43.6711.9 JTD 16v
MeasurementValueValidity
Camshaft journal second diameter (mm)43.446 ÷ 43.4711.9 JTD 16v
MeasurementValueValidity
Camshaft journal third diameter (mm)43.246 ÷ 43.2711.9 JTD 16v
MeasurementValueValidity
Camshaft journal fourth diameter (mm)43.046 ÷ 43.0711.9 JTD 16v
MeasurementValueValidity
Camshaft journal fifth diameter (mm)30.045 ÷ 30.0701.9 JTD 16v
- The outer diameter of the valve housings is as follows.
MeasurementValueValidity
Inlet valve seat outer diameter (mm)29.600 ÷ 29.6111.9 JTD 16v
MeasurementValueValidity
Exhaust valve seat outer diameter (mm)27.600 ÷ 27.6111.9 JTD 16v
MeasurementValueValidity
Valve seat band angle in contact with valve45° 30’ +/- 1°1.9 JTD 16v
1. Grind the valve seats to the recommended size.
- Grind the valve seats using a suitable tool.LOWER CYLINDER HEAD- Position the lower cylinder head in the vice using the tool.
ToolDescriptionFunctionValidity
1860470000MountOverhaul cylinder head
Fit the valves in the seats, then support them using the wooden stand and secure with suitable bolts.
ToolDescriptionFunctionValidity
1860804001StandRemoving/ refitting valves1.9 JTD 16v
1. Place valve guide oil seal (1a) in position using tool (1b).
ToolDescriptionFunctionValidity
1870897100Extractor/ Fitting toolExtracting/fitting valve guides Valve guide oil seal fitting1.9 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 half-cones (4a) in their housings using tools (4b) and (4c).
ToolDescriptionFunctionValidity
1860644000LeverDismantling valves
ToolDescriptionFunctionValidity
1870890000ChamberDismantling valves1.4 16v1.9 JTD 16v
- Carry out the same operations on the other valves.
- Remove the wooden stand for supporting the valves from the cylinder head plane.
ToolDescriptionFunctionValidity
1860804001StandRemoving/ refitting valves1.9 JTD 16v
1. Position water pump (1a), complete with gasket (1b), in its housing and secure it by tightening bolts (1c) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Water pumpBoltM82.3 ÷ 2.81.9 JTD
1. Place thermostat (1a) complete with gasket back in its housing and secure it by tightening bolts (1b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
ThermostatBoltM82.3 ÷ 2.81.9 JTD
2. Place the hydraulic tappets in their housings.
- Place the intake manifold gasket in its housing.- Replace the intake manifold in its housing and secure it by tightening the nuts to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Intake manifoldNutM82.3 ÷ 2.81.9 JTD 16v
- Connect the degassing pipe to the thermostat and secure with the band.- 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.
ComponentFasteningdia  Value (daNm)Validity
E.G.R. exhaust gas heat exchangerBoltM82.3 ÷ 2.81.9 JTD
- 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.CAMSHAFT HOUSING1. Position the camshaft housing (1a) in a vice using the tool (1b).
ToolDescriptionFunctionValidity
1860470000MountOverhaul cylinder head
- Tighten the engine oil lubrication duct plugs.- Place the camshafts in their housings.- Refit 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.
ToolDescriptionFunctionValidity
1870896900TemplatesEngine tuning1.9 JTD 16v
1. Tighten the camshaft gear bolts to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Camshaft gearsBoltM122.9 ÷ 3.2 + 40°1.9 JTD 16v
1. Fit exhaust side camshaft front oil seal (1a) using tool (1b).
ToolDescriptionFunctionValidity
1870896800Fitting toolFitting camshaft front oil seal, exhaust side1.9 JTD 16v
- Fit the inlet side camshaft plug.- Place the exhaust side camshaft toothed drive pulley in its housing and secure it without tightening the bolt.1. Position cam angle sensor (1a) in its housing and secure it by tightening bolt (1b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Cam angle sensorBoltM60.8 ÷ 1.01.9 JTD
1. Fit vacuum pump (1a), complete with gasket (1b), back in its housing and secure it by tightening bolts (1c) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Vacuum pumpBoltM60.4 ÷ 0.6 + 50°1.9 JTD 16v
1. Place engine oil filler (1a), complete with gasket (1b), back in its housing and secure it by tightening bolts (1c) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Engine oil fillerBolt M60.8 ÷ 1.01.9 JTD 16v
- Remove the support tool complete with cylinder head extension from the vice and separate them.