199000425 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

Removing ( Refitting ) CYLINDER HEAD EXTENSION1. Position the camshaft housing (1a) in a vice using the tool (1b).
ToolDescriptionFunctionValidity
1860470000MountHead overhaul1.2 8v1.4 8v1.4 16v1.3 Multijet1.9 Multijet
1. Undo the bolts (1a) and remove the vacuum unit (1b).2. Remove the gasket.3. Undo the bolts (3a) and remove the pressure pump (3b) complete with O-ring.4. Remove the joint.
1. Undo the bolt (1a) and remove the cam angle sensor (1b).
- Temporarily remove the tool fitted previously on the exhaust side camshaft.
ToolDescriptionFunctionValidity
1870896900TemplatesEngine tuning1.3 Multijet
- Check that the camshaft endfloat is within the recommended values using a dial gauge.
MeasurementValueValidity
Camshaft end float (mm)0.15 ÷ 0.341.3 Multijet
- 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 tool (1b) on the intake side camshaft.
Fit the tool positioning it with the millings horizontal and checking that it is correctly inserted in the housing in the camshaft.
ToolDescriptionFunctionValidity
1870896900TemplatesEngine tuning1.3 Multijet
2. Undo the bolts fixing the camshaft gears.
1. Remove the camshaft timing tools for the cylinder head extension.
ToolDescriptionFunctionValidity
1870896900TemplatesEngine tuning1.3 Multijet
2. Release the camshafts (2a), as necessary and remove the camshaft gears (2b).- Completely remove the camshafts.
- Remove the support tool complete with camshaft housing from the vice and separate them. CYLINDER HEAD1. Undo the nuts (1a) and remove the intake manifold (1b).2. Remove the exhaust manifold gasket.3. Unscrew the glow plugs and remove.
1. Position the cylinder head (1a) in a vice using the tool (1b).
ToolDescriptionFunctionValidity
1860470000MountHead overhaul1.2 8v1.4 8v1.4 16v1.3 Multijet1.9 Multijet
2. Remove the valve rockers.3. Remove the hydraulic tappets.4. Remove the cylinder head extension locating bushes.
1. Loosen the collars and remove the coolant delivery sleeve from the thermostat to the coolant/exhaust gas heat exchanger for the EGR system.2. Undo the bolts (2a) and remove the thermostat (2b) complete with O-ring.3. Undo and remove the engine oil pressure warning light switch.
1. Loosen the collar securing the exhaust gas/coolant heat exchanger for the EGR system, air chamber side.2. Undo the bolts (2a) and remove the water/exhaust gas heat exchanger for the E.G.R. system (2b).
1. Release the engine oil vapour recirculation pipe for the retaining collars on the air capacity chamber.2. Unscrew bolts (2a) and remove the engine oil vapour separator (2b) complete with engine oil vapour recirculation pipe (2c).
1. Undo the bolts (1a) and remove the air chamber (1b) complete with pressure relief sensor.2. Remove the gasket.
1. Fit a wooden stand on the cylinder head plane to support the valves and secure it using bolts.
ToolDescriptionFunctionValidity
1860749000StandValve support1.2 8v1.4 8v1.3 Multijet
1. Fit the cotters (1a) using the tools (1b) and (1c).
ToolDescriptionFunctionValidity
1860644001LeverRemoving/ refitting valves1.2 8v1.4 8v1.3 Multijet
ToolDescriptionFunctionValidity
1870881000ChamberRemoving/ refitting valves1.3 Multijet
2. Remove the valve upper shim.3. Remove the valve spring.
- Carry out the same operations on the other valves.- Remove the wooden stand and keep the valves.
ToolDescriptionFunctionValidity
1860749000StandValve support1.2 8v1.4 8v1.3 Multijet
1. Remove the valve guide oil seals (1a) using the tool (1b).
ToolDescriptionFunctionValidity
1870894000CalliperRemoving valve guide oil seals1.3 Multijet
2. Fit the lower valve shims.
- Remove the cylinder head from the support tool.- 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.- Clean traces of the oil gasket off the mating surfaces between the cylinder head and the cylinder head extension.- Check that the planarity of the lower cylinder head plane corresponds to the recommended values.
MeasurementValueValidity
Cylinder head lower surface flatness (mm)0.11.3 Multijet1.9 Multijet
- 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.- The head may be levelled to 0.1 m if starting from a gasket with 0 notches and using a new gasket with 1 notch.- The head may be levelled to 0.2 m if starting from a gasket with 0 notches and using a new gasket with 2 notches.- The head may be levelled to 0.1 m if starting from a gasket with 1 notch and using a new gasket with 2 notches.
When within limit conditions (head gasket with 2 notches before levelling), the lower head surface cannot be levelled.
MeasurementValueValidity
Cylinder head nominal height (mm)105.5 +/- 0.051.3 Multijet
- 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.
MeasurementValueValidity
Exhaust/inlet valve stem diameter (mm)5.90 ÷ 5.941.3 Multijet
- Check that the length of the valve springs released is within the recommended values.
MeasurementValueValidity
Valve spring free length (mm)37.91.3 Multijet
- 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 16.2 - 18.0 daN (mm)31.01.3 Multijet
MeasurementValueValidity
Length of valve springs under a load of 36.1 - 39.5 daN (mm)23.51.3 Multijet
- Check that the diameter of the camshaft bearings corresponds to the recommended figures; if not, replace the worn camshaft.
MeasurementValueValidity
Camshaft bearing diameter - First bearing (mm)38.500 ÷ 38.5151.3 Multijet
MeasurementValueValidity
Camshaft bearing diameter - Second bearing (mm)38.000 ÷ 38.0151.3 Multijet
MeasurementValueValidity
Camshaft bearing diameter - Third bearing (mm)30.000 ÷ 30.0151.3 Multijet
- Check that the nominal camshaft cam lift corresponds to the recommended figures; if not, replace the worn camshaft.
MeasurementValueValidity
Nominal inlet cam lift (mm)6.41.3 Multijet
MeasurementValueValidity
Nominal exhaust cam lift (mm)7.51.3 Multijet
1. Check that the diameter of the camshaft supports corresponds to the recommended figures; if not, replace the cylinder head.
MeasurementValueValidity
Camshaft support diameter - First support38.545 ÷ 38.5701.3 Multijet
MeasurementValueValidity
Camshaft support diameter - Second support38.045 ÷ 38.0701.3 Multijet
MeasurementValueValidity
Camshaft support diameter - Third support30.045 ÷ 30.0701.3 Multijet
1. Grind the valve seats to the recommended size.
MeasurementValueValidity
Valve seat band angle in contact with valve45° +/- 20’1.3 Multijet1.9 Multijet
- Grind the valve seats using a suitable tool.CYLINDER HEAD- Position the cylinder head in the vice using the tool.
ToolDescriptionFunctionValidity
1860470000MountHead overhaul1.2 8v1.4 8v1.4 16v1.3 Multijet1.9 Multijet
- Fit the valves in the seats, then support them using the wooden stand and secure it using suitable bolts.
ToolDescriptionFunctionValidity
1860749000StandValve support1.2 8v1.4 8v1.3 Multijet
- Place the lower valve shims in their housings.1. Fit the valve guide oil seals (1a) in their seats using the tool (1b).
ToolDescriptionFunctionValidity
1870900800Installing toolValve guide oil seal fitting1.3 Multijet
1. Fit the valve spring in its seat.2. Refit the upper valve shim.3. Place the half-cones (3a) in their housings using the tools (3b) and (3c).
ToolDescriptionFunctionValidity
1860644001LeverRemoving/ refitting valves1.2 8v1.4 8v1.3 Multijet
ToolDescriptionFunctionValidity
1870881000ChamberRemoving/ refitting valves1.3 Multijet
- Carry out the same operations on the other valves.- Remove the wooden stand for supporting the valves from the cylinder head plane.
ToolDescriptionFunctionValidity
1860749000StandValve support1.2 8v1.4 8v1.3 Multijet
- Refit the air chamber complete with gasket and pressure relief sensor back in its housing and secure it tightening the bolts to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Intake manifoldBoltM82.3 ÷ 2.81.3 Multijet
- Replace the engine oil vapour separator wiht engine oil vapour recirculation pipe in its seat and secure with bolts.- Fasten the engine oil vapour recirculation pipe to the retaining collars on the air capacity chamber.- Place the exhaust gas/water heat exchanger for the E.G.R. system complete with gasket back in its housing and secure it by tightening the bolts to the specified torque.
ComponentFasteningdia  Value (daNm)Validity
Exhaust gas/water heat exchanger for E.G.R. systemBoltM82.3 ÷ 2.81.3 Multijet1.9 Multijet
- Replace the engine oil pressure warning light switch in its housing and tighten it to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Switch for engine oil pressure warning light-M142.9 ÷ 3.5
- Place the thermostat in its housing with the O-ring and secure it by tightening the bolts to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
ThermostatBoltM82.2 ÷ 2.71.3 Multijet1.9 Multijet
- Replace the coolant delivery sleeve from the thermostat to the coolant/exhaust gas heat exchanger for the EGR system and secure with the relevant collars.- Refit the camshaft housing locating bushes in their seats in the cylinder head.
Before fitting the locating bushes, check that the height is 13 mm.
- Place the hydraulic tappets in their housings.
Position the hydraulic tappets with the oil channel hole turned toward the outside of the cylinder head: this position brings the hole into communication with the oil duct on the lower cylinder head.
- Place the valve rockers in their housings.- Remove the cylinder head from the support tool.
ToolDescriptionFunctionValidity
1860470000MountHead overhaul1.2 8v1.4 8v1.4 16v1.3 Multijet1.9 Multijet
- Refit the glow plugs and tighten them to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Glow heater plug-M80.9 ÷ 1.11.3 Multijet
- Place the exhaust manifold gasket in its housing.- Place the air conditioning compressor mounting in its housing and secure it by tightening the nuts to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Exhaust manifoldNut (to be replaced)M81.4 ÷ 1.6 + 30° +/- 3°1.2 8v1.4 8v1.4 16v1.3 Multijet
CYLINDER HEAD EXTENSION- Position the cylinder head extension in the vice using the tool.
ToolDescriptionFunctionValidity
1860470000MountHead overhaul1.2 8v1.4 8v1.4 16v1.3 Multijet1.9 Multijet
- Place the camshafts in their housings.- Place the camshaft caps in their housings and secure them without tightening the bolts.1. Fit the camshaft timing tools.
Fit the tools and position with their millings horizontal. Ensure they fit into the seats on the camshafts.
ToolDescriptionFunctionValidity
1870896900TemplatesEngine tuning1.3 Multijet
2. Tighten the camshaft gear fixing bolts to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Camshaft gearsBoltM1213.5 ÷ 16.51.3 Multijet
- Place the cam angle sensor back in its housing and secure it tightening the bolt to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Cam angle sensorBoltM60.64 ÷ 0.961.3 Multijet1.9 Multijet
1. Position the pressure pump (1a), complete with coupling (1b) and a new o-ring, in its housing and secure it tightening the bolts (1c) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Pressure pumpBoltM71.4 ÷ 1.71.3 Multijet
2. Place the vacuum unit (2a), complete with gasket (2b), back in its housing and secure it tightening the bolts (2c) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Vacuum pumpBoltM81.8 ÷ 2.21.3 Multijet
Follow the order shown in the figure for each tightening sequence. The tightening to 2.0 daNm is performed in two stages: a pretightening to 0.5 daNm followed by an additional tightening of 1.8 -2.2 daNm.
- Remove the support tool complete with camshaft housing from the vice and separate them.