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

2585285 - 1016E10 single cylinder head, removed - overhaul

Fit the valve springs, the upper valve plates and the half-cones using the same tool as for the removal.

	Description	Code
-	Tool	1.860.644.000

Remove the flywheel lock fitted previously.

	Description	Code
-	Stand	1.860.749.000

Remove the camshaft tappet sleeves with shims. Op. 1036B14 CAMSHAFT IN CYLINDER HEAD - R.R. WITH HEAD REMOVED.

Removing ( Refitting

) 1. Position the cylinder head in the vice supporting it using a suitable tool.

	Description	Code
1	Support	1.860.470.000

2. Remove the spark plugs using the tool.

	Description	Code
2	Spanner	1.850.184.000

1. With the tools (1a), (1b), (1c), (1d) and (1e) assembled as illustrated in the diagram, compress the valve springs.2. Release the cotters (2a), caps (2b) and springs (2c), then, removing the tool, release the inlet and exhaust valves (2d) from the cylinder head.

	Description	Code
1a	Lever	1.860.790.000

	Description	Code
1b	Lever hook	1.860.788.000

	Description	Code
1c	Extension	1.860.787.000

	Description	Code
1d	Valve retaining base	1.860.786.000

	Description	Code
1e	Chamber	1.860.789.000

1. User pliers (1a) to remove oils seals (1b) from the valve guides.

Refitting ( Removing

) De-carbonize and clean the valve seats and ducts.Clean any residues of the gasket from the lower cylinder head plane.Check that the cylinder head plane flatness is within the recommended values.

	Measurement		Value
-	Lower plane planarity (mm)		0.1

If the planarity of the cylinder head plane is not within the recommended values, regrind the head plane.1. When the cylinder head has been reground, check that the minimum height between the reference plane inside the combustion chamber and the cylinder head plane is within the recommended values using a dial gauge (1a) and tool (1b).

	Measurement		Value
-	Minimum height between combustion chamber/cylinder head plane (mm)		12.5 ÷ 13.0

The minimum permitted height after refacing is 12.5 mm

	Description	Code
1b	Dial gauge support	1.870.404.000

Depending on the planarity value measured, the cylinder head can be refaced until it reaches the minimum permitted valueIf the value measured is within the tolerance, but close to the minimum permitted figure, refacing the cylinder head may alter the specifications of the actual cylinder head because it could produce too great an increase in the compression ratio resulting in engine knock.Also check the volume of all the combustion chambers by carrying out the following procedure.1. Fit the valves and spark plugs provisionally and use a graduated test tube containing a known amount of engine oil.2. Rest a glass plate on the cylinder head with holes corresponding to the combustion chambers.3. Fill the combustion chamber completely, taking care not to pour oil outside the combustion chamber.Wait about 10 minutes to allow the oil to decant.Measure the amount of oil remaining in the burette and then calculate the difference between this and the amount of oil used initially with the burette full. The difference is the volume of the chamber.Check that this value is within specified values, otherwise replace the cylinder head.

	Measurement		Value
-	Volume of combustion chamber in cylinder head (cm)		33.35

De-carbonize the valves removing the combustion residues.Check that the valves do not show signs of scoring or seizing.Check that the thickness in the part in contact with the valve seat is within the recommended values.

	Measurement		Value
-	Valve size (mm)		/= 1

Check that the diameter of the valve stem corresponds to the recommended figures; if not, replace the valves.

	Measurement		Value
-	Inlet valve inner diameter (mm)		6.982 ÷ 7.000

	Measurement		Value
-	Exhaust valve inner diameter (mm)		6.974 ÷ 6.992

Check that the diameter of the valve head corresponds to the recommended figures; if not, replace the valves.

	Measurement		Value
-	Inlet valve outer diameter (mm)		30.200 ÷ 30.500

	Measurement		Value
-	Exhaust valve outer diameter (mm)		29.750 ÷ 30.050

Check that the contact angle with the valve seat for both valves is within the recommended values or else the valve has to be replaced.

	Measurement		Value
-	Angle of band in contact with valve seat (-)	Inlet	45° 30'' +/- 5''

	Measurement		Value
-	Contact band angle with exhaust valve seat (-)		45° 30'' +/- 5''

Using special equipment, check that the valve spring specifications in the different load conditions have not changed or else they must be replaced.

	Measurement		Value
-	Height of inlet spring (mm)		34
	Under a load of (daN)	27.5 ÷ 30.5

	Measurement		Value
-	Height of inlet spring (mm)		22.5
	Under a load of (daN)	61.1 ÷ 66.9

	Measurement		Value
-	Height of exhaust spring (mm)		34
	Under a load of (daN)	27.5 ÷ 30.5

	Measurement		Value
-	Height of exhaust spring (mm)		26
	Under a load of (daN)	59 ÷ 64.8

Regrind the valve seats to the recommended measurements for a length of around 2 mm.

	Measurement		Value
-	Width of ring in contact with valve (mm)	"b"	45° +- 5''

Ream the valve guide inner diameter using a suitable reamer.Check that the inner diameter of the valve guide and the clearance after refacing between it and the valve are within specified values, otherwise replace the valve guide.If necessary, replace the valve guides, refer to Op. 1016E14 SINGLE CYLINDER HEAD VALVE GUIDES - REPLACE DURING OPERATION 1016E10

	Measurement		Value
-	Valve guide inner diameter (mm)		7.022 ÷ 7.040

	Measurement		Value
-	Inlet valve - inlet valve guide clearance (mm)		0.022 ÷ 0.058

	Measurement		Value
-	Exhaust valve - exhaust valve guide clearance (mm)		0.030 ÷ 0.066

1. Fit the oil seals (1a) on the valve guides, positioning the intaller (1b) on the valve stem fitted provisioinally in its seat, then fit a new oil seal on the drift.2. Remove the installer and use a drift to press-fit the oil seal in its seat.

	Description	Code
1b	Drift	1.860.813.000

	Description	Code
1b	Drift	1.860.813.000

Refit the valves, springs, cotters and caps using the same equipment as for the dismantling.

	Description	Code
-	Lever	1.860.790.000

	Description	Code
-	Lever hook	1.860.788.000

	Description	Code
-	Extension	1.860.787.000

	Description	Code
-	Valve retaining base	1.860.786.000

	Description	Code
-	Chamber	1.860.789.000

Carry out a seal test on the valves with reference to operationValve leakage testRemove the cylinder head from the vice.Remove the cylinder head support tool fitted earlier .

	Description	Code
-	Support	1.860.470.000

1. Remove the hydraulic tappets from the camshaft housing taking care to place them on a suitable surface making a note of their fitting position in the camshaft housing.

Do not turn the tappets upsidedown to prevent part of the fuel in them from escaping.

1. Fit the support tool (1a) on the camshaft housing (1b) and place it in a vice.

	Description	Code
1a	Support	1.860.470.000

1. Undo the nut (1a) and remove the rear cover (1b).Release the camshaft complete with oil seal from the housing.

Measure the diameters of the supports for the camshaft housings checking that the values measured correspond to the recommended figures or else the damaged camshaft housing has to be replaced.

	Measurement		Value
-	1st inlet side camshaft support diameter in camshaft housing (mm)		29.989 - 30.014

	Measurement		Value
-	2nd inlet side camshaft support diameter in camshaft housing (mm)		52.445 - 52.470

	Measurement		Value
-	3rd inlet side camshaft support diameter in camshaft housing (mm)		52.845 - 52.870

	Measurement		Value
-	4th inlet side camshaft support diameter in camshaft housing (mm)		53.245 - 53.270

	Measurement		Value
-	5th inlet side camshaft support diameter in camshaft housing (mm)		53.645 - 53.670

Measure the camshaft bearings checking that the figures correspond to the recommended values or else the damaged camshaft has to be replaced.

	Measurement		Value
-	1st timing side shaft bearing diameter (mm)		29.944 - 29.960

	Measurement		Value
-	2nd timing side shaft bearing diameter (mm)		52.400 - 52.415

	Measurement		Value
-	3rd timing side shaft bearing diameter (mm)		52.800 - 52.815

	Measurement		Value
-	4th timing side shaft bearing diameter (mm)		53.200 - 53.215

	Measurement		Value
-	5th timing side shaft bearing diameter (mm)		53.600 - 53.615

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

	Measurement		Value
-	Camshaft cam height (mm)	Inlet	8.5
Exhaust	8

Also check that the surfaces of the cams and the bearings should not show signs of wear, grooves or seizing.Fit the camshafts in the camshaft housing bearing in mind that the matching of the two components must not exceed the recommended clearance.

	Measurement		Value
-	Clearance between camshaft bearings and camshaft housing supports (mm)		0.030 - 0.070

1. Fit the new oil seal (1a) on the camshaft housings using the tool (1b).

	Description	Code
1b	Fitting tool	1.860.882.000

Measure the diameters of the tappet housings checking that the values measured correspond to the recommended figures or else the camshaft housing has to be replaced.

	Measurement		Value
-	Tappet housing diameter (mm)		33.000 - 33.025

1. Measure the diameters of the tappets checking that the values measured correspond to the recommended figures or else the tappets have to be replaced.

	Measurement		Value
-	Tappet housing diameter (mm)		33.000 - 33.025

Fit the hydraulic tappets in the special housings in the camshaft housing.Calculate the tappet clearance with the housing in the cylinder head extension checking that the figures are within the recommended values.

	Measurement		Value
-	Tappet outer diameter (mm)		32.959 - 32.975