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

2585285 - 1016E10 single cylinder head, removed - overhaul

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

	Description	Code
1b	Support	1.860.470.001

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 to the exhaust camshaft.

	Description	Code
-	Templates	1.870.896.900

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

	Measurement		Value
-	End float (mm)		0.15 ÷ 0.34

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 and position with its millings horizontal. Ensure it fits nto the seat on the camshaft.

	Description	Code
1b	Templates	1.870.896.900

2. Undo the bolts fixing the camshaft gears.

1. Remove the camshaft timing tools from the cylinder head extension.

	Description	Code
1	Templates	1.870.896.900

2. Release the camshafts (2a), as necessary and remove the camshaft gears (2b).Completely remove the camshafts.

Remove the support tool complete with cylinder head extension 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).

	Description	Code
1b	Support	1.860.470.001

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).3. Remove gaskets (3a) and (3b).

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.

	Description	Code
1	Stand	1.860.749.000

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

	Description	Code
1b	Lever	1.860.644.001

	Description	Code
1c	Chamber	1.870.881.000

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 recover the valves.

	Description	Code
-	Stand	1.860.749.000

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

	Description	Code
1b	Caliper	1.870.894.000

2. Fit the lower valve shims.

Remove the cylinder head from the support tool.

	Description	Code
-	Support	1.860.470.000

Replace the valve guide Op. 1016E14 SINGLE CYLINDER HEAD VALVE GUIDES - REPLACE DURING OPERATION 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 flatness of the lower cylinder head plane corresponds to the recommended values.

	Measurement		Value
-	Lower plane planarity (mm)		0.1

If 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.

	Measurement		Value
-	Nominal height (mm)		105.5 ± 0.05

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
-	Intake/exhaust stem diameter (mm)		5.90 ÷ 5.94

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

	Measurement		Value
-	Free length (mm)		37.9

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

	Measurement		Value
-	Length (mm)		31.0
	Under a load of (daN)	16.2 ÷ 18.0

	Measurement		Value
-	Length (mm)		23.5
	Under a load of (daN)	36.1 ÷ 39.5

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

	Measurement		Value
-	Journal diameter (mm)	First journal	38.500 ÷ 38.515
Second journal	38.000 ÷ 38.015
Third journal	30.000 ÷ 30.015

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

	Measurement		Value
-	Nominal cam height (mm)	Inlet	6.4
Exhaust	7.5

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

	Measurement		Value
1	Bearing diameter (mm)	First bearing	38.545 ÷ 38.570
Second bearing	38.045 ÷ 38.070
Third bearing	30.045 ÷ 30.070

1. Grind the valve seats to the recommended size.

	Measurement		Value
1	Angle of ring in contact with valve (-)		45° ± 20''

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

	Description	Code
-	Support	1.860.470.001

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

	Description	Code
-	Stand	1.860.749.000

Place the lower valve shims in their housings.1. Fit the valve guide oil seals (1a) in their seats using the tool (1b).

	Description	Code
1b	Drift	1.870.900.800

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).

	Description	Code
3b	Lever	1.860.644.001

	Description	Code
3c	Chamber	1.870.881.000

Carry out the same operations on the other valves.Remove the wooden stand for supporting the valves from the cylinder head plane.

	Description	Code
-	Stand	1.860.749.000

1. Refit the air chamber (1a) complete with gasket (1b) and pressure relief sensor back in its housing and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1c	Bolt	INLET AIR DUCT	M8	(Cylinder head side) 2.3 - 2.8

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.1. Replace the exhaust gas/water heat exchanger for the EGR valve (1a) with gaskets (1b) and (1c) in its seat, then secure by tightening bolts (1d) to the specified torque.

	Fastening	Component	dia	Value(daNm)
1d	Bolt	EGR EXHAUST GAS HEAT EXCHANGER	M8	(Cylinder head side) 2.0 - 2.4

2. Tighten the collar securing the exhaust gas/coolant heat exchanger for the EGR system, air chamber side.

1. Place the engine oil pressure warning light switch in its housing and tighten it to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1	-	INSUFFICIENT ENGINE OIL PRESSURE SWITCH	M14	(Cylinder head side) 2.9 - 3.5

2. Place the thermostat (2a) in its housing with the o-ring and secure it by tightening the bolts (2b) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
2b	Bolt	THERMOSTAT	M8	(Cylinder head side) 2.3 - 2.8

3. 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 upper cylinder head locating bushes in their seats.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 lower valve rockers in their housings.Remove the cylinder head from the support tool.

	Description	Code
-	Support	1.860.470.001

1. Refit the glow plugs and tighten them to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1	-	GLOW PLUGS	M8	(Cylinder head side) 0.9 - 1.0

2. Place the exhaust manifold gasket in its housing.3. Place the air conditioning compressor mounting (3a) in its housing and secure it by tightening the nuts (3b) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
3b	Nut	EXHAUST MANIFOLD/S	M8	(Cylinder head side) 2.1 - 2.5

CYLINDER HEAD EXTENSIONPosition the cylinder head extension in the vice using the tool.

	Description	Code
-	Support	1.860.470.001

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.

Fit the tools and position with their millings horizontal. Ensure they fit into the seats on the camshafts.

	Description	Code
1	Templates	1.870.896.900

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

	Fastening	Component	dia	Value(daNm)
2	Bolt	CYLINDER HEAD EXTENSION	M12	(camshaft side) 10.8 - 13.2

1. Position the cam angle sensor (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1b	Bolt	CAM ANGLE SENSOR	M6	(Cylinder head extension side) 0.6 - 0.8

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.

	Fastening	Component	dia	Value(daNm)
1c	Bolt	PRESSURE PUMP	M7	(Cylinder head extension side) 1.4 - 1.7

2. Place the vacuum pump (2a), complete with gasket (2b), back in its housing and secure it tightening the bolts (1c) to the recommended torque.

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.

	Fastening	Component	dia	Value(daNm)
2c	Bolt	VACUUM PUMP FOR BRAKES	M8	(Cylinder head side) 1.8 - 2.2

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