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

2585285 - 1016E10 single cylinder head, removed - overhaul

Remove the cylinder head from the vice.Unscrew the bolts and remove the mounting tool.

	Description	Code
-	Support	1.860.470.000

Removing ( Refitting

) Place the cylinder head on the workbench.1. Use the nut and counternut to unscrew the stud.2. Fit the tool (2a) on the cylinder head (2b) and secure it using the nuts (2c).

	Description	Code
2a	Support	1.860.470.000

Place the tool in the vice.1. Loosen the manifold side connectors for the pipes from the fuel manifold to the injectors.2. Undo the injector side connectors for the pipes from the fuel manifold to the injectors.3. Undo the nuts (3a) and remove the fuel distribution manifold (3b) complete with fuel pressure sensor and pipes (3c).

	Description	Connector
3c	Fuel pressure sensor	See K83 FUEL PRESSURE SENSOR ( ENGINE )

4. Remove clips (4a) and withdraw the fuel return pipe to lubricate injectors (4b).Undo the nuts and disconnect the supply wiring from the glow plugs.

	Description	Connector
-	Heater plugs	See A040 HEATER PLUGS

Disconnect the coolant return pipe to the expansion tank and de-aeration system from the thermostat.5. Undo the nuts (5a) and remove the air intake manifold assembly (5b).

1. Undo the bolts (1a) and disconnect the water/exhaust gas heat exchanger for the E.G.R. system (1b) from the EGR system solenoid.2. Undo the fixing bolts (2a) and remove the E.G.R. system solenoid valve (2b).3. Remove the bracket.

1. Release the vacuum pipe from the fastening bands.2. Disconnect the vacuum pipe from the air valve on the electropneumatically-controlled throttle body.3. Loosen the band and disconnect the engine oil vapour recovery pipe from the cam cover.4. Loosen the band securing the air intake sleeve to the electropneumatically-controlled throttle body.

1. Undo the bolts (1a) and remove the electropneumatically-controlled throttle body (1b).2. Remove the gasket.

Unscrew the bolt securing the water/exhaust gas heat exchanger for the EGR system to the cylinder head.1. Unscrew the nut securing the water/exhaust gas heat exchanger for the EGR system to the cylinder head.2. Undo the bolt (2a) and the nut (2b) and remove the thermostat (2c) together with the water/exhaust gas heat exchanger for the E.G.R. system (2d).3. Remove the thermostat gasket.

1. Undo the bolts (1a) and remove the vacuum pump (1b) complete with gasket.

1. Undo the toothed driven pulley bolt (1a) using the tool (1b).

	Description	Code
1b	Support for counter-torque	1.860.831.000

2. Remove the toothed driven pulley.3. Undo the bolts (3a) and remove the timing sensor (3b).

	Description	Connector
3b	Timing sensor	See K47 TIMING SENSOR ( ENGINE )

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).

	Description	Connector
2a	Injector	See N070 INJECTOR

3. Remove the injector bracket support pads.4. Remove the heater plugs.

	Description	Connector
4	Heater plugs	See A040 HEATER PLUGS

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

	Measurement		Value
-	End float (mm)		0.100 - 0.230

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.

When removing, mark the camshaft caps with a progressive number to define their installation position.

4. Remove the camshaft.5. Remove the camshaft front oil seal.6. Remove the cups complete with valve clearance adjustment pads.

When removing, mark the cups with a progressive number to define their installation position.

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.Lock the cylinder head in the vice.1. Remove the cotters (1a) using the tool (1b).

	Description	Code
1b	Tool	1.860.644.000

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

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

	Description	Code
1b	Extractor	1.860.989.000

2. Remove the lower shim.Carry out the same operations on the other valves.Release the cylinder head from the vice and position on the workbench.Remove the wooden stand and recover the valves.

Mark the valves with a progressive number to define their installation position.

Remove the support tool from the cylinder head.

	Description	Code
-	Support	1.860.470.000

1. Remove the valve guides (1a) using the tool (1b).

	Description	Code
1b	Extractor	1.860.395.001

Refitting ( Removing

) Clean any residues of the old gasket from the lower cylinder head plane.Check that the flatness of the lower cylinder head plane corresponds to the recommended values.

	Measurement		Value
-	Lower plane planarity (mm)		0.1

1. If the planarity of the lower cylinder head plane does not correspond to the recommended figures, regrind it without exceeding the minimum permitted height.

	Measurement		Value
1	Minimum permitted height (mm)		140.6

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
-	Stem diameter (mm)		7.974 - 7.992

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

	Measurement		Value
-	Outer diameter (mm)		36.975 - 36.995

Check that the diameter of the cup seats corresponds to the recommended figures; if not, replace the cylinder head.

	Measurement		Value
-	Cup housing diameter (mm)		37.000 - 37.025

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

	Measurement		Value
-	Free length (mm)		53.9

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

	Measurement		Value
-	Length (mm)		36
	under a load of (daN)	36.7 - 39.6

	Measurement		Value
-	Length (mm)		26.5
	under a load of (daN)	56.0 - 61.0

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

	Measurement		Value
-	Journal diameter (mm)		26.000 - 26.015

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

	Measurement		Value
-	Nominal cam height (mm)		8.5

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

	Fastening	Component	dia	Value(daNm)
1b	Bolt	CAMSHAFT CAPS	M7	1.3 - 1.6

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

	Measurement		Value
2	Diameter (mm)		26.045 - 26.070

Undo the bolts and remove the camshaft caps.

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

	Measurement		Value
-	Outer diameter (mm)		14.010 ÷ 14.030
	Oversizes (mm)	0.05, 0.10, 0.25

1. Fit the valve guides (1a) using the tool (1b).

The valve guides should be fitted after the cylinder head has been heated to a temperature of 80° - 100°C.

	Description	Code
1b	Fitting tool	1.860.812.000

Ream the valve guide bore to the recommended figure.

	Measurement		Value
-	Inner diameter (mm)		8.022 ÷ 8.040

Temporarily fit the valves.1. Check the clearance between the valve stem and valve guide.

Grind the valve seats to the required values if they are ground, or replace the valves or valve guides

	Measurement		Value
-	Upper ring taper (mm)	"a"	70°

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

	Measurement		Value
-	Lower ring taper (mm)	"c"	15°

	Measurement		Value
-	Width of band in contact with valve (mm)	" I "	+- 2

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 corresponds to the recommended figures using the tool fitted with a dial gauge.

	Measurement		Value
1	Cylinder head plane recess (mm)		0.1 - 0.5

	Description	Code
1	Dial gauge support	1.870.404.000

If the valve recess in relation to the cylinder head plane does not correspond to the recommended figures, regrind the valve seats once again.

Fit the support tool on the cylinder head and secure it using the nuts.Position a suitable wooden stand on the cylinder head plane to support the valves and secure it using bolts.Fit the cylinder head, complete with valves, in the vice.Fit the lower shim.1. Remove the valve guide oil seals (1a) on the valve using the tool (1b).

	Description	Code
1b	Drift	1.860.814.000

1. Fit the valve guide oil seals (1a) using the tools (1b) and (1c).

	Description	Code
1b	Fitting tool	1.860.313.000

	Description	Code
1c	Drift	1.867.019.000

Fit the valve spring.Fit the valve upper shim.1. Fit the cotters (1a) using the tool (1b).

	Description	Code
1b	Tool	1.860.644.000

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 in their position prior to removal.Fit the camshaft.1. Fit the camshaft caps in their position prior to removal.

Apply LOCTITE 573 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.

	Fastening	Component	dia	Value(daNm)
2	Bolt	CAMSHAFT CAPS	M7	1.3 - 1.6

1. Fit the camshaft front oil seal (1a) using the tool (1b).

	Description	Code
1b	Fitting tool	1.860.824.000

2. Fit the spark plugs and tighten them to the recommended torque.

	Description	Connector
2	Heater plugs	See A040 HEATER PLUGS

	Fastening	Component	dia	Value(daNm)
2	-	GLOW PLUGS	M12	1.3 - 1.6

1. Fit the injector bracket support pads.2. Fit the injectors (2a) complete with gasket (2b).

	Description	Connector
2a	Injector	See N070 INJECTOR

3. Fit the injector brackets (3a) and tighten the nuts (3b) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
3b	Nut	INJECTORS(DIESEL)	M8	2.6 - 3.2

4. Fit the fuel return pipe to lubricate injectors (4a) and secure with clips (4b).

1. Fit the water pump (1a), complete with a new O-Ring (1b) and tighten the bolts (1c) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1c	Bolt	COOLANT PUMP	M8	2.5

2. Fit timing sensor (2a) and tighten bolts (2b).

	Description	Connector
2a	Timing sensor	See K47 TIMING SENSOR ( ENGINE )

3. Fit the toothed driven pulley.4. Tighten the toothed driven pulley bolt (4a) to the recommended torque using the tool (4b).

	Fastening	Component	dia	Value(daNm)
4a	Bolt	TIMING DRIVEN PULLEY	M12	10.2 - 12.6

	Description	Code
4b	Support for counter-torque	1.860.831.000

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
-	Inlet valve clearance in closed position (mm)	Inlet	0.25 - 0.35
Exhaust	0.30 - 0.40

1. Lower the tappet in question using the tool.

	Description	Code
1	Lever	1.860.443.000

2. Fit the tool to lock the cup in lowered position.

	Description	Code
2	Lever	1.860.724.000

Remove the tool.

	Description	Code
-	Lever	1.860.443.000

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

	Description	Code
-	Lever	1.860.724.000

Remove the seal.1. Fit the thermostat (1a) complete with pipes and sensors and tighten the bolts (1b) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	COOLANT PUMP PULLEY	M8	2.5

2. Fit the vacuum pump (2a) complete with gasket and tighten the bolts (2b) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
3b	Bolt	VACUUM PUMP FOR BRAKES	M8	2.5

1. Refit the water/exhaust gas heat exchanger for the E.G.R. system (1a) with thermostat (1b) complete with gasket (1c)..2. Tighten pin (2a) and bolt (2b) securing the thermostat to the recommended torque.

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

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

3. Tighten the nut securing the water/exhaust gas heat exchanger for the E.G.R. system to the cylinder head.

Tighten the bolts securing the water/exhaust gas heat exchanger for the E.G.R. system to the cylinder head.Refit the electrical wiring in its seat and connect the electrical connections to the injectors.Connect the coolant intake pipe and the coolant outlet pipe to the EGR exhaust gas heat exchanger, then tighten the collars.Connect the coolant return pipe to the engine coolant reservoir to the thermostat and tighten the band.Connect the coolant delivery pipe to the climate control system heater to the thermostat and tighten the band.Connect the outlet pipe from the climate control system heater to the T-connector and the delivery pipe to the water pump liquid rigid inlet pipe, then tighten the collars.Connect the radiator upper coolant inlet hose to the radiator and tighten the band.Connect the electrical connection to the engine coolant temperature sensor.Tighten the bolts securing the water/exhaust gas heat exchanger for the E.G.R. system to the exhaust manifold.Secure the turbocharger vane position actuator control solenoid to the protection on the gearbox.Connect the electrical connection to the turbocharger vane position actuator solenoid valve.1. Refit the electro-pneumatically operated throttle casing (1a) complete with gasket (1b) back in its housing and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	dia	Value(daNm)
1c	-	-	-	-

Tighten the band securing the air intake sleeve to the electropneumatically-controlled throttle body.Connect the engine oil vapour recovery pipe to the cam cover and tighten the band.Connect the vacuum pipe to the air valve on the electropneumatically-controlled throttle body.Secure the vacuum pipe to the fastening bands.Place the E.G.R. system solenoid valve in its housing complete with bracket and fasten it tightening the bolts to the recommended torque.Connect the water/exhaust gas heat exchanger for the E.G.R. system to the EGR system solenoid and tighten the bolts.1. Fit the intake air manifold assembly (1a) and tighten the nuts (1b).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.

	Description	Connector
-	Heater plugs	See A040 HEATER PLUGS

2. Connect the fuel return pipe to lubricate injectors (2a) to the fuel manifold and secure with clips (2b).3. Fit the fuel rail (3a) complete with pipes and fuel pressure sensor (3b) and tighten the nuts (3c).

	Description	Connector
-	Fuel pressure sensor	See K83 FUEL PRESSURE SENSOR ( ENGINE )

4. Using a fixed wrench, bring the connectors of the pipes from the fuel rail to the injectors, injector side, into contact, then tighten to the specified torque using a fork-type torque wrench.

	Fastening	Component	dia	Value(daNm)
4	Connector	PIPE FUEL MANIFOLD TO INJECTORS	M12	(injector side) 2.3

5. Tighten the connectors (5a) for the pipes from the fuel manifold to the manifold side injectors to the recommended torque using tool (5b).

	Fastening	Component	dia	Value(daNm)
5a	Connector	PIPE FUEL MANIFOLD TO INJECTORS	M14	(Manifold side) 2.3

	Description	Code
5b	Spanner	1.852.138.000

Remove the cylinder head from the vice.Unscrew the bolts and remove the mounting tool.

	Description	Code
-	Support	1.860.470.000

Retighten the stud.