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

2585285 - 1016E10 single cylinder head, removed - overhaul

Place the 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. Undo the bolts (1a) and remove the vacuum pump (1b) complete with gasket.2. Undo the bolts (2a) and remove the thermostat (2b) complete with pipe, sensors and o-ring.

1. Disconnect the diesel return pipes (1a) and injectors (1b).2. Remove the heater plugs.

	Description	Connector
2	Heater plugs	See A040 HEATER PLUGS

1. Undo the lockring (1b), using the tool (1a), and remove the combustion prechambers (1c).

	Description	Code
1a	Tool	1.860.884.000

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 water pump (3b) complete with O-ring (3c).

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).

	Description	Code
-	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
-	Extractor	1.860.395.001

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)		141 ± 0.15

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 mechanical tappets 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 tappet seats corresponds to the recommended figures; if not, replace the cylinder head.

	Measurement		Value
-	Tappet sleeve seat diameter (mm)		37.000 - 37.025

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

	Measurement		Value
-	Length of spring released (mm)		53.9

	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)	Inlet	9.5
Exhaust	8.5

	Measurement		Value
-	H (mm)		362 ± 8
	With unladen vehicle levelled (-)	-

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	M6	1

	Fastening	Component	dia	Value(daNm)
1b	Bolt	CAMSHAFT CAPS	M7	1.5

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

	Measurement		Value
2	Camshaft support 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
	Oversize (mm)	0.005

	Measurement		Value
-	Outer diameter oversize ()		0.05 - 0.10 - 0.25

	Measurement		Value
-	Valve guide outer diameter undersized by 0.05 (mm)		14.060 - 14.080

	Measurement		Value
-	Valve guide outer diameter undersized by 0.10 (mm)		14.110 - 14.130

	Measurement		Value
-	Valve guide outer diameter undersized by 0.25 (mm)		14.260 - 14.280

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
-	Taper of ring in contact with valve "a" (Degrees)		45° 30''+/- 5''

	Measurement		Value
-	Width of ring in contact with valve "I" (approx), (mm)		2.0

	Measurement		Value
-	Taper of upper ring with valve (Degrees)	Inlet	20°
Exhaust	28°

Grind the valve seats using a suitable tool.Temporarily fit the valves.1. Check that the change in the combustion prechamber surface in relation go the cylinder head surface is within specified values, using the tool with dial gauge.

	Measurement		Value
1	Change in prechamber surface compared to the cylinder head surface ()		-0.200 - -0.600

	Description	Code
1	Dial gauge support	1.870.404.000

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	Fitting tool	1.860.313.000

1. Press-fit the valve guide oil seals (1a) using the tool (1b).

	Description	Code
1b	Fitting tool	1.860.313.000

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

	Description	Code
-	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	M6	1

	Fastening	Component	dia	Value(daNm)
2	Bolt	CAMSHAFT CAPS	M7	1.5

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

	Description	Code
1b	Fitting tool	1.860.824.000

Fit the combustion prechamber, centring using the tool (dummy plug), then secure with the lockrings using the specific tightening tool.

	Description	Code
-	Tool	1.860.810.000

	Fastening	Component	dia	Value(daNm)
-	Ring nut	PRECOMBUSTION CHAMBERS	M35	12

	Description	Code
-	Tool	1.860.884.000

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

	Description	Connector
1	Heater plugs	See A040 HEATER PLUGS

	Fastening	Component	dia	Value(daNm)
1	Heater plug	GLOW PLUGS	M12	1.5

2. Fit the injectors and tighten them to torque.

	Fastening	Component	dia	Value(daNm)
2	Injector assembly	DIESEL INJECTORS	M24	6

3. Fit the diesel return pipes.

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

	Fastening	Component	dia	Value(daNm)
3a	Bolt	TIMING DRIVEN PULLIES	M12	12

	Description	Code
3b	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)
1	Bolt	THERMOSTAT	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)
2b	Bolt	VACUUM PUMP FOR BRAKES	M8	2.5