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

2585285 - 1016E10 single cylinder head, removed - overhaul

Op. 1036B14 CAMSHAFT IN CYLINDER HEAD - R.R. WITH HEAD REMOVED1. Remove the mechanical tappets with shims.

1. Fit valve retainer tool (1a) beneath the cylinder head.

	Description	Code
1a	Stand	1.860.749.000

1. Remove the cotters (1a) using the tool (1b).2. Fit the upper valve shims.3. Remove the valve springs.

	Description	Code
1b	Tool	1.860.644.000

1. User pliers (1a) to remove oils seals (1b) from the valve guides.2. Fit the lower valve spring shims.

	Description	Code
1a	Extractor	1.860.989.000

Remove the valve retainer fitted previously and remove the valves.

	Description	Code
-	Stand	1.860.749.000

1. Undo the nut (1a) and remove the mobile timing belt tensioner (1b).2. Remove the spark plugs.

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

De-carbonize and clean the valve seats and ducts.Clean any residues of the old gasket from the lower cylinder head plane.1. Check cylinder head flatness and if necessary flatten the lower cylinder head surface. It is permitted to remove 0.1 mm of material from the minimum cylinder head height (factory value).

	Measurement		Value
-	Cylinder head height (factory value) (mm)		126.5 +/- 0.35

After flattening, check that combustion chamber volume is within specified values as follows1. Fit the valves and spark plugs provisionally. Take a graduated burette 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
-	Combustion chamber volume (cm)		35.28

If the combustion chamber volume is not within specified values, remove material from the arrowed points.

Check that the valve stem does not show signs of scoring or binding.Check that the diameter of the valve stems corresponds to the recommended figures; if not, replace the worn valves.

	Measurement		Value
-	Intake and exhaust valve stem diameter (mm)		6.982 - 7.000

Check that the thickness of the cylindrical section of the valve head is within specified values.

	Measurement		Value
-	Thickness of cylindrical section of valve head (mm)		1

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

	Measurement		Value
-	Intake valve outer diameter (mm)		31.20 - 31.50

	Measurement		Value
-	Exhaust valve outer diameter (mm)		27.20 - 27.50

1. Check that the inner diameter of the valve guide and the clearance between it and the valve are within specified values, otherwise replace the valve guide.If necessary, replace the valve guide with reference to op. Op. 1016E14 SINGLE CYLINDER HEAD VALVE GUIDES - REPLACE DURING OPERATION 1016E10.

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

	Measurement		Value
-	Intake/exhaust valve stem - valve guide clearance (mm)		0.022 - 0.058

1. In the event of valve and valve guide replacement, grind the valve seats to specified values (1a), (1b), (1c) and (1d).

	Measurement		Value
1a	Upper ring taper (-)		75°

	Measurement		Value
1b	Taper of ring in contact with valve (-)		45° 30'' +/- 5''

	Measurement		Value
1c	Lower ring taper (-)		20°

	Measurement		Value
1d	Width of band in contact with valve (mm)		~ 2

When the operation is complete, clean the valve seats thoroughly.

Using an appropriate tool, check that the valve spring specifications correspond to the recommended figures; if not, replace the worn components.

	Measurement		Value
-	Height of spring released (mm)		37

	Measurement		Value
-	Height of spring (mm)		22.6
	Under a load of (daN)	58.4 ÷ 62.6

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

	Measurement		Value
-	Side journal diameter (mm)		24.000 - 24.015

	Measurement		Value
-	Central journal diameter (mm)		23.500 - 23.515

1. Check that the nominal camshaft cam lift (1a) corresponds to the recommended figures; if not, replace the worn camshaft. Also measure the diameter of shaft (1b) and the height of each cam (1c).

	Measurement		Value
1a	Nominal cam height (mm)		38.4

	Measurement		Value
1b	Camshaft diameter (mm)		29.6

	Measurement		Value
1c	Height of each cam (mm)		8.8

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

	Measurement		Value
-	Mechanical tappet outer diameter (mm)		34.975 ÷ 34.995

Check that the diameter of the cylinder head camshaft tappet sleeve housings corresponds to the recommended figures; if not, replace the cylinder head.

	Measurement		Value
-	Mechanical tappet outer diameter (mm)		35.000 ÷ 35.025

Position the thermostat, complete with a new gasket, and secure it tightening the bolts to the recommended torque.

	Fastening	Component	dia	Value(daNm)
-	Bolt	THERMOSTAT	M6	1

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

	Fastening	Component	dia	Value(daNm)
-	-	SPARK PLUGS	M14 X 1.5	2.7

Fit the moving timing belt tensioner and secure it with the nut without tightening.1. Fit valve retaining tool (1a) after positioning the valves in their seats.

	Description	Code
1a	Stand	1.860.749.000

1. Fit the lower valve shims.2. Fit the valve guide oil seal (2a) using the tool (2b).

	Description	Code
2b	Fitting tool	1.860.313.000