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

244000645 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

) - Fit the tool to the cylinder head and secure in the vice.

	Description	Code	Function
.	Support	1.860.470.000	Cylinder head in vice

1. Check that the 10 mm diameter reference pin is correctly inserted.2. Undo the gear retaining bolt.3. Remove the gear.- Remove the 10 mm diameter reference pin.

- Remove the spark plugs.- Remove the press-fitted lubrication pipe and the sealing rings.1. Unscrew nuts (1a) securing the camshaft caps in the order shown and remove caps (1b).

Mark the camshaft caps to ensure correct installation.

2. Remove the camshaft.

1. Remove tappets (1a) and calibrated valve clearance pads (1b).

Mark the tappets and pads to ensure correct installation.

1. Fit the tool beneath the cylinder head.

	Description	Code	Function
1	Valve retaining base	1.860.804.000	Valve retention

2. Remove semicones (2a) from the valve using tools (2b).

	Description	Code	Function
2b	Tool	1.860.644.000	Removing/refitting valves

	Description	Code	Function
2b	Tool	1.860.644.030	Removing/refitting valves

3. Remove upper plate (3a), spring (3b) and lower plate (3c) in order.- Repeat the operation for all valves.- Remove the tool.

	Description	Code	Function
.	Valve retaining base	1.860.804.000	Valve retention

4. Remove all valves.

Mark each valve and its components to allow correct assembly.

1. Remove the valve stem sealing ring using the tool.

	Description	Code	Function
1	Extractor	1.860.792.000	Valve guide oil seals

- Repeat the operation for all valve stem sealing rings.

1. Remove the filter from the lubricant delivery channel to the cylinder head.

1. Remove the valve guide from its seat using the tool.

	Description	Code	Function
1	Drift	1.860.395.000	Valve guide extraction

- Remove the cylinder head from the tool.

	Description	Code	Function
.	Support	1.860.470.000	Cylinder head in vice

Refitting ( Removing

) - Clean all ducts thoroughly.1. Check the lower surface and ensure that flatness is within specified limits.

	Subject	Value
1	CYLINDER HEAD	mm
-	Flatness	0,05

- Fit the camshaft and caps provisionally.- Tighten the nuts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	1,6	Nut	CAMSHAFT CAPS	-

1. Check that cylinder head height is within recommended limits.

	Subject	Value
1	CYLINDER HEAD	mm
-	Height	140,95 - 141,05

Measure height h1, measure dimension d; the required height h = h1 - d/2.

- Remove the caps and camshaft.- If cylinder head flatness and/or height are not within specified limits, grind the lower surface to reduce the height to the specified value.

	Subject	Value
.	CYLINDER HEAD	mm
-	Cylinder head height reduction	0,20

If the grinding involves removing material in excess the specified amount, the cylinder head must be replaced.

1. Grind the intake valve seats using a suitable tool.

	Subject	Value
1a	VALVE SEATS
-	Contact band angle with intake valve	45°

	Subject	Value
1b	VALVE SEATS
-	Intake port outlet angle	65°

	Subject	Value
1c	VALVE SEATS
-	Intake port intake angle	25°

2. Grind the exhaust valve seats using a suitable tool.

	Subject	Value
2a	VALVE SEATS
-	Contact band angle with intake valve	45°

	Subject	Value
2b	VALVE SEATS
-	Exhaust port outlet angle	65°

	Subject	Value
2c	VALVE SEATS
-	Exhaust port intake angle	20°

	Subject	Value
.	VALVE SEATS	mm
-	Intake valve contact band width	1,70
-	Exhaust valve contact band width	2,20

1. Check contact between valve and seat is correct after grinding.

- If it is not possible to obtain centred, even contactg between valve and seat, replace the valve seat.1. Whenever necessary, replace the valve seats using new oversize valve seats to restore the initial conditions.

	Subject	Value
1a	VALVE SEATS	mm
-	Intake valve seat housing diameter, 1st oversize	42,3
-	Intake valve seat housing diameter, 2nd oversize	42,5

	Subject	Value
1a	VALVE SEATS	mm
-	Exhaust valve seat housing diameter, 1st oversize	36,3
-	Exhaust valve seat housing diameter, 2nd oversize	36,5

	Subject	Value
1b	VALVE SEATS	mm
-	Intake valve seat housing height	15,98
-	Exhaust valve seat housing height	15,25

Measure the housing height from the lower cylinder head surface.

	Subject	Value
1c	VALVE SEATS	mm
-	Intake valve seat diameter, 1st oversize	42,4
-	Intake valve seat diameter, 2nd oversize	42,6

	Subject	Value
1c	VALVE SEATS	mm
-	Exhaust valve seat diameter, 1st oversize	36,4
-	Exhaust valve seat diameter, 2nd oversize	36,6

	Subject	Value
1d	VALVE SEATS	mm
-	Oversize intake valve seat height	8,40
-	Oversize exhaust valve seat height	7,35

- Ream the valve guide seats using a suitable tool.

	Subject	Value
.	VALVE GUIDES	mm
-	Valve guide seat diameter, 1st oversize	13,195 - 13,227
-	Valve guide seat diameter, 2nd oversize	13,495 - 13,527

1. Press-fit new valve guides (1a) from the top of the cylinder head using tool (1b).

	Description	Code	Function
1b	Fitting tool	1.870.751.000	Valve guide fitting

It is advisable to heat the cylinder head to 80-100°C to aid fitting.

1. Check that valve guide position is within specified limits.

	Subject	Value
1	VALVE GUIDES	mm
-	Gap between intake valve guide - lower cylinder head surface	43,65 - 44,35
-	Gap between exhaust valve guide - lower cylinder head surface	38,05 - 38,75

- Ream the valve guides using an appropriate tool

	Subject	Value
.	VALVE GUIDES	mm
-	Valve guide bore	8,000 - 8,022

1. Check that the valve specifications are within specified limits; if not, replace the valves.

	Subject	Value
1a	INLET VALVES	mm
-	Stem diameter	7.965 - 7,980

	Subject	Value
1b	INLET VALVES	mm
-	Head diameter	41,4 - 41,8

	Subject	Value
1c	INLET VALVES	mm
-	Height	108,8, mm

	Subject	Value
1d	INLET VALVES
-	Contact angle	45°

	Subject	Value
1a	EXHAUST VALVES	mm
-	Stem diameter	7.955 - 7,970

	Subject	Value
1b	EXHAUST VALVES	mm
-	Head diameter	34,3 - 34,7

	Subject	Value
1c	EXHAUST VALVES	mm
-	Height	108,4

	Subject	Value
1d	EXHAUST VALVES
-	Contact angle	45°30'

- Fit the valves and spark plugs provisionally as described later.1. Carry out a valve leak test using tools (1a) and (1b).

	Description	Code	Function
1a	Lever	1.860.490.000	Valve leakage test

	Description	Code	Function
1b	Sealing pad with pressure gauge	1.895.868.000	Valve leakage test

- Using a torque wrench, check that the valve spring specifications meet specified limits; if not, replace the springs.

	Subject	Value
.	EXTERNAL VALVE SPRING
-	Length	54,5 mm
-	Under a load of	0 daN

	Subject	Value
.	EXTERNAL VALVE SPRING
-	Length	42,5 mm
-	Under a load of	39 daN

	Subject	Value
.	EXTERNAL VALVE SPRING
-	Length	31,0 mm
-	Under a load of	85 daN

- Fit the tool to the cylinder head and secure in the vice.

	Description	Code	Function
.	Support	1.860.470.000	Cylinder head in vice

- Fit a new filter in the lubricant delivery channel to the cylinder head.1. Fit all the valve in their valve guides.2. Fit the tool beneath the cylinder head.

	Description	Code	Function
2	Valve retaining base	1.860.804.000	Valve retention

1. Fit the sealing ring (1a) into its seat using tool (1b).

	Description	Code	Function
1b	Fitting tool	1.860.313.000	Valve guide oil seal fitting.

- Repeat the operation for all rings.1. Fit the lower plate (1a), spring (1b) and upper plate (1c) in order, respecting the marks made upon disassembly.2. Fit semicones (2a) and settle in their seats using tools (2b).

	Description	Code	Function
2b	Tool	1.860.644.030	Removing/refitting valves

	Description	Code	Function
2b	Tool	1.860.644.000	Removing/refitting valves

- Repeat the operation for all valves.1. Fit the calibrated pads to adjust the clearance. Ensure they are fitted in the correct direction.2. Fit the tappets in their housing.

1. Fit the camshaft.2. Fit the camshaft caps (2a) and tighten retaining nuts (2b) to the specified torque in the order shown.

	Value - daNm	Fastening	Component	Ø
2b	1,6	Nut	CAMSHAFT CAPS	-

- Fit the timing gear provisionally.1. 1. Position each cam upright and check the clearance is within specified limits.

	Subject	Value
.	VALVE TAPPETS	mm
-	Inlet valve clearance check	0,15 - 0,25
-	Exhaust valve clearance check	0,35 - 0,45

- if not as specified, remove the camshaft caps, camshaft and tappets.- Remove a calibrated pad and measure its thickness.- Calculate the difference between the measured clearance and the specified clearance for each pad.

The difference may be positive (+ sign) or negative (- sign).

- Calculate the thickness of the pad to be fitted by adding the thickness of the current pad to the calculated difference (including the + or - sign).- Repeat the procedure for all calibrated pads.- Fit the tappets.1. Fit the camshaft.2. Fit the camshaft caps (2a) and tighten retaining nuts (2b) to the specified torque in the order shown.

	Value - daNm	Fastening	Component	Ø
2b	1,6	Nut	CAMSHAFT CAPS	-

1. Press-fit the lubrication pipe (1a) and the sealing rings (1b).