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

244000645 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

) 1. Position the cylinder head in the vice supporting it using a suitable tool.

	Description	Code	Function
1	Support	1.860.470.000	Cylinder head in vice

2. Undo the bolts (2a) and the nuts (2b).3. Undo the bolts (3a) and remove the connector (3b) from the cylinder head.4. Remove the seal.5. Remove the heat exchanger for the EGR (5a) and the gaskets (5b).

1. Undo the bolt (1a) and remove the fixed timing belt tensioner (1b).

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

1. Undo the bolts (1a) and remove the intake manifold (1b).2. Remove the seal.

1. Undo the bolts (1a) and remove the brackets (1b).

- Position the tool for supporting the valves in the lower part of the cylinder head.

	Description	Code	Function
1	Valve retaining base	1.860.804.000	Valve retention

1. Compress the valve springs using the special tool.

	Description	Code	Function
1	Tool	99360260	Valve spring compression

2. Release the cotters (2a), caps (2b) and springs (2c), then, removing the tools, release the valves (2d) from the cylinder head.

Separate the exhaust valves and the inlet valves and mark them.

1. Remove the oil seals (1b) from the valve guides using pliers (1a).

	Description	Code	Function
1a	Extractor	1.860.989.000	Valve guide oil seal extraction

See in Op. 1016E14

Refitting ( Removing

) - De-carbonize and clean the valve seats and ducts.- Clean any residues of the old gasket from the lower cylinder head plane.- Check that the planarity of the lower cylinder head plane corresponds to the recommended values.

	Subject	Value
.	Cylinder head	mm
-	Lower plane planarity	0.1

- If the planarity of the lower cylinder head plane does not correspond to the recommended figures, regrind it without exceeding the minimum permitted height.- Check that the valves do not show signs of grooves or seizing.- Check that the diameter of the valve stems corresponds to the recommended figures; if not, replace the worn valves.

	Subject	Value
.	INLET VALVES	mm
-	Stem diameter	5.985 - 6,000

	Subject	Value
.	EXHAUST VALVES	mm
-	Stem diameter	5.975 - 5.990

See in Op. 1016E14- Using a torque wrench, check that the spring specifications correspond to the recommended figures; if not, replace the worn components.

	Subject	Value
.	VALVE SPRINGS	mm
-	Length	45
-	Under a load of	23.1 - 25.5

	Subject	Value
.	VALVE SPRINGS	mm
-	Length	35
-	Under a load of	50.9 - 55.7

1. Grind the valve seats at (1a), (1b) and (1c) using a suitable tool.

	Subject	Value
1a	VALVE SEATS
-	Contact band angle with inlet/exhaust valve	44° 25' - 44° 35'

- Check that the valve recess in relation to the cylinder head plane corresponds to the recommended figures using the tool fitted with a magnetic base.

	Description	Code	Function
.	Dial gauge support	1.870.404.000	Valve recess in cylinder head plane measurement

- 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 all the valves in the correct positions.- Position the tool for supporting the valves in the lower part of the cylinder head.

	Description	Code	Function
.	Valve retaining base	1.860.804.000	Valve retention

- Fit the oil seals (1b) on the valve stems using the tool (1a).

	Description	Code	Function
.	Fitting tool	1.860.993.000	Fitting oil seals on valve stems

- Fit the valve springs and shims.- Compress the valve springs and fit the cotters using the special tool.

	Description	Code	Function
.	Tool	99360260	Valve spring compression

- Remove the tools used for fitting the valves.

	Description	Code	Function
.	Valve retaining base	1.860.804.000	Valve retention

	Description	Code	Function
.	Tool	99360260	Valve spring compression

- Position the brackets and tighten the fixing bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.5	Bolt	HOISTS	M8 X 1.25

- Fit a new gasket, position the intake manifold and tighten the fixing bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.5	Bolt	INLET MANIFOLD	M8 X 1.25

- Position the thermostat and tighten the fixing bolts.- Fit the fixed timing belt tensioner and tighten the retaining bolt to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.5	Bolt	FIXED TENSIONER	M8 X 1.25

- Fit the new gaskets, position the EGR heat exchanger and tighten the fixing bolts and nuts.- Connect the EGR heat exchanger connector to the cylinder head and tighten the fixing bolt.- Remove the cylinder head from the vice.- Remove the support tool.

	Description	Code	Function
1	Support	1.860.470.000	Cylinder head in vice