244000645 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

- Proceed with the DISMANTLING.- Place the head on a workbench.1. Fit the tool (1a) on the cylinder head (1b) and secure it using the nuts (1c), then place the tool (1a) in a vice.
DescriptionCodeFunction
1aCounter-torque1.860.765.001Loosen/tighten auxiliary shaft toothed drive pulley bolt
1. Fit the tool.
DescriptionCodeFunction
1Counter-torque1.860.765.001Loosen/tighten toothed timing drive pulley bolt
2. Undo the fixing bolts (2a) and remove the driven timing pulley (2b).3. Undo the fixing nuts (3a) and remove the front cover (3b).
1. Undo the nuts fixing the camshaft caps.2. Remove the camshaft caps.3. Remove the camshaft.4. Remove the tappets.
1. Undo the nuts (1a) and remove the fuel distribution manifold cover (1b).2. Remove the fuel distribution manifold.
1. Undo the bolts (1a) and remove the thermostat unit (1b).2. Remove the seal.3. Undo the fixing bolts (3a) and remove the bracket (3b).4. Undo the fixing bolts (4a) and remove the cover (4b).5. Undo the fixing nuts (5a) and remove the bracket (5b).
- 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.- Refit the cylinder head in the vice.1. Remove the cotters (1a) using the tool (1b).
DescriptionCodeFunction
1bTool1.860.644.000Removing/refitting valves
2. Remove the valve upper shim.3. Remove the outer valve spring (3a) and the inner one (3b).
1. Remove the valve guide oil seal (1a) using the tool (1b).
DescriptionCodeFunction
1bExtractor1.860.989.000Valve guide oil seal extraction
2. Remove the lower shim.- Carry out the same operations on the other valves.- Remove the cylinder head from the vice.- Remove the wooden stand and keep the valves.- Remove the support tool from the cylinder head.
DescriptionCodeFunction
.Support1.860.470.000Cylinder head in vice
See in Op. 1016E14- Proceed with the REASSEMBLY- 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.
SubjectValue
.Cylinder headmm
-Lower plane planarity0.1
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.
SubjectValue
1Cylinder headmm
-Minimum permitted height149,5 - 149,7
- 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.
SubjectValue
.Cylinder head valves (all)mm
-Stem diameter7,985 - 8,000
See in Op. 1016E14- Check that the tappet outer diameter corresponds to the recommended figures; if not, replace the tappets with oversize ones.
SubjectValue
.Cylinder head camshaft tappet casesmm
-Outer diameter43,950 - 43,970
-Outer diameter oversize44,150 - 44,170
This operation involves replacing the cylinder head with one with oversize tappet housings.
- Check that the diameter of the tappet housings corresponds to the recommended figures; if not, replace the cylinder head.
SubjectValue
.Engine cylinder headmm
-Tappet housing diameter44,000 - 44,025
-Tappet housing diameter oversize44,200 - 44,225
- Using a torque wrench, check that the spring specifications correspond to the recommended figures; if not, replace the worn components.
SubjectValue
.Inner valve spring
-Length mm33,5
-under a load of daN15,4 - 17,4
SubjectValue
.Inner valve spring
-Length mm23,5
-under a load of daN28,5 - 38,5
SubjectValue
.Inner valve spring
-Length mm38,5
-under a load of daN41,3 - 46,3
SubjectValue
.Inner valve spring
-Length mm28,5
-under a load of daN73,4 - 81,4
1. Reface the valve seats to the recommended figure using a suitable tool.
SubjectValue
1Cylinder head valve seats (all)
-Contact band angle with inlet valve29° 55' - 30° 05'
-Contact band angle with exhaust valve44° 55' - 45° 05'
SubjectValue
2Cylinder head valve seats (all)
-Inlet/exhaust manifold outlet angle20°
SubjectValue
3Cylinder head valve seats (all)
-Inlet/exhaust manifold inlet angle75°
- Temporarily fit the injectors.1. Check that the injector projection in relation to the cylinder head plane (1a) corresponds to the recommended figures using the tool (1b) fitted with a dial gauge.
SubjectValue
.Injectors (DIESEL)mm
-Projection from cylinder head plane2,230 - 2,690
DescriptionCodeFunction
1bDial gauge support1.870.404.000Injector projection from cylinder head plane measurement
2. If the projection of the injectors in relation to the cylinder head plane does not correspond to the recommended figures, fit an approriate oversize washer in the injector seat.
- Remove the injectors.- Temporarily fit the valves.1. Check that the valve recess in relation to the cylinder head plane (1a) corresponds to the recommended figures using the tool (1b) fitted with a dial gauge.
SubjectValue
1aCylinder head valves (all)
-Valve recess in relation to cylinder head planemm
-inlet1,2 - 1,5
-exhaust1,0 - 1,3
DescriptionCodeFunction
1bDial gauge support1.870.404.000Valve 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.
- Remove the valves.- Check that the nominal camshaft cam lift corresponds to the recommended figures; if not, replace the worn camshaft.
SubjectValue
.INTAKE AND EXHAUST CAMSHAFT
-Nominal cam liftmm
-inlet9,5
-exhaust10,5
- Check that the diameter of the camshaft bearings corresponds to the recommended figures; if not, replace the worn camshaft with an oversize one.
SubjectValue
.INTAKE AND EXHAUST CAMSHAFTmm
-Journal diameter33,934 - 33,950
SubjectValue
.INTAKE AND EXHAUST CAMSHAFTmm
-Journal diameter oversize0,20
This operation involves regrinding the camshaft supports as described below.
- Fit the camshaft caps (1a) on the cylinder head and tighten the nuts (1b) to the recommended torque.
Value - daNmFasteningComponentØ  
.1,8NutCAMSHAFT SUPPORTSM8
follow the progressive numbering for the camshaft caps (1 = timing pulley side) and position the caps so that the numbers stamped on them are legible from the injector side.
- Check that the camshaft support diameter corresponds to the recommended figures; if not, proceed with the regrinding using the recommended oversize.
SubjectValue
.Camshaft capsmm
-Support diameter33,985 - 34,015
SubjectValue
.Camshaft capsmm
-Support diameter oversize0,20
The camshaft supports should all be reground to the same oversize.
This operation involves replacing the camshaft with an oversize one.
- Fit the support tool on the cylinder head and secure it using the nuts.
DescriptionCodeFunction
.Support1.860.470.000Cylinder head in vice
- Fit all the valves.- 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. Fit the valve guide oil seal (1a) using the tool (1b).
DescriptionCodeFunction
1bFitting tool1.860.313.000Valve guide oil seal fitting.
1. Fit the inner valve spring (1a) and the outer one (1b).2. Fit the valve upper shim.3. Fit the cotters (3a) using the tool (3b).
DescriptionCodeFunction
3bTool1.860.644.000Removing/refitting valves
- 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 tappets complete with valve clearance adjustment pads.- Fit the camshaft.1. Fit the camshaft caps.2. Tighten the camshaft cap bolts to the recommended torque.
Value - daNmFasteningComponentØ  
.1,8NutCAMSHAFT SUPPORTSM8
follow the progressive numbering for the camshaft caps (1 = timing pulley side) and position the caps so that the numbers stamped on them are legible from the injector side.
1. Fit the front oil seal on the camshaft cover (1a) using the tools (1b) and (1c).
DescriptionCodeFunction
1bFitting tool1.860.623.000Camshaft front oil seal fitting
DescriptionCodeFunction
1cGrip1.870.007.000Camshaft front oil seal fitting
2. Fit the front cover applying sealant and tighten the fixing nuts to the recommended torque.
Value - daNmFasteningComponentØ  
20.75NutINLET AND EXHAUST CAMSHAFT FRONT COVERM6
3. Fit the bracket tightening the fixing nuts.4. Fit the cover applying sealant and tightening the fixing bolts.5. Fit the bracket tightening the fixing nuts.
- Fit the tool.
DescriptionCodeFunction
.Counter-torque1.860.765.001Loosen/tighten toothed timing drive pulley bolt
- Fit the toothed driven pulley and tighten the fixing bolts to the recommended torque.
Value - daNmFasteningComponentØ  
.2,5BoltTIMING DUCT PULLEYM8
- Remove the tool.
DescriptionCodeFunction
.Counter-torque1.860.765.001Loosen/tighten toothed timing drive pulley bolt
1. 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.
SubjectValue
.Cylinder head valves (all)
-Inlet valves clearance in closed positionmm
-inlet0,45 - 0,55
-exhaust0,45 - 0,55
2. Lower the tappet in question using the tool.
DescriptionCodeFunction
2Lever1.860.443.000Lower tappets
3. Fit the tool.
DescriptionCodeFunction
3Lever1.860.724.001Keep tappets lowered
- Remove the tool.
DescriptionCodeFunction
.Lever1.860.443.000Lower tappets
4. Remove the valve clearanance adjustment plate and replace it with a one of a suitable thickness.- Remove the tool.
DescriptionCodeFunction
.Lever1.860.724.001Keep tappets lowered
1. Remove the seal.2. Fit the thermostat (2a) complete with pipes and tighten the bolts (2b) to the recommended torque.
Value - daNmFasteningComponentØ  
2b1,8BoltTHERMOSTATM8
- Fit the fuel distribution manifold complete with pipes and fuel pressure sensor and tighten the nuts.- Remove the cylinder head from the vice.- Remove the support tool from the cylinder head.
DescriptionCodeFunction
.Support1.860.470.000Cylinder head in vice