244000645 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

Removing ( Refitting ) - Fit the tool to the cylinder head and secure in the vice.
DescriptionCodeFunction
.Support1.860.470.000Cylinder 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.
DescriptionCodeFunction
1Valve retaining base1.860.804.000Valve retention
2. Remove semicones (2a) from the valve using tools (2b).
DescriptionCodeFunction
2bTool1.860.644.000Removing/refitting valves
DescriptionCodeFunction
2bTool1.860.644.030Removing/refitting valves
3. Remove upper plate (3a), spring (3b) and lower plate (3c) in order.- Repeat the operation for all valves.- Remove the tool.
DescriptionCodeFunction
.Valve retaining base1.860.804.000Valve 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.
DescriptionCodeFunction
1Extractor1.860.792.000Valve 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.
DescriptionCodeFunction
1Drift1.860.395.000Valve guide extraction
- Remove the cylinder head from the tool.
DescriptionCodeFunction
.Support1.860.470.000Cylinder head in vice
Refitting ( Removing ) - Clean all ducts thoroughly.1. Check the lower surface and ensure that flatness is within specified limits.
SubjectValue
1CYLINDER HEADmm
-Flatness0,05
- Fit the camshaft and caps provisionally.- Tighten the nuts to the recommended torque.
Value - daNmFasteningComponentØ  
.1,6NutCAMSHAFT CAPS-
1. Check that cylinder head height is within recommended limits.
SubjectValue
1CYLINDER HEADmm
-Height140,95 - 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.
SubjectValue
.CYLINDER HEADmm
-Cylinder head height reduction0,20
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.
SubjectValue
1aVALVE SEATS
-Contact band angle with intake valve45°
SubjectValue
1bVALVE SEATS
-Intake port outlet angle65°
SubjectValue
1cVALVE SEATS
-Intake port intake angle25°
2. Grind the exhaust valve seats using a suitable tool.
SubjectValue
2aVALVE SEATS
-Contact band angle with intake valve45°
SubjectValue
2bVALVE SEATS
-Exhaust port outlet angle65°
SubjectValue
2cVALVE SEATS
-Exhaust port intake angle20°
SubjectValue
.VALVE SEATSmm
-Intake valve contact band width1,70
-Exhaust valve contact band width2,20
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.
SubjectValue
1aVALVE SEATSmm
-Intake valve seat housing diameter, 1st oversize42,3
-Intake valve seat housing diameter, 2nd oversize42,5
SubjectValue
1aVALVE SEATSmm
-Exhaust valve seat housing diameter, 1st oversize36,3
-Exhaust valve seat housing diameter, 2nd oversize36,5
SubjectValue
1bVALVE SEATSmm
-Intake valve seat housing height15,98
-Exhaust valve seat housing height15,25
Measure the housing height from the lower cylinder head surface.
SubjectValue
1cVALVE SEATSmm
-Intake valve seat diameter, 1st oversize42,4
-Intake valve seat diameter, 2nd oversize42,6
SubjectValue
1cVALVE SEATSmm
-Exhaust valve seat diameter, 1st oversize36,4
-Exhaust valve seat diameter, 2nd oversize36,6
SubjectValue
1dVALVE SEATSmm
-Oversize intake valve seat height8,40
-Oversize exhaust valve seat height7,35
- Ream the valve guide seats using a suitable tool.
SubjectValue
.VALVE GUIDESmm
-Valve guide seat diameter, 1st oversize13,195 - 13,227
-Valve guide seat diameter, 2nd oversize13,495 - 13,527
1. Press-fit new valve guides (1a) from the top of the cylinder head using tool (1b).
DescriptionCodeFunction
1bFitting tool1.870.751.000Valve 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.
SubjectValue
1VALVE GUIDESmm
-Gap between intake valve guide - lower cylinder head surface43,65 - 44,35
-Gap between exhaust valve guide - lower cylinder head surface38,05 - 38,75
- Ream the valve guides using an appropriate tool
SubjectValue
.VALVE GUIDESmm
-Valve guide bore8,000 - 8,022
1. Check that the valve specifications are within specified limits; if not, replace the valves.
SubjectValue
1aINLET VALVESmm
-Stem diameter7.965 - 7,980
SubjectValue
1bINLET VALVESmm
-Head diameter41,4 - 41,8
SubjectValue
1cINLET VALVESmm
-Height108,8, mm
SubjectValue
1dINLET VALVES
-Contact angle45°
SubjectValue
1aEXHAUST VALVESmm
-Stem diameter7.955 - 7,970
SubjectValue
1bEXHAUST VALVESmm
-Head diameter34,3 - 34,7
SubjectValue
1cEXHAUST VALVESmm
-Height108,4
SubjectValue
1dEXHAUST VALVES
-Contact angle45°30'
- Fit the valves and spark plugs provisionally as described later.1. Carry out a valve leak test using tools (1a) and (1b).
DescriptionCodeFunction
1aLever1.860.490.000Valve leakage test
DescriptionCodeFunction
1bSealing pad with pressure gauge1.895.868.000Valve leakage test
- Using a torque wrench, check that the valve spring specifications meet specified limits; if not, replace the springs.
SubjectValue
.EXTERNAL VALVE SPRING
-Length54,5 mm
-Under a load of0 daN
SubjectValue
.EXTERNAL VALVE SPRING
-Length42,5 mm
-Under a load of39 daN
SubjectValue
.EXTERNAL VALVE SPRING
-Length31,0 mm
-Under a load of85 daN
- Fit the tool to the cylinder head and secure in the vice.
DescriptionCodeFunction
.Support1.860.470.000Cylinder 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.
DescriptionCodeFunction
2Valve retaining base1.860.804.000Valve retention
1. Fit the sealing ring (1a) into its seat using tool (1b).
DescriptionCodeFunction
1bFitting tool1.860.313.000Valve 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).
DescriptionCodeFunction
2bTool1.860.644.030Removing/refitting valves
DescriptionCodeFunction
2bTool1.860.644.000Removing/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 - daNmFasteningComponentØ  
2b1,6NutCAMSHAFT CAPS-
- Fit the timing gear provisionally.1. 1. Position each cam upright and check the clearance is within specified limits.
SubjectValue
.VALVE TAPPETSmm
-Inlet valve clearance check0,15 - 0,25
-Exhaust valve clearance check0,35 - 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 - daNmFasteningComponentØ  
2b1,6NutCAMSHAFT CAPS-
1. Press-fit the lubrication pipe (1a) and the sealing rings (1b).