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

244000645 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

) 1. Fit the tool on the cylinder head and secure the tool on a vice.

	Description	Code	Function
1	Support	1.860.470.000	Cylinder head in vice

1. Undo bolts (1a) and remove pulley (1b) using tool (1c).

	Description	Code	Function
1c	Counter-torque	1.860.776.000	Timing pulley lock

1. Undo central nut (1a) and remove flange (1b) using tool (1c).

	Description	Code	Function
1c	Counter-torque	1.860.776.000	Timing pulley lock

1. Undo the bolts and nut (1a) and remove the vacuum pump (1b).

- Remove the fuel return pipe from the injector.1. Undo nut (1a) securing the injector bracket.2. Remove injector (2a), sealing ring (2b), washer (2c), bracket (2d) and support dowel (2e).- Repeat the operation for all the injectors.

If the injector is difficult to remove, after removing bracket (2d), remove stud (2f) using a counternut, then use a wrench at the point indicated to shift the injector from its seat.

3. Remove spark plug supply lead (3a) and spark plugs (3b).

1. Undo the twelve bolts in the order indicated.

1. Remove the cylinder head extension (1a), camshaft (1b) and oil sealing ring (1c).

1. Remove rocker (1a) and tappet (1b).- Repeat the operation for all rocker-tappet assemblies.

Mark each rocker-tappet pair to allow correct assembly.

1. Fit the tool beneath the cylinder head.

	Description	Code	Function
1	Valve retaining base	1.860.804.000	Valve retention

2. Remove half-cones (2a) from the valve using tools (2b).

	Description	Code	Function
2b	Tool	1.860.644.000	Removing/refitting valves

	Description	Code	Function
2b	Tool	1.860.877.000	Removing/refitting valves

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

	Description	Code	Function
.	Valve retaining base	1.860.804.000	Valve retention

4. Remove all the valves.

Mark each valve and associated components to allow correct fitting.

1. Remove valve stem sealing ring (1a) using tool (1b).

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

- Repeat the operation for all the valve stem sealing rings.

1. Remove the lubrication circuit check valve.

1. Remove the valve guides from their seats using the tool.

	Description	Code	Function
1	Extractor	1.860.939.000	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 the ports thoroughly.1. Check the lower surface and check that flatness is within specified limits.

	Subject	Value
1	CYLINDER HEAD	mm
-	Flatness	0,05

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

	Subject	Value
1	CYLINDER HEAD	mm
-	Height	132,95 - 133,05

- if cylinder head flatness and/or height are not within the specified limits, grind the lower surface without exceeding the minimum pemitted height.

	Subject	Value
.	CYLINDER HEAD	mm
-	Minimum permitted height	132,55 - 132,65

If the height is lower than the minimum level, 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 intake angle	25°

	Subject	Value
.	VALVE SEATS	mm
-	Intake valve contact band width	1,00

	Subject	Value
.	VALVE SEATS	mm
-	Exhaust valve contact band width	2,25

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

- If it is not possible to achieve centred, uniform contact between valve and seat, replace the valve seat.- Ream the valve guide seats using a suitable tool.

	Subject	Value
.	VALVE GUIDES	mm
-	Oversize valve guide seat diameter	12,398 - 12,521

1. Press-fit new and oversize valve guides (1a) from the upper part of the cylinder head using tool (1b).

	Description	Code	Function
1b	Fitting tool	1.870.768.000	Valve guide fitting

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

1. Check that valve guide position is within specified limits

	Subject	Value
1	VALVE GUIDES	mm
-	Distance between valve guide - lower cylinder head surface	34,50 - 35,50

- Ream the valve guides using a suitable tool.1. Check that the valve specifrications correspond to the recommended limits; if not, replace the valves.

	Subject	Value
1a	INLET VALVES	mm
-	Stem diameter	5,971 - 5,985

	Subject	Value
1b	INLET VALVES	mm
-	Head diameter	35,5 - 35,7

	Subject	Value
1c	INLET VALVES	mm
-	Height	106,78 - 107,18

	Subject	Value
1d	INLET VALVES	mm
-	Contact angle	45° - 45° 7'30"

	Subject	Value
1a	EXHAUST VALVES	mm
-	Stem diameter	5,961 - 5,975

	Subject	Value
1b	EXHAUST VALVES	mm
-	Head diameter	33,7 - 33,9

	Subject	Value
1c	EXHAUST VALVES	mm
-	Height	107,18 - 106,78

	Subject	Value
1d	EXHAUST VALVES	mm
-	Contact angle	45° - 45°7'30"

1. Check that valve protrusion (1a) in relation to the cylinder head surface meets specified limits using tool (1b).

	Description	Code	Function
1b	Dial gauge support	1.870.404.000	Injector projection from cylinder head plane measurement

Make four diametrically opposed measurements and use the average reading.

	Subject	Value
.	CYLINDER HEAD VALVES (ALL)	mm
-	Protrusion from lower cylinder head surface	0,20

- Repeat the operation for each valve.- Fit the valves, injectors and glow plugs provisionally as described below.1. Test the valve seal using tool (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 spring specifications correspond to the recommended figures; if not, replace the worn springs.

	Subject	Value
.	EXTERNAL VALVE SPRING
-	Length	37,0 mm
-	Under a load of	24,700-27,300 daN

	Subject	Value
.	EXTERNAL VALVE SPRING
-	Length	27,7 mm
-	Under a load of	43,225-47,775 daN

- Fit the cylinder head extension together with the camshaft as described below.- Tighten the ten retaining bolts to the specified torque as described below.

	Value - daNm	Fastening	Component	Ø
.	1,0	Bolt	CYLINDER HEAD EXTENSION FASTENERS	-

1. Check that the axial clearance is within specified limits.

	Subject	Value
1	CAMSHAFT INTAKE AND EXHAUST	mm
-	End float	0,08 - 0,38

- Remove the bolts, cylinder head extension and camshaft.- Fit the tool on the cylinder head and secure the tool on a vice.

	Description	Code	Function
.	Support	1.860.470.000	Cylinder head in vice

- Fit the lubrication circuit check valve.1. Fit all the valves in the valve guide.2. Fit the tool beneath the cylinder head.

	Description	Code	Function
2	Valve retaining base	1.860.804.000	Valve retention

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

	Description	Code	Function
1b	Fitting tool	1.860.993.000	Fitting oil seals on valve stems

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

	Description	Code	Function
2b	Tool	1.860.644.000	Removing/refitting valves

	Description	Code	Function
2b	Tool	1.860.877.000	Removing/refitting valves

- Repeat the operation for all the valves.- Fit the tappet and rockers, respecting the marks made upon disassembly.- Repeat the operation for all rocker-tappet assemblies.1. Apply silicone sealant to the cylinder head extension mating surfaces.

	Description	Qty.	Component	Type	Classification
.	DOW CORNING, 7091	-	CYLINDER HEAD EXTENSION	Silicone sealant	-

- Fit the cylinder head extension together with the camshaft.1. Tighten the twelve bolts (1a) to the specified torque in the order indicated.

	Value - daNm	Fastening	Component	Ø
1	1,0	Bolt	CYLINDER HEAD EXTENSION FASTENERS	-

1. Lubricate and, if necessary, replace the seals (1a) and the oil filter (1b).2. Fit the vacuum unit and tighten the bolts (2a) and the nut (2b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2a	4,3	Bolt	BRAKING SYSTEM BRAKES	-

	Value - daNm	Fastening	Component	Ø
2b	4,3	Nut	BRAKING SYSTEM BRAKES	-

1. Fit the oil sealing ring (1a) using the tool (1b)

	Description	Code	Function
1b	Fitting tool	1.860.990.000	Camshaft front oil seal

- Fit the camshaft pulley flange, centring the drive tooth.- Tighten the central flange retaining nut to the specified torque using the tool.

	Description	Code	Function
.	Counter-torque	1.860.776.000	Timing pulley lock

	Value - daNm	Fastening	Component	Ø
.	4,3	Nut	TIMING PULLEY FLANGE	-

- Check spark plug continuity using a multimeter.1. Fit spark plugs (1a), tighten to the specified torque and fit spark plug supply lead (1b).

	Value - daNm	Fastening	Component	Ø
1a	2,3	Spark plug	GLOW PLUGS	-

2. Fit the shim (2a), sealing ring (2b) and injector (2c) in order3. Fit support dowel (3a), bracket (3b) and tighten nut (3c) to the specified torque.

	Value - daNm	Fastening	Component	Ø
3c	2,3	Nut	INJECTORS(DIESEL)	-

- Repeat the operation for all the injectors.4. Fit the fuel return pipe.