312002368 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

Removing ( Refitting ) CYLINDER HEAD EXTENSION1. Position cylinder head extension (1a) in a vice using tool (1b).
ToolDescriptionFunctionValidity
1.860.470.000MountHead overhaulall versions
1. Undo bolts (1a) and remove vacuum pump (1b).2. Remove the gasket.3. Undo bolts (3a) and remove pressure pump (3b) complete with O-ring.4. Remove the joint.
1. Undo bolt (1a) and remove cam angle sensor (1b).
- Temporarily remove the tool fitted previously on the exhaust side camshaft.
ToolDescriptionFunctionValidity
1.870.896.900TemplatesEngine tuning1.3 Mjet
- Check that the camshaft endfloat is within the recommended values using a dial gauge.
MeasurementValueValidity
Camshaft end float (mm)0.15 ÷ 0.341.3 Mjet
- If the camshaft endfloat value is not within the recommended values, replace the worn components when reassembling the cylinder head.1. Remove plug (1a) and fit tool (1b) on the intake side camshaft.
Fit the tool, positioning it with the millings horizontal and checking that it is correctly inserted in the camshaft housing.
ToolDescriptionFunctionValidity
1.870.896.900TemplatesEngine tuning1.3 Mjet
2. Undo the bolts securing the camshaft gears.
1. Remove the camshaft timing tools for the cylinder head extension.
ToolDescriptionFunctionValidity
1.870.896.900TemplatesEngine tuning1.3 Mjet
2. Release camshafts (2a), as necessary and remove camshaft gears (2b).- Completely remove the camshafts.
- Remove the support tool complete with camshaft housing from the vice and separate them. CYLINDER HEAD1. Undo nuts (1a) and remove exhaust manifold (1b).2. Remove the exhaust manifold gasket.3. Unscrew the glow heater plugs and remove.
1. Position cylinder head (1a) in a vice using tool (1b).
ToolDescriptionFunctionValidity
1.860.470.000MountHead overhaulall versions
2. Remove the valve rockers.3. Remove the hydraulic tappets.4. Remove the cylinder head extension locating bushes.
1. Loosen the collars and remove the coolant delivery sleeve from the thermostat to the coolant/exhaust gas heat exchanger for the EGR system.2. Undo bolts (2a) and remove thermostat (2b) complete with O-ring.3. Undo and remove the engine oil pressure warning light switch.
1. Loosen the collar securing the exhaust gas/coolant heat exchanger for the EGR system, air chamber side.2. Undo bolts (2a) and remove coolant/exhaust gas heat exchanger for E.G.R. system (2b).
1. Release the engine oil vapour recirculation pipe for the retaining band on the air capacity chamber.2. Unscrew bolts (2a) and remove engine oil vapour separator (2b) complete with engine oil vapour recirculation pipe (2c).
1. Undo bolts (1a) and remove air capacity chamber (1b) complete with excess pressure sensor.2. Remove the gasket.
1. Fit a wooden stand on the cylinder head plane to support the valves and secure it using bolts.
ToolDescriptionFunctionValidity
1.860.749.000StandValve support1.2 8V1.3 Mjet
1. Remove half-cones (1a) using tools (1b) and (1c).
ToolDescriptionFunctionValidity
1.860.644.001LeverRemoving/ refitting valves1.2 8V1.3 Mjet
ToolDescriptionFunctionValidity
1.870.881.000ChamberRemoving/ refitting valves1.3 Mjet
2. Remove the valve upper shim.3. Remove the valve spring.
- Carry out the same operations on the other valves.- Remove the wooden stand and keep the valves.
ToolDescriptionFunctionValidity
1.860.749.000StandValve support1.2 8V1.3 Mjet
1. Remove valve guide oil seals (1a) using tool (1b).
ToolDescriptionFunctionValidity
1.870.894.000CalliperRemoving valve guide oil seals1.3 Mjet1.4 16V
2. Fit the lower valve shims.
- Remove the cylinder head from the support tool.- Replace the valve guides    Op. 1016E14 VALVE GUIDES IN SINGLE CYLINDER HEAD - REPLACE DURING OP. 1016E10 Refitting ( Removing ) - Clean any traces of the old gasket from the lower cylinder head surface.- Clean traces of the oil gasket off the mating surfaces between the cylinder head and the cylinder head extension.- Check that the flatness of the lower cylinder head surface corresponds to the recommended values.
MeasurementValueValidity
Cylinder head lower support surface flatness (mm)0.11.3 Mjet
- If the lower surface flatness of the lower cylinder head is not within the specified values, grind from the nominal head height and then fit a new gasket with the number of notches determined as described below.- The head may be levelled to 0.1 m if starting from a gasket with 0 notches and using a new gasket with 1 notch.- The head may be levelled to 0.2 m if starting from a gasket with 0 notches and using a new gasket with 2 notches.- The head may be levelled to 0.1 m if starting from a gasket with 1 notch and using a new gasket with 2 notches.
When within limit conditions (head gasket with 2 notches before levelling), the lower cylinder head surface cannot be levelled.
MeasurementValueValidity
Cylinder head nominal height (mm)105.5 ± 0.051.3 Mjet
- 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.
MeasurementValueValidity
Valve stem/inlet valve diameter - exhaust (mm)5.90 ± 5.941.3 Mjet
- Check that the length of the valve springs released is within the recommended values.
MeasurementValueValidity
Valve spring free length (mm)37.91.3 Mjet
- Using a torque wrench, check that the valve spring specifications correspond to the recommended figures; if not, replace the worn components.
MeasurementValueValidity
Length of valve springs under a load of 16.2 - 18.0 daN (mm)31.01.3 Mjet
MeasurementValueValidity
Length of valve springs under a load of 36.1 - 39.5 daN (mm)23.51.3 Mjet
- Check that the diameter of the camshaft bearings corresponds to the recommended figures; if not, replace the worn camshaft/s.
MeasurementValueValidity
Camshaft bearing diameter - First bearing (mm)38.500 ÷ 38.5151.3 Mjet
MeasurementValueValidity
Camshaft bearing diameter - Second bearing (mm)38.000 ÷ 38.0151.3 Mjet
MeasurementValueValidity
Camshaft bearing diameter - Third bearing (mm)30.000 ÷ 30.0151.3 Mjet
- Check that the nominal camshaft cam lift corresponds to the recommended figures; if not, replace the worn camshaft/s.
MeasurementValueValidity
Nominal inlet cam lift (mm)6.41.3 Mjet
MeasurementValueValidity
Nominal exhaust cam lift (mm)7.51.3 Mjet
1. Check that the diameter of the camshaft supports corresponds to the recommended figures; if not, replace the cylinder head.
MeasurementValueValidity
Camshaft support diameter - First support38.545 ÷ 38.5701.3 Mjet
MeasurementValueValidity
Camshaft support diameter - Second support38.045 ÷ 38.0701.3 Mjet
MeasurementValueValidity
Camshaft support diameter - Third support30.045 ÷ 30.0701.3 Mjet
1. Grind the valve seats to the recommended size.
MeasurementValueValidity
Valve seat band angle in contact with valve45° ± 20'1.3 Mjet
- Grind the valve seats using a suitable tool.CYLINDER HEAD- Position the cylinder head in the vice using the tool.
ToolDescriptionFunctionValidity
1.860.470.000MountHead overhaulall versions
- Fit the valves in the seats, then support them using the wooden stand and secure it using suitable bolts.
ToolDescriptionFunctionValidity
1.860.749.000StandValve support1.2 8V1.3 Mjet
- Place the lower valve shims in their housings.1. Fit valve guide oil seals (1a) in their seats using tool (1b).
ToolDescriptionFunctionValidity
1.870.900.800Installing toolValve guide oil seal fitting1.3 Mjet
1. Fit the valve spring in its seat.2. Refit the upper valve shim.3. Place half-cones (3a) in their housings using tools (3b) and (3c).
ToolDescriptionFunctionValidity
1.860.644.001LeverRemoving/ refitting valves1.2 8V1.3 Mjet
ToolDescriptionFunctionValidity
1.870.881.000ChamberRemoving/ refitting valves1.3 Mjet
- Carry out the same operations on the other valves.- Remove the wooden stand for supporting the valves from the cylinder head plane.
ToolDescriptionFunctionValidity
1.860.749.000StandValve support1.2 8V1.3 Mjet
- Refit the air chamber complete with gasket and excess pressure sensor back in its housing and secure it by tightening the bolts to the recommended torque.
Component Fasteningdia  Value (daNm)Validity
Intake manifold (on cylinder head)BoltM8x1.25x652.51.3 Multijet
Component Fasteningdia  Value (daNm)Validity
Intake manifold (on cylinder head)BoltM8x1.25x202.51.3 Multijet
- Replace the engine oil vapour separator with engine oil vapour recirculation pipe in its seat and secure with bolts.- Fasten the engine oil vapour recirculation pipe to the band on the air capacity chamber.- Place the exhaust gas/coolant heat exchanger for the E.G.R. system, complete with gasket, back in its housing and secure it by tightening the bolts to the specified torque.
Component Fasteningdia  Value (daNm)Validity
E.G.R. valve (on cylinder head)BoltM8x1.25x902.21.3 Multijet
- Replace the engine oil pressure warning light switch in its housing and tighten it to the recommended torque.
Component Fasteningdia  Value (daNm)Validity
Engine oil pressure switch-M14x1.53.2all versions
- Replace the thermostat in its housing with the O-ring and secure it by tightening the bolts to the recommended torque.
Component Fasteningdia  Value (daNm)Validity
Thermostat unit (on cylinder head)BoltM8x1.25x222.51.3 Multijet
- Replace the coolant delivery sleeve from the thermostat to the coolant/exhaust gas heat exchanger for the EGR system and secure with the relevant bands.- Refit the cylinder head extension locating bushes in their seats in the cylinder head.
Before fitting the locating bushes, check that the height is 13 mm.
- Place the hydraulic tappets in their housings.
Position the hydraulic tappets with the oil channel hole turned toward the outside of the cylinder head: this position brings the hole into communication with the oil duct on the lower cylinder head.
- Place the valve rockers in their housings.- Remove the cylinder head from the support tool.
ToolDescriptionFunctionValidity
1.860.470.000MountHead overhaulall versions
- Place the glow heater pugs in their housings.- Place the exhaust manifold gasket in its housing.- Place the exhaust manifold in its housing and secure it by tightening the nuts to the recommended torque.
Component Fasteningdia  Value (daNm)Validity
Exhaust manifold (on cylinder head)NutM8x1.251.5 + 30°1.3 Multijet
CYLINDER HEAD EXTENSION- Position the cylinder head extension in the vice using the tool.
ToolDescriptionFunctionValidity
1.860.470.000MountHead overhaulall versions
- Place the camshafts in their housings.- Refit the camshaft gears in their housings and secure them without tightening the bolts.1. Fit the camshaft timing tools.
Fit the tools and position with their millings horizontal. Ensure they fit into the seats on the camshafts.
ToolDescriptionFunctionValidity
1.870.896.900TemplatesEngine tuning1.3 Mjet
2. Tighten the camshaft gear bolts to the recommended torque.
Component Fasteningdia  Value (daNm)Validity
Camshsaft idler gear (inlet side)BoltM12x1.25x3315.01.3 Multijet
Component Fasteningdia  Value (daNm)Validity
Camshsaft idler gear (exhaust side)BoltM12x1.25x3315.01.3 Multijet
- Position the cam angle sensor in its housing and secure it using the bolt.1. Position pressure pump (1a), complete with coupling (1b) and a new o-ring, in its housing and secure it by tightening bolts (1c) to the recommended torque.
Component Fasteningdia  Value (daNm)Validity
Injection pumpBoltM7x1x201.51.3 Multijet
2. Place vacuum pump (2a), complete with gasket (2b), back in its housing and secure it by tightening bolts (2c) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Vacuum pump (on cylinder head extension)BoltM8X1,25X222.0T.i.T
Follow the order shown in the diagram for each tightening sequence. The tightening to 2.0 daNm is performed in two stages: a pre-tightening to 0.5 daNm followed by an additional tightening of 1.8 - 2.2 daNm.
- Remove the support tool complete with cylinder head extension from the vice and separate them.