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

323002064 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

) CYLINDER HEAD EXTENSION1. Position cylinder head extension (1a) in a vice using tool (1b).

Tool	Description	Function	Validity
1860470000	Mount	Head overhaul

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.

Tool	Description	Function	Validity
1870896900	Templates	Engine tuning	1.3 Multijet

- Check that the camshaft endfloat is within the recommended values using a dial gauge.

Measurement	Value	Validity
Camshaft end float (mm)	0.15 ÷ 0.34	1.3 Multijet

- If the camshaft endfloat 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 in a horizontal direction and checking that it is correctly inserted in the camshaft housing.

Tool	Description	Function	Validity
1870896900	Templates	Engine tuning	1.3 Multijet

2. Undo the bolts securing the camshaft gears.

1. Remove the camshaft timing tools for the cylinder head extension.

Tool	Description	Function	Validity
1870896900	Templates	Engine tuning	1.3 Multijet

2. Release camshafts (2a) as necessary and remove camshaft gears (2b).- Completely remove the camshafts.

- Remove the support tool complete with cylinder head extension 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).

Tool	Description	Function	Validity
1860470000	Mount	Head overhaul

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 (2b) for E.G.R. system.

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 surface to support the valves, and secure it using bolts.

Tool	Description	Function	Validity
1860749000	Stand	Valve support	1.4 8v

1. Remove half-cones (1a) using tools (1b) and (1c).

Tool	Description	Function	Validity
1860644001	Lever	Removing/ refitting valves	1.4 8v1.3 Multijet

Tool	Description	Function	Validity
1870881000	Chamber	Removing/ refitting valves	1.3 Multijet

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.

Tool	Description	Function	Validity
1860749000	Stand	Valve support	1.4 8v

1. Remove valve guide oil seals (1a) using tool (1b).

Tool	Description	Function	Validity
1870894000	Calliper	Removing valve guide oil seals	1.3 Multijet

2. Remove 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 cylinder head lower surface.- Clean traces of the old gasket off the mating surfaces between the cylinder head and the cylinder head extension.- Check that the flatness of the cylinder head lower surface corresponds to the recommended values.

Measurement	Value	Validity
Cylinder head lower surface flatness (mm)	0.1	1.3 Multijet

- 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 cylinder head lower surface cannot be levelled.

Measurement	Value	Validity
Cylinder head nominal height (mm)	105.5 +/- 0.05	1.3 Multijet

- 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.

Measurement	Value	Validity
Valve stem/inlet valve diameter - exhaust (mm)	5.90 ÷ 5.94	1.3 Multijet

- Check that the length of the valve springs released is within the recommended values.

Measurement	Value	Validity
Valve spring free length (mm)	37.9	1.3 Multijet

- Using a torque wrench, check that the valve spring specifications correspond to the recommended figures; if not, replace the worn components.

Measurement	Value	Validity
Length of valve springs under a load of 16.2 - 18.0 daN (mm)	31.0	1.3 Multijet

Measurement	Value	Validity
Length of valve springs under a load of 36.1 - 39.5 daN (mm)	23.5	1.3 Multijet

- Check that the diameter of the camshaft bearings corresponds to the recommended figures; if not, replace the worn camshaft/s.

Measurement	Value	Validity
Camshaft bearing diameter - First bearing (mm)	38.500 ÷ 38.515	1.3 Multijet

Measurement	Value	Validity
Camshaft bearing diameter - Second bearing (mm)	38.000 ÷ 38.015	1.3 Multijet

Measurement	Value	Validity
Camshaft bearing diameter - Third bearing (mm)	30.000 ÷ 30.015	1.3 Multijet

- Check that the nominal camshaft cam lift corresponds to the recommended figures; if not, replace the worn camshaft.

Measurement	Value	Validity
Nominal inlet cam lift (mm)	6.4	1.3 Multijet

Measurement	Value	Validity
Nominal exhaust cam lift (mm)	7.5	1.3 Multijet

1. Check that the diameter of the camshaft supports corresponds to the recommended figures; if not, replace the cylinder head.

Measurement	Value	Validity
Camshaft support diameter - First support	38.545 ÷ 38.570	1.3 Multijet

Measurement	Value	Validity
Camshaft support diameter - Second support	38.045 ÷ 38.070	1.3 Multijet

Measurement	Value	Validity
Camshaft support diameter - Third support	30.045 ÷ 30.070	1.3 Multijet

1. Grind the valve seats to the recommended size.

Measurement	Value	Validity
Valve seat band angle in contact with valve	45° +/- 20’	1.3 Multijet

- Grind the valve seats using a suitable tool.CYLINDER HEAD- Position the cylinder head in the vice using the tool.

Tool	Description	Function	Validity
1860470000	Mount	Head overhaul

- Fit the valves in the seats, then support them using the wooden stand and secure it using suitable bolts.

Tool	Description	Function	Validity
1860749000	Stand	Valve support	1.4 8v

- Place the lower valve shims in their housings.1. Fit valve guide oil seals (1a) in their seats using tool (1b).

Tool	Description	Function	Validity
1870900800	Installing tool	Valve guide oil seal fitting	1.3 Multijet

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).

Tool	Description	Function	Validity
1860644001	Lever	Removing/ refitting valves	1.4 8v1.3 Multijet

Tool	Description	Function	Validity
1870881000	Chamber	Removing/ refitting valves	1.3 Multijet

- Carry out the same operations on the other valves.- Remove the wooden stand for supporting the valves from the cylinder head plane.

Tool	Description	Function	Validity
1860749000	Stand	Valve support	1.4 8v

- 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	Fastening	dia	Value (daNm)	Validity
Intake manifold	Bolt	M8	2.3 ÷ 2.8	1.4 8v

- 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	Fastening	dia	Value (daNm)	Validity
Exhaust gas/water heat exchanger for E.G.R. system	Bolt	M8	2.3 ÷ 2.8	1.3 Multijet

- Replace the engine oil pressure warning light switch in its housing and tighten it to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Switch for engine oil pressure warning light	-	M14	2.9 ÷ 3.5

- Replace the thermostat in its housing with the O-ring and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Thermostat	Bolt	M8	2.2 ÷ 2.7	1.3 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.

Tool	Description	Function	Validity
1860470000	Mount	Head overhaul

- Refit the glow heater plugs and tighten them to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Glow heater plug	-	M8	0.9 ÷ 1.1	1.3 Multijet

- 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	Fastening	dia	Value (daNm)	Validity
Exhaust manifold to cylinder head	Nut	M8	1.4 ÷ 1.6 +30° ± 3°	1.3 Multijet

CYLINDER HEAD EXTENSION- Position the cylinder head extension in the vice using the tool.

Tool	Description	Function	Validity
1860470000	Mount	Head overhaul

- 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 in a horizontal direction. Ensure they fit into the seats on the camshafts.

Tool	Description	Function	Validity
1870896900	Templates	Engine tuning	1.3 Multijet

2. Tighten the camshaft gear bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Camshaft gears	Bolt	M12	13.5 ÷ 16.5	1.3 Multijet

- Place the cam angle sensor back in its housing and secure it by tightening the bolt to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Cam angle sensor	Bolt	M6	0.64 ÷ 0.96	1.3 Multijet

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	Fastening	dia	Value (daNm)	Validity
Pressure pump	Bolt	M7	1.4 ÷ 1.7	1.3 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.

Component	Fastening	dia	Value (daNm)	Validity
Vacuum unit	Bolt	M8	1.8 ÷ 2.2	1.3 Multijet

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.