74688 - 1016E10 SINGLE CYLINDER HEAD, removed - Overhaul

Removing ( Refitting ) 1. Position the cylinder head (1a) in a vice using the tool (1b).

	Description	Code	Function
1b	Support	1.860.470.000	Cylinder head support

- Unscrew the heater plugs and remove them.1. Disconnect the engine temperature sensor wiring.

	Description	Connector
1	I.E. engine temperature sensor	K045

2. Disconnect the engine coolant pipe, thermostat side. - Disconnect the electrical connection for the cam angle sensor.

	Description	Connector
.	Timing sensor	K047

1. Undo the fixing bolts (1a) and nuts (1b) and disconnect the earth lead (1c). 1. Undo the bolts fixing the intake chamber to the manifold.2. Disconnect the bands (2b) joining the intake chamber to the hoses connected to the intake manifold.3. Remove the intake chamber. 1. Undo the fixing bolt (1a) and the nuts (1b) and remove the intake manifold (1c), complete with hoses (1d) connected to the intake chamber and the throttle casing.2. Remove the seal. 1. Undo the bolts (1a) and remove the thermostat (1b).- Remove the gasket. 1. Undo the bolt (1a) for the exhaust side timing driven pulley using the tools (1b) and (1c) for counter-torque.

	Description	Code	Function
1b	Support for counter-torque	1.860.831.000	Loosen/tighten bolt fixing exhaust side driven timing pulley

	Description	Code	Function
1c	Counter-torque	1.860.848.000	Loosen/tighten bolt fixing exhaust side driven timing pulley

2. Remove the exhaust side timing driven pulley.3. Undo the inlet side timing driven pulley bolts (3a) using the tool (3b) for counter-torque.

	Description	Code	Function
3b	Counter-torque	1.860.856.000	Loosen/tighten bolts fixing inlet side toothed driven timing pulley

4. Remove the inlet side timing driven pulley.5. Undo the bolts (5a) and remove the side timing belt guards (5b). 1. Undo the bolt (1a) and remove the cam angle sensor (1b).2. Undo the bolts (2a) and remove the water pump (2b) complete with O-ring (2c). - Check that the camshaft endfloat corresponds to the recommended values using a dial gauge on a magnetic base.

	Subject	Value
.	Cyliner head inlet and exhaust shafts	mm
-	End float	0.10 - 0.23

- If the endfloat for the camshafts does not correspond to the recommended values, replace the worn components when reassembling the cylinder head. 1. Undo the bolts (1a) and remove the camshaft caps (1b).2. Remove the inlet side camshaft front supper upper half-bearing.3. Remove the camshafts.4. Remove the camshaft front oil seals.5. Remove the inlet side camshaft front support lower half-bearing. 1. Remove the cotters (1a) using the tools (1b), (1c), (1d), (1e) and (1f).

	Description	Code	Function
1b	Valve support	1.860.786.000	Removing/refitting valves

	Description	Code	Function
1c	Special nut	1.860.787.000	Removing/refitting valves

	Description	Code	Function
1d	Support	1.860.788.000	Removing/refitting valves

	Description	Code	Function
1e	Chamber	1.860.840.000	Removing/refitting valves

	Description	Code	Function
1f	Lever	1.860.790.000	Removing/refitting valves

2. Remove the valve upper shim.3. Remove the valve springs.- Remove the tools used for dismantling the valves.4. Remove the valve.- Carry out the same operations for removing the remaining valves. 1. Remove the valve guide oil seal (1a) using the tool (1b).

	Description	Code	Function
1b	Extractor	1.860.989.000	Removing valve guide oil seal

2. Remove the lower valve shim. 1. Remove the valve guides (1a) using the tool (1b).

	Description	Code	Function
1b	Extractor	1.860.395.000	Valve guide extraction

Refitting ( Removing ) - 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.

	Subject	Value
.	Engine cylinder head	mm
-	Lower plane planarity	0.1

- If the planarity of the lower cylinder head plane does not correspond to the recommended figures, regrind it without exceeding the minimum permitted height.

	Subject	Value
.	Engine cylinder head	mm
-	Minimum permitted height after regrinding	140,85

- After the cylinder head has been refaced, check that the volume of the combustion chamber (with the valves and spark plugs fitted temporarily) is within the recommended values.

	Subject	Value
.	Engine cylinder head	mm
-	Combustion chamber volume	53.26
-	Volume of combustion chamber in head	39.00

- If the volume of the combustion chamber does not correspond to the recommended values, remove material from inside the combustion chamber at the points shown by the arrows. - Decarbonize the valves and check that there are no signs of grooves on the stem.- Check that the diameter of the valve stems corresponds to the recommended figures; if not, replace the worn valves.

	Subject	Value
.	Cylinder head inlet valves	mm
-	Inlet valve stem diameter	6.900 - 6.940

	Subject	Value
.	Cylinder head exhaust valves	mm
-	Exhaust valve stem diameter	6.900 - 6.940

- Check that the puter diameter of the hydraulic tappets corresponds to the recommended figures; if not, replace the worn components.

	Subject	Value
.	Hydraulic tappet casings	mm
-	Outer diameter	32.959 - 32.975

- Check that the diameter of the hydraulic tappet housings corresponds to the recommended figures; if not, replace the cylinder head.

	Subject	Value
.	Engine cylinder head	mm
-	Hydraulic tappet housing diameter	33.000 - 33.025

- Using a torque wrench, check that the valve spring specifications correspond to the recommended figures; if not, replace the worn components.- The figures are valid for the inlet and exhaust.

	Subject	Value
.	Cylinder head valve springs (all)	mm
-	Length of internal spring released	39.00
-	Length of external spring released	46.00

	Subject	Value
.	Cylinder head valve springs (all)
-	Length of inner spring	31.20 mm
-	Under a load of	30.10 da N/mm2

	Subject	Value
.	Cylinder head valve springs (all)
-	Length of inner spring	23.40 mm
-	Under a load of	63.60 da N/mm2

	Subject	Value
.	Cylinder head valve springs (all)
-	Length of external spring released	36.80 mm
-	Under a load of	34.40 da N/mm2

	Subject	Value
.	Cylinder head valve springs (all)
-	Length of outer spring	27.60 mm
-	Under a load of	68.50 da N/ mm2

- Check that the surfaces of the camshaft bearings and cams do not show signs of wear, grooves or seizing; if this is not the case, replace the camshafts.- Check that the diameter of the camshaft bearings corresponds to the recommended figures; if not, replace the worn camshaft.

	Subject	Value
.	Cyliner head inlet and exhaust shafts	mm
-	Journal diameter	26.000 - 26.015

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

	Subject	Value
.	Intake shaft	mm
-	Nominal inlet shaft cam lift	9.3

	Subject	Value
.	Exhaust shaft	mm
-	Nominal exhaust shaft cam lift	9.0

1. Fit the camshaft caps (1a) on the cylinder head and tighten the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	1.4 - 1.7 (cylinder head side)	Bolt	CAMSHAFT CAPS	M7

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

	Subject	Value
2	Engine cylinder head	mm
-	Diameter of camshaft support	26.045 - 26.070

- Check that the outer diameter of the valve guides to be fitted corresponds to the recommended figures.

	Subject	Value
.	Cylinder head valve guides (all)	mm
-	Outer diameter	13.010 - 13.021

1. Fit the valve guides (1a) using the tool (1b).

	Description	Code	Function
1b	Fitting tool	1.860.812.000	Valve guide fitting

Before fitting the new valve guides, heat the cylinder head in the oven to a temperature of 80 - 100 °C.

- In the case of slight distortions due to fitting, ream the inner diameter of the valve guides to the recommended value.

	Subject	Value
.	Cylinder head valve guides (all)	mm
-	Inner diameter	7.022 - 7.040

Grind the valve seats each time the valves or the valve guides are replaced.

1. Grind the valve seat with the cutter at 44° 30'.- Reduce the valve seat from above with the grinder at 20° and from below with the grinder at 75° until the correct valve contact band width is obtained.

	Subject	Value
.	Cylinder head valve seats (all)	mm
-	Contact band width with valve	~ 2

- Check the valve seating; if it is not centered, make the appropriate reductions as described previously.1. Temporarily fit the valves and the spark plugs and carry out the valve compression leakage test using tools (1a) and (1b).

	Description	Code	Function
1a	Lever	1.860.490.000	Valve leakage test

	Description	Code	Function
1b	Test equipment	1.895.868.00	Valve leakage test

- Place the lower valve shims in their housings.1. Fit the valve guide oil seal (1a) using the tools (1b) and (1c).

	Description	Code	Function
1b	Centering	1.860.813.000	Fitting valve guide oil seal

	Description	Code	Function
1c	Fitting tool	1.860.454.000	Fitting valve guide oil seal

1. Fit the valve (1a) and support it using the tools (1b) and (1c).

	Description	Code	Function
1b	Valve support	1.860.786.000	Removing/refitting valves

	Description	Code	Function
1c	Valve support	1.860.786.000	Removing/refitting valves

2. Place the valve springs in their housings.3. Refit the upper valve shim.4. Place the cotters (4a) in their housings using the tools (4b), (4c) and (4d).

	Description	Code	Function
4b	Support	1.860.788.000	Removing/refitting valves

	Description	Code	Function
4c	Chamber	1.860.840.000	Removing/refitting valves

	Description	Code	Function
4d	Lever	1.860.790.000	Removing/refitting valves

- Carry out the same operations for refitting the remaining valves.- Remove the tools used for refitting the valves. - Place the inlet side camshaft front support lower half-bearing in its housing.- Place the camshafts in their housings.- Place the inlet side camshaft front support upper half-bearing in its housing.1. - Place the camshaft caps (1a) in their housings and secure them tightening the bolts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1b	1.4 - 1.7 (cylinder head side)	Bolt	CAMSHAFT CAPS	M7

2. Position the water pump (2a) , complete with O-ring (2b), in its housing and secure it tightening the bolts (2c) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2c	(Cylinder head side) 2.3 - 3.3	Bolt	COOLANT PUMP	M8

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

	Value - daNm	Fastening	Component	Ø
.	2,3 - 3,3	Bolt	CAM ANGLE SENSOR

1. Fit the exhaust side camshaft front oil seal (1a) using the tool (1b).

	Description	Code	Function
1b	Fitting tool	1.860.824.000	Fitting exhaust camshaft front oil seal

1. Fit the inlet side camshaft front oil seal (1a) using the tool (1b).

	Description	Code	Function
1b	Fitting tool	1.860.844.000	Fitting inlet camshaft front oil seal

- Place the timing belt side guards in their housings and secure them using the bolts.

	Value - daNm	Fastening	Component	Ø
.	0,8 - 1,2	Bolt	TIMING BELT COVER GUARDS	M6

1. Place the inlet side timing driven pulley in its housing.2. Tighten the bolts (2a) for the inlet side toothed timing driven pulley using tool (2b) for counter-torque.

	Value - daNm	Fastening	Component	Ø
2a	0,8 - 1,0	Bolt	PRESSURE PUMP CONTROL PULLEY

	Description	Code	Function
2b	Counter-torque	1.860.856.000	Loosen/tighten bolts fixing inlet side toothed driven timing pulley

3. Place the exhaust side timing driven pulley in its housing.4. Tighten the bolt (4a) for the exhaust side toothed timing driven pulley using the tools (4b) and (4c) for counter-torque.

	Value - daNm	Fastening	Component	Ø
4a	10.8 -13.2 (Exhaust camshaft side)	Bolt	TIMING DRIVEN TIMING SYSTEM	M12

	Description	Code	Function
4b	Support for counter-torque	1.860.831.000	Loosen/tighten exhaust side camshaft drive pulley bolt

	Description	Code	Function
4c	Counter-torque	1.860.848.000	Loosen/tighten bolt fixing exhaust side driven timing pulley

- Place the thermostat complete with gasket back in its housing and secure it tightening the bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.3 - 3.3 (cylinder head side)	Bolt	THERMOSTAT	M8

- Place the intake manifold gasket in its housing.- Place the intake manifold complete with modular intake manifold and throttle casing back in its housing, then secure it tightening the nuts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.3 - 3.3 (cylinder head side)	Nut	MANIFOLD/INLET	M8

- Connect the electrical connection for the cam angle sensor.- Connect the earth lead to the cylinder head.- Connect the coolant return pipe to the engine coolant reservoir, thermostat side.- Connect the electrical connection to the engine coolant temperature sensor.- Fit the spark plugs and tighten them to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	(Cylinder head side) 2.5 - 3.6	-	SPARK PLUGS	M14

- Remove the cylinder head from the vice and place it in the housing on the support tool.

	Description	Code	Function
.	Support	1.860.470.000	Cylinder head support