75545 - 1016E10 SINGLE CYLINDER HEAD, removed - Overhaul

Removing ( Refitting ) 1. Undo the bolts (1a) and remove the water pump rigid inlet pipe (1b).2. Remove the seal. - Place the head on the workbench.1. Undo the stud using the nut and locknut.2. Fit the tool (2a) on the cylinder head (2b) and secure it using the nuts (2c).

	Description	Code	Function
2a	Support	1.860.460.000	Fitting cylinder head support

1. Loosen the manifold side connectors for the pipes from the fuel manifold to the injectors.2. Undo the injector side connectors for the pipes from the fuel manifold to the injectors.3. Undo the nuts (3a) and remove the fuel distribution manifold (3b) complete with fuel pressure sensor and pipes (3c).- Completely undo the connectors loosened previously and separate the pipes from the fuel manifold ot the injectors from the fuel manifold.

Use new pipes from the fuel manifold to the injectors when refitting.

4. Disconnect the pipe from the injectors to the fuel recovery manifold, fuel recovery manifold side.- Undo the nuts and disconnect the supply wiring from the heater plugs.5. Undo the nuts (5a) and remove the air intake manifold assembly (5b). 1. Undo the bolts (1a) and remove the vacuum unit (1b) complete with O-ring.2. Undo the bolts (2a) and remove the thermostat (2b) complete with pipe and sensors.3. Remove the seal. 1. Undo the driven toothed pulley bolt (1a) using the tools (1b).

	Description	Code	Function
1b	Support for counter-torque	1.860.831.000	Removing toothed pulley bolt

	Description	Code	Function
1b	Counter-torque	1.860.831.001	Counter-torque

2. Remove the toothed driven pulley.3. Undo the bolts (3a) and remove the cam angle sensor (3b).

	Description	Connector
3b	Supercharging sensor	K082

4. Undo the bolts (4a) and remove the water pump (4b) complete with O-ring (4c). 1. Unscrew the glow plugs and remove.2. Manually push the clips (2a) and disconnect the pipe from the injectors to the fuel recovery manifold (2b), injector side, and remove it.3. Undo the nuts for the brackets fastening the injectors and the washers. 1. Remove the injectors (1a), complete with gaskets and mounting brackets (1b), using the tool (1c).

	Description	Code	Function
1c	Extractor	1.870.739.000	Removing injectors

- Remove the injector bracket support pads. - Check that the camshaft endfloat is within the recommended values using a dial gauge.

	Subject	Value
.	INTAKE AND EXHAUST CAMSHAFT	mm
-	End float	0.100 - 0.230

- If the camshaft endfloat is not within the recommended values, replace the worn components when reassembling the cylinder head.1. Undo the camshaft cap bolts.2. Remove the camshaft support lubrication pipe.3. Remove the camshaft caps.4. Remove the camshaft.5. Remove the camshaft front oil seal.6. Remove the cups complete with valve clearance adjustment pads. - Remove the cylinder head from the vice.- Place a suitable wooden bench between the support tools and the cylinder head to support the valves.- Refit the cylinder head in the vice.1. Remove the cotters (1a) using the tool (1b).

	Description	Code	Function
1b	Support	1.860.644.000	Removing cotters

2. Remove the valve upper shim.3. Remove the valve spring. 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 shim.- Carry out the same operations on the other valves.- Remove the cylinder head from the support tools and keep the valves. - Position the cylinder head on a special workbench.1. Thread the special extraction tool (1b) in the valve seat (1a). - Turn the cylinder head upsidedown on the workbench.1. Remove the valve seat (1a) using the extraction tool (1b).- Carry out the same operations on the other valve seats.     See in Op. 1016E14 Valve guides for single cylinder head - Replace during Op. 1016E10- For the replacement of the valve guides 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
.	Cylinder head	mm
-	Lower plane planarity	0.1

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
1	Cylinder head	mm
-	Minimum permitted height	140.85 ÷ 141.15

- 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.

	Subject	Value
.	Valves	mm
-	Stem diameter	7.890 - 7.940

- With the valve guide fitted in the head, check that the diameter corresponds to the recommended values.

	Subject	Value
.	Cylinder head valve guides (all)	mm
-	valve guide diameter	8.040 - 8.022

- Check that the outer diameter of the cups corresponds to the recommended figures; if not, replace the worn components.

	Subject	Value
.	Valve rocker arms	mm
-	Outer diameter	36.975 ÷ 36.991

- Check that the diameter of the cup seats corresponds to the recommended figures; if not, replace the cylinder head.

	Subject	Value
.	Cylinder head	mm
-	-		37.000 ÷ 37.025

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

	Subject	Value
.	Valve springs	mm
-	Free length	53.9

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

	Subject	Value
.	Valve springs	mm
-	Length	24.5 ÷ 21.5

	Subject	Value
.	Valve springs	mm
-	Length	48.6 ÷ 43.6

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

	Subject	Value
.	Camshaft	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
.	Camshaft	mm
-	Nominal exhaust cam lift	9.0

	Subject	Value
.	Camshaft	mm
-	Nominal inlet cam lift	8.5

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	(cylinder head side) 1.4 - 2.0	Bolt	CAMSHAFT CAPS	M7

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

	Subject	Value
2	Camshaft supports	mm
-	Diameter	26.045 - 26.070

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

	Subject	Value
.	Valve seats	mm
-	-	Outer diameter
-	Inlet	36.135 - 36.150
-	Exhaust	35.142 - 35.157

1. Fit the valve seats (1a) using a suitable tool (1b). 1. Grind the valve seats to the recommended size.

	Subject	Value
1	Valve seats
-	Contact band angle with valve	45° 30' ±1°

- Grind the valve seats using a suitable tool.- Temporarily fit the valves.1. Check that the valve recess in relation to the cylinder head plane corresponds to the recommended figures using the tool fitted with a dial gauge.

	Subject	Value
1	Valves	mm
-	Cylinder head plane recess	0.1 - 0.5

	Description	Code	Function
1	Dial gauge support	1.870.404.000	Checking valve recess

- If the valve recess in relation to the cylinder head plane does not correspond to the recommended figures, regrind the valve seats once again. - Place a suitable wooden bench between the support tools and the cylinder head to support the valves.- Fit the cylinder head, complete with valves, on the support tools and secure it using the nuts.- Fit the lower shim.1. Fit the valve guide oil seals (1a) using the tools (1b) and (1c).

	Description	Code	Function
1b	Drift	1.860.814.001	Valve guide oil seal fitting

	Description	Code	Function
1c	Fitting tools	1.860.313.000	Fitting oil seal

- Fit the valve spring.- Fit the valve upper shim.1. Fit the cotters (1a) using the tool (1b).

	Description	Code	Function
1b	Support	1.864.644.000	Fitting cotters

- Carry out the same operations on the other valves. - Remove the cylinder head from the support tools.- Remove the wooden valve support bench from the support tools.- Refit the cylinder head on the support tools.- Fit the cups complete with valve clearance adjustment pads.- Fit the camshaft.1. Fit the camshaft caps.- Fit the camshaft bearing lubrication pipe.2. Tighten the camshaft cap bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2	(cylinder head side) 1.4 - 2.0	Bolt	CAMSHAFT CAPS	M7

	Value - daNm	Fastening	Component	Ø
2	(camshaft side) 0.9 -2.0	Bolt	CAMSHAFT CAPS	-

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

	Description	Code	Function
1b	Fitting tool	1.860.824.000	Fitting oil seal

2. Fit the spark plugs and tighten them to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2	1.4 -1.8 (cylinder head side)	-	HEATER PLUGS PREHEATING	M12

1. Fit the injector bracket support pads.2. Fit the injectors (2a) complete with gaskets (2b).3. Fit the injector brackets (3a) and tighten the nuts (3b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
3b	2.7 -4.0 (cylinder head side)	Nut	INJECTORS(Petrol)	M8

4. Position the connectors for the pipe from the injectors to the fuel recovery manifold (4a) in the corresponding injector seats and insert them fully until the clip (4b) can be heard to click. 1. Fit the water pump (1a), complete with a new O-Ring (1b) and tighten the bolts (1c) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
1c	2.3 - 3.3	Bolt	WATER PUMP	M8

2. Fit the cam angle sensor (2a) and tighten the bolts (2b).3. Fit the toothed driven pulley.4. Tighten the toothed driven pulley bolt (4a) to the recommended torque using the tools (4b).

	Value - daNm	Fastening	Component	Ø
2b	0.9 ÷ 1.2	Bolt	CAM ANGLE SENSOR	-

	Value - daNm	Fastening	Component	Ø
4a	11.0 ÷ 15.9	Bolt	TOOTHED DRIVEN PULLEY	M12

	Description	Code	Function
4b	Support for counter-torque	1.860.831.000	Tightening with counter-torque

	Description	Code	Function
4b	Counter-torque	1.860.831.001	Tightening with counter-torque

- Check that the valve clearance, with the valves closed, corresponds to the recommended figures; if not, replace the valve clearance adjustment pads following the instructions given below.

	Subject	Value
.	Valves	mm
-	-	Inlet valve clearance in closed position
-	Inlet	0.30 ÷ 0.40
-	Exhaust	0.30 ÷ 0.40

1. Lower the tappet in question using the tool.

	Description	Code	Function
1	Lever	1.860.443.000	Lower tappet

2. Fit the tool.

	Description	Code	Function
2	Lever	1.860.724.001	Keeping tappet lowered

- Remove the tool.

	Description	Code	Function
.	Lever	1.860.443.000	Lower tappet

- Extract the valve clearanance adjustment plate and replace it with a one of a suitable thickness.- Decreasing the size of the plate, increases the clearance whilst increasing it decreases the clearance.- Remove the tool.

	Description	Code	Function
.	Lever	1.860.724.001	Keeping tappet lowered

1. Remove the seal.2. Fit the thermostat (2a) complete with pipes and sensors and tighten the bolts (2b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2b	1.4 - 2.0	Bolt	THERMOSTAT	M8

3. Fit the thermostat (3a) complete with O-Ring and tighten the bolts (3b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
3b	2.3 ÷ 3.3	Bolt	VACUUM UNIT	M6

1. Remove the seal.2. Fit the water pump rigid inlet pipe (2a) and tighten the bolts (2b).

	Value - daNm	Fastening	Component	Ø
2b	0.9 - 1.2	Bolt	COOLANT PUMP RIGID INLET PIPE	M6

1. Fit the intake air manifold assembly (1a) and tighten the nuts (1b).

	Value - daNm	Fastening	Component	Ø
1b	2.3 - 3.3	Nut	INLET MANIFOLD

- Position the heater plugs supply wiring and secure it using the nuts.

	Value - daNm	Fastening	Component	Ø
.	0.2 - 0.4	Nuts	CONNECTOR FOR GLOW PLUGS

2. Connect the fuel return pipe for lubricating the injectors to the fuel manifold.- Assemble new pipes from the fuel manifold to the injectors on the fuel manifold without tightening the connectors.3. Fit the fuel distribution manifold (3a) complete with pipes and fuel pressure sensor and tighten the nuts (3b).4. Tighten the injector side connectors to the recommended torque.

	Value - daNm	Fastening	Component	Ø
4	2.2 (injector side)	Connector	PIPES FROM FUEL MANIFOLD TO INJECTORS	M12

5. Tighten the connectors for the pipes from the fuel manifold to the manifold side injectors to the recommended torque.

	Value - daNm	Fastening	Component	Ø
5	2.2 (manifold side)	Connector	PIPES FROM FUEL MANIFOLD TO INJECTORS	M14

- Remove the cylinder head from the support tools.- Remove the cylinder head support tools from the vice and put them down.