939010421 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

Removing ( Refitting ) CYLINDER HEAD EXTENSION1. Position the cylinder head extension (1a) in a vice using the tool (1b).
ToolDescriptionFunctionValidity
1860470000SupportOverhaul cylinder head
1. Undo the bolts (1a) and remove the engine oil filler (1b).2. Remove the gasket.
1. Undo the bolts (1a) and remove the vacuum unit (1b).2. Remove the gasket.
1. Undo the bolt (1a) and remove the cam angle sensor (1b).
1. Remove the plugs (1a) and fit camshaft timing tools (1b) on the camshaft housing.
Check that the tools are correctly fitted in the housings in the camshafts.
ToolDescriptionFunctionValidity
1870896900TemplateEngine tuning1.9 JTD 16V
1. Undo the bolts fixing the camshaft gears.
1. Undo the bolt (1a) and remove the exhaust side camshaft toothed drive pulley (1b).
Remove the camshaft timing tools from the cylinder head extension.
ToolDescriptionFunctionValidity
1870896900TemplateEngine tuning1.9 JTD 16V
1. Wtihdraw the camshafts (1a), as far as necessary and remove the camshaft gears (1b).
1. Using a suitable drift, extract the inlet side camshaft (1a) and plug (1b).2. Using a suitable drift, extract the exhaust side camshaft (2a) and oil seal (2b).
1. Undo and remove the engine oil lubrication duct plugs.
1. Position the cylinder head (1a) in a vice using the tool (1b).
ToolDescriptionFunctionValidity
1860470000SupportOverhaul cylinder head
1. Loosen collar (1a), unscrew nut (1b) and bolts (1c), then remove the rigid fluid inlet pipe to the water pump assembly (1d).- Remove the gasket.
1. Undo the bolts (1a) and (1b) and remove the water/exhaust gas heat exchanger for the E.G.R. system assembly (1c).
1. Loosen the collar and disconnect the degasing pipe from the thermostat.1. Undo the nuts (2a) and remove the intake manifold assembly (2b).- Remove the gasket.
1. Remove the hydraulic tappets.2. Undo the bolts (2a) and remove the thermostat (2b).Remove the gasket.
1. Undo the bolts (1a) and remove the water pump (1b).2. Remove the gasket.
1. Fit a wooden stand on the cylinder head plane to support the valves and secure it using bolts.
ToolDescriptionFunctionValidity
1860804001StandRemoving/refitting valves1.81.9 JTD 16V
1. Fit the cotters (1a) using the tools (1b) and (1c).
ToolDescriptionFunctionValidity
1860644001LeverRemoving/refitting valves1.81.9 JTD 16V
ToolDescriptionFunctionValidity
1870890000ChamberRemoving/refitting valves1.9 JTD 16V
2. Remove the valve upper shim.3. Remove the valve spring.4. Remove the shim (for exhaust valves only).5. Remove the valve guide oil seal with integrated lower valve shim.Carry out the same operations on the other valves.
Remove the wooden stand and recover the valves.
ToolDescriptionFunctionValidity
1860804001StandRemoving/refitting valves1.81.9 JTD 16V
Remove the lower cylinder head from the support tool.
ToolDescriptionFunctionValidity
1860470000SupportOverhaul cylinder head
Replace the valve guide    Op. 1016E14 VALVE GUIDES IN SINGLE CYLINDER HEAD - REPLACE DURING OP. 1016E10 Refitting ( Removing ) Clean any residues of the old gasket from the lower cylinder head plane.Check that the flatness of the lower cylinder head plane corresponds to the recommended values.
MeasurementValueValidity
Cylinder head lower surface flatness (mm)0.1 ± 0.051.9 JTD 16V
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.
MeasurementValueValidity
Minimum permitted cylinder head height (mm)107.00 ± 0.051.9 JTD 16V
Check that the valves do not show signs of scoring or seizing.Check that the diameter of the valve stems corresponds to the recommended figures; if not, replace the worn valves.
MeasurementValueValidity
Inlet valve stem diameter (mm)5.982 ÷ 6.0001.9 JTD 16V
MeasurementValueValidity
Exhaust valve stem diameter (mm)5.972 ÷ 5.9901.9 JTD 16V
Check that the length of the valve springs when released is within the recommended values.
MeasurementValueValidity
Valve spring free length (mm)43.11.9 JTD 16V
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 20.47 - 21.84 daN (mm)34.01.9 JTD 16V
MeasurementValueValidity
Length of valve springs under a load of 44.81 - 47.59 daN (mm)24.51.9 JTD 16V
Check that the diameter of the camshaft bearings corresponds to the recommended figures; if not, replace the worn camshaft/s.
MeasurementValueValidity
Camshaft first support diameter (mm)43.600 ÷ 43.6151.9 JTD 16V
MeasurementValueValidity
Camshaft second support diameter (mm)43.400 ÷ 43.4151.9 JTD 16V
MeasurementValueValidity
Camshaft third support diameter (mm)43.200 ÷ 43.2151.9 JTD 16V
MeasurementValueValidity
Camshaft fourth support diameter (mm)43.000 ÷ 43.0151.9 JTD 16V
MeasurementValueValidity
Camshaft fifth support diameter (mm)30.000 ÷ 30.0151.9 JTD 16V
Check that the nominal camshaft cam lift corresponds to the recommended figures; if not, replace the worn camshaft/s.
MeasurementValueValidity
Nominal inlet/exhaust cam lift (mm)8.01.9 JTD 16V
1. Check that the diameter of the camshaft supports corresponds to the recommended figures; if not, replace the cylinder head.
MeasurementValueValidity
Camshaft first support diameter (mm)43.646 ÷ 43.6711.9 JTD 16V
MeasurementValueValidity
Camshaft second support diameter (mm)43.446 ÷ 43.4711.9 JTD 16V
MeasurementValueValidity
Camshaft third support diameter (mm)43.246 ÷ 43.2711.9 JTD 16V
MeasurementValueValidity
Camshaft fourth support diameter (mm)43.046 ÷ 43.0711.9 JTD 16V
MeasurementValueValidity
Camshaft fifth support diameter (mm)30.045 ÷ 30.0701.9 JTD 16V
The outer diameter of the valve seats is as follows.
MeasurementValueValidity
Inlet valve seat outer diameter (mm)29.600 ÷ 29.6111.9 JTD 16V
MeasurementValueValidity
Exhaust valve seat outer diameter (mm)27.600 ÷ 27.6111.9 JTD 16V
1. Grind the valve seats to the recommended size.
MeasurementValueValidity
Valve seat band angle in contact with valve45° 30’ +/- 1°1.9 JTD 16V
Grind the valve seats using a suitable tool.LOWER CYLINDER HEADPosition the lower cylinder head in the vice using the tool.
ToolDescriptionFunctionValidity
1860470000SupportOverhaul cylinder head
Fit the valves in the seats, then support them using the wooden stand and secure it using suitable bolts.
ToolDescriptionFunctionValidity
1860804001StandRemoving/refitting valves1.81.9 JTD 16V
1. Place the valve guide oil seal (1a) in position using the tool (1b).
ToolDescriptionFunctionValidity
1870897100Extractor/Fitting toolExtracting/fitting valve guidesValve guide oil seal fitting1.9 JTD 16V
1. Place the shim in position (for exhaust valves only).2. Fit the valve spring in its seat.3. Refit the upper valve shim.4. Place the cotters (4a) in their housings using the tools (4b) and (4c).
ToolDescriptionFunctionValidity
1860644001LeverRemoving/refitting valves1.81.9 JTD 16V
ToolDescriptionFunctionValidity
1870890000ChamberRemoving/refitting valves1.9 JTD 16V
Carry out the same operations on the other valves.
Remove the wooden stand for supporting the valves from the cylinder head plane.
ToolDescriptionFunctionValidity
1860804001StandRemoving/refitting valves1.81.9 JTD 16V
1. Position the water pump (1a), complete with gasket (1b), in its housing and secure it tightening the bolts (1c) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Water pumpBoltM8(cylinder head side) 2.3 - 2.81.9 JTD 8v1.9 JTD 16v
1. Place the thermostat (1a) complete with gasket back in its housing and secure it by tightening the bolts (1b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
ThermostatBoltM8(cylinder head side) 2.51.9 JTD 16v2.4 JTD 20v
2. Place the hydraulic tappets in their housings.
- Place the intake manifold gasket in its housing.- Replace the air conditioning compressor mounting in its housing and secure it by tightening the nuts to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Intake manifoldNutM8(cylinder head side) 2.3 - 2.81.9 JTD 16v
- Connect the degasing pipe to the thermostat and secure with the collar.- Place the exhaust gas/water heat exchanger for the E.G.R. system back in its housing and secure it by tightening the bolts to the specified torque.
ComponentFasteningdia  Value (daNm)Validity
Exhaust gas/water heat exchanger for E.G.R. systemBoltM8(cylinder head side) 2.3 - 2.81.9 JTD 16v1.9 JTD 8v2.4 JTD 20v
ComponentFasteningdia  Value (daNm)Validity
Exhaust gas/water heat exchanger for E.G.R. systemBoltM8(EGR solenoid side) 2.3 - 2.81.9 JTD 16v1.9 JTD 8v2.4 JTD 20v
- Replace the water pump rigid inlet pipe, complete with gasket, in position and secure it using the bolts, the nut and the collar. Remove the lower cylinder head from the support tool.
ToolDescriptionFunctionValidity
1860470000SupportOverhaul cylinder head
CYLINDER HEAD EXTENSION1. Position the cylinder head extension (1a) in a vice using the tool (1b).
ToolDescriptionFunctionValidity
1860470000SupportOverhaul cylinder head
Tighten the engine oil lubrication duct plugs.Place the camshafts in their housings.Place the camshaft gears in their housings and secure them without tightening the bolts.1. Fit the camshaft timing tools.
Check that the tools are correctly fitted in the housings in the camshafts.
ToolDescriptionFunctionValidity
1870896900TemplateEngine tuning1.9 JTD 16V
1. Tighten the camshaft gear fixing bolts to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Camshaft gearsBoltM12(camshaft side) 2.9 - 3.2 + 40°1.9 JTD 16v
1. Fit the exhaust side camshaft front oil seal (1a) using the tool (1b).
ToolDescriptionFunctionValidity
1870896800Fitting toolFitting exhaust camshaft oil seal1.9 JTD 16V
Fit the intake side camshaft plug.Refit the exhaust side camshaft toothed pulley and secure by screwing in the bolt without tightening.1. Position the cam angle sensor (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Cam angle sensorBolt (pretreated to be replaced for 1.9 JTD 8v)M6(cylinder head extension side) 0.8 - 1.01.9 JTD 8V1.9 JTD 16v2.4 JTD 20v
1. Place the vacuum pump (1a), complete with gasket (1b), back in its housing and secure it tightening the bolts (1c) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Vacuum unitBolt (pretreated to be replaced)M6(cylinder head extension side) 0.5 + 50°1.9 JTD 16v2.4 JTD 20v
1. Place the engine oil filler fitting (1a), complete with gasket (1b), back in its housing and secure it tightening the bolts (1c) to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Engine oil fillerBoltM6(cylinder head extension side) 0.8 - 1.01.9 JTD 16v2.4 JTD 20v
Remove the support tool complete with cylinder head extension from the vice and separate them.