939004944 - 1016E20 CYLINDER HEAD (ONE), LEFT OR RIGHT, REMOVED - OVERHAUL

Removing ( Refitting )
The dismantling of the left cylinder head is illustrated below, carry out the same operations for the right cylinder head.
1. Position the cylinder head in the vice using the tool.
ToolDescriptionFunctionValidity
1860470000SupportSupporting cylinder head in vice
2. Undo the engine coolant temperature sensor and remove it.
1. Undo the connectors (1a) for the fuel pipes (1b) connected to the fuel manifold pipe.2. Undo the bolts (2a) and remove the pressure pump (2b) complete with pipes.
1. Undo the bolts (1a) and remove the fuel manifold pipe (1b) with injectors (1c) and electrical wiring (1d).
1. Undo the bolts (1a) and remove the camshaft caps (1b).
Mark the positionof the camshaft caps for the correct refitting.
2. Remove the camshafts.
1. Remove rockers (1a) and hydraulic tappets (1b).
1. Fit the reaction tool for supporting the valves during the removal.
ToolDescriptionFunctionValidity
1860804000StandRemoving/ refitting valves3.2 JTS
1. Fit the cotters (1a) using the tools (1b) and (1c).
ToolDescriptionFunctionValidity
1870881000ChamberRemoving/ refitting valves3.2 JTS
ToolDescriptionFunctionValidity
1860644000LeverRemoving/ refitting valves3.2 JTS
2. Remove the valve upper shim.3. Remove the valve spring.- Carry out the same operations for removing the remaining valves.- Remove the tools used for dismantling the valves.
1. Remove the valve guide oil seals (1a) using the tool (1b).
ToolDescriptionFunctionValidity
1870894000ExtractorRemoving valve guide oil seals3.2 JTS
- Remove the reaction tool for supporting the valves during the removal.
ToolDescriptionFunctionValidity
1860804000StandRemoving/ refitting valves3.2 JTS
2. Keep the valves.
Refitting ( Removing ) - Clean any residues of the old gasket from the lower cylinder head plane.- Check the planarity of the cylinder head lower plane.- If the maximum difference in planarity is less than 0.05 mm, then the cylinder head lower plane does not require refacing.- If the maximum difference in planarity is 0.05 - 0.20 mm, then the cylinder head lower plane should be refaced.
If grinding is necessary, it should be carried out on both cylinder heads.
The maximum permitted regrinding depth is 0.25 mm; if the cylinder head lower plane requires more regrinding , the cylinder head must be replaced.
- Remove valve deposits, checking the rod for scoring or signs of binding.- Check that the diameter of the valve stem corresponds to the recommended figures.
MeasurementValueValidity
Inlet valve stem diameter (mm)5.955 ÷ 5.9753.2 JTS
MeasurementValueValidity
Exhaust valve stem diameter (mm)5.945 ÷ 5.9653.2 JTS
- Check that the length of the valve springs released is within the recommended values.
MeasurementValueValidity
Valve spring free length (mm)42.050 ÷ 44.8503.2 JTS
- Check that the diameter of the camshaft bearings is as specified.
MeasurementValueValidity
Camshaft journal diameter (mm)26.936 ÷ 26.9603.2 JTS
The surfaces of the camshaft bearings should not show signs of wear, grooves or seizing.
- Check that the nominal camshaft cam lift is within the recommended figures.
MeasurementValueValidity
Nominal camshaft cam lift (mm)113.2 JTS
The surfaces of the camshaft cams should not show signs of wear, grooves or seizing.
- Refit the camshaft caps on the cylinder head according to the position marked during the dismantling.
The camshaft caps are marked with a number starting from the timing side going toward the flywheel side (even numbers for the left cylinder head and uneven numbers for the right cylinder head) and a letter, "I" for the intake side camshaft and "E" for the exhaust side camshaft.The projections on the camshaft caps should be facing the centre of the cylinder head.
- Tighten the camshaft cap bolts to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Camshaft capsBolt-1.03.2 JTS
- Check that the diameter of the camshaft mounts is as specified.
MeasurementValueValidity
Camshaft support diameter (mm)27.000 ÷ 27.0203.2 JTS
MeasurementValueValidity
Camshaft support diameter - timing side (mm)35.000 ÷ 35.0203.2 JTS
- Position the cylinder head in the vice using the tool.
ToolDescriptionFunctionValidity
1860470000SupportSupporting cylinder head in vice
- Place the valves in their seats and keep them in position using the support tool.
ToolDescriptionFunctionValidity
1860804000StandRemoving/ refitting valves3.2 JTS
- Place the valve guide oil seals in their housings.1. Fit the valve spring in its seat.2. Refit the upper valve shim.3. Place the half-cones (3a) in their housings using the tools (3b) and (3c).
ToolDescriptionFunctionValidity
1870881000ChamberRemoving/ refitting valves3.2 JTS
ToolDescriptionFunctionValidity
1860644000LeverRemoving/ refitting valves3.2 JTS
- Carry out the same operations for refitting the remaining valves.- Remove the tools used for fitting the valves.
- Place the hydraulic tappets and rockers in their housings.1. Place the camshafts in their housings.2. Refit the camshaft caps on the right cylinder head according to the position marked during the dismantling.
The camshaft caps are marked with a number starting from the timing side going toward the flywheel side (even numbers for the left cylinder head and uneven numbers for the right cylinder head) and a letter, "I" for the intake side camshaft and "E" for the exhaust side camshaft.The projections on the camshaft caps should be facing the centre of the cylinder head.
3. Tighten the camshaft cap bolts to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Camshaft capsBolt-1.03.2 JTS
1. Place the fuel manifold pipe (1a) in its housing complete with injectors (1b) and electrical wiring (1c) and tighten the bolts (1d).
ComponentFasteningdia  Value (daNm)Validity
Fuel manifold pipeBolt-1.03.2 JTS
- Place the pressure pump in its housing complete with pipes and secure it using the bolts.- Connect the fuel pipes to the fuel manifold and tighten the connectors. 1. Place the engine coolant temperature sensor in its housing and tighten it to the recommended torque.
ComponentFasteningdia  Value (daNm)Validity
Engine coolant temperature sensor-M122.2
2. Remove the cylinder head from the support tool.
ToolDescriptionFunctionValidity
1860470000SupportSupporting cylinder head in vice