939010421 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

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

Tool	Description	Function	Validity
1860470000	Support	Overhaul cylinder head

1. Undo the bolts (1a) and remove the water pump inlet pipe (1b).2. Remove the gasket. 1. Unscrew the connectors (1a) and (1b) and remove the pipes from the fuel manifold to the injectors (1c).

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

2. Undo the nuts (2a) and remove the fuel distribution manifold (3b) complete with fuel pressure sensor and pipes (2c).3. Manually push the clips (3a) and disconnect the pipe from the injectors to the fuel recovery manifold (3b), injector side, and remove it.- Undo the nuts and disconnect the supply wiring from the heater plugs.- Disconnect the coolant return pipe to the expansion tank and de-aeration system from the thermostat.4. Undo the nuts (4a) and remove the air chamber (4b) complete with E.G.R. electrical valve (4c) and throttle body (4d). 1. Undo the bolts (1a) and remove the vacuum unit (1b) complete with O-ring.2. Loosen the retaining band (2a) and disconnect the pipe (2b) from the thermostat to the oil heat exchanger, heat exchanger side.3. Undo the bolts (3a) and remove the thermostat (3b) complete with pipe and sensor.4. Remove the gasket.5. Undo the bolt (5a) and the nut (5b) and remove the water/exhaust gas heat exchanger for the E.G.R. system (5c). 1. Undo the driven toothed pulley bolt.2. Remove the toothed driven pulley.3. Undo the bolts (3a) and remove the cam angle sensor (3b).4. Undo the bolts (4a) and remove the water pump (4b) complete with O-ring (4c). 1. Undo the nuts (1a) and remove the brackets (1b) for the injectors.2. Remove the injectors (2a) complete with gasket (2b).3. Remove the injector bracket support pads.4. Remove the heater plugs. - Check that the camshaft endfloat is within the recommended values using a dial gauge.

Measurement	Value	Validity
Camshaft end float	0.100 - 0.230 mm	1.9 JTD 8V

- 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.- Position a suitable wooden stand on the cylinder head plane to support the valves and secure it using bolts.- Refit the cylinder head in the vice.1. Remove the cotters (1a) using the tools (1b), (1c) and (1d).

Tool	Description	Function	Validity
1820257000	Support	Valve support	1.9 JTD 8V

Tool	Description	Function	Validity
1821058000	Lever	Valve spring compression lever	1.9 JTS2.2 JTS1.9 JTD 8V

Tool	Description	Function	Validity
1821205000	Chamber	Removing/ refitting valves	1.9 JTD 8V

2. Remove the valve upper shim.3. Remove the valve spring. 1. Remove the valve guide oil seal (1a) using the tool (1b).

Tool	Description	Function	Validity
1870894000	Extractor	Valve guide oil seal extraction	1.81.9 JTD 8V

2. Remove the lower shim.- Carry out the same operations on the other valves.- Remove the cylinder head from the vice.- Remove the wooden stand and keep the valves.- Remove the cylinder head from the support tools. - Position the cylinder head on the 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. - For the replacement of the valve guides    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 planarity of the lower cylinder head plane corresponds to the recommended values.

Measurement	Value		Validity
Cylinder head lower surface flatness	0.1 mm		1.9 JTD 8V2.4 JTD 20V

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.

Measurement	Value		Validity
Cylinder head lower plane minimum permitted height	140.85 - 141.15 mm		1.9 JTD 8V

- 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
Exhaust/inlet valve stem diameter	7.974 - 7.992 mm	1.9 JTD 8V

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

Measurement	Value	Validity
Tappet rod outer diameter	36.975 - 36.991 mm	1.9 JTD 8V

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

Measurement	Value	Validity
Tappet rod housing diameter	37.010 - 37.030 mm	1.9 JTD 8V

- Check that the length of the valve springs released corresponds to the recommended figures; if not, replace the weakened components.

Measurement	Value	Validity
Valve spring free length	53.9 mm	1.9 JTD 8V

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

Measurement	Value	Validity
Length of valve springs under a load of 21.5 - 24.5 daN	43.12 mm	1.9 JTD 8V

Measurement	Value	Validity
Length of valve springs under a load of 43.6 - 48.6 daN	32.34 mm	1.9 JTD 8V

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

Measurement	Value	Validity
Camshaft journal diameter	26.000 - 26.015 mm	1.9 JTD 8V

- 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	8.5 mm	1.9 JTD 8V

Measurement	Value	Validity
Nominal exhaust cam lift	9.0 mm	1.9 JTD 8V

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

Component	Fastening	dia	Value (daNm)	Validity
Camshaft caps	Bolt	M7	(cylinder head side) 1.3 - 1.6	1.9 JTD 8V

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

Measurement	Value	Validity
Diameter of camshaft mounts	26.045 - 26.070 mm	1.9 JTD 8V

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

Measurement	Value	Validity
Inlet valve seat outer diameter	36.039 - 36.064 mm	1.9 JTD 8V

Measurement	Value	Validity
Exhaust valve seat outer diameter	35.039 - 35.064 mm	1.9 JTD 8V

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

Measurement	Value	Validity
Valve seat band angle in contact with valve	45° +/- 20’	1.9 JTD 8V

- 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 (1a) corresponds to the recommended figures using the tool (1b) fitted with a dial gauge.

Measurement	Value	Validity
Valve recess in relation to cylinder head plane	0.1 - 0.5 mm	1.9 JTD 8V

Tool	Description	Function	Validity
1820253000	Dial gauge support	Measure the piston projection/valve recess in relation to the cylinder head plane	1.9 JTD 8V2.4 JTD 20V

- 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).

Tool	Description	Function	Validity
1860814001	Shrink disk	Fit valve oil seals	1.9 JTS2.2 JTS1.9 JTD 8V

Tool	Description	Function	Validity
1821178000	Fitting tool	Valve guide oil seal fitting	1.9 JTD 8V

- Fit the valve spring.- Fit the valve upper shim.1. Fit the cotters (1a) using the tools (1b), (1c) and (1d).

Tool	Description	Function	Validity
1820257000	Support	Valve support	1.9 JTD 8V

Tool	Description	Function	Validity
1821058000	Lever	Valve spring compression lever	1.9 JTS2.2 JTS1.9 JTD 8V

Tool	Description	Function	Validity
1821205000	Chamber	Removing/ refitting valves	1.9 JTD 8V

- Carry out the same operations on the other valves. - Remove the cylinder head from the vice.- Remove the wooden stand supporting the valves.- Refit the cylinder head in the vice.- Fit the cups complete with valve clearance adjustment pads.- Fit the camshaft.1. Fit the camshaft caps.

Apply LOCTITE to the contact surfaces with the head for the 1st and 5th camshaft caps.

- Fit the camshaft bearing lubrication pipe.2. Tighten the camshaft cap bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Camshaft caps	Bolt	M7	(cylinder head side) 1.3 - 1.6	1.9 JTD 8V

1. Fit the camshaft front oil seal (1a) using the tool (1b).2. Fit the spark plugs and tighten them to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Heater plug	-	M12	1.3 ÷ 1.6	1.9 Multijet

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

Component	Fastening	dia	Value (daNm)	Validity
Injector brackets	Nut	M8	2.7 ÷ 3.3	1.9 JTD 8V

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. - Fit the water pump, complete with a new O-Ring and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Water pump	Bolt	M8	(cylinder head side) 2.3 - 2.8	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

- Fit the cam angle sensor and tighten the bolts.- Fit the driven toothed pulley and tighten the bolt to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Driven toothed pulley	Bolt	M12	(camshaft side) 2.9 - 3.2 + 40°	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

- 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.

Measurement	Value	Validity
Inlet valves clearance in closed position	0.25 - 0.35 mm	1.9 JTD 8V

Measurement	Value	Validity
Exhaust valves clearance in closed position	0.30 - 0.40 mm	1.9 JTD 8V

1. Lower the tappets in question using the tool.

Tool	Description	Function	Validity
1820262000	Lever	Lower tappets	1.9 JTD 8V

2. Fit the tool.

Tool	Description	Function	Validity
1860724001	Lever	Keep valve tappets lowered	1.9 JTD 8V

- Remove the tool.

Tool	Description	Function	Validity
1820262000	Lever	Lower tappets	1.9 JTD 8V

- Extract the valve clearanance adjustment plate and replace it with a one of a suitable thickness.- Remove the tool.

Tool	Description	Function	Validity
1860724001	Lever	Keep valve tappets lowered	1.9 JTD 8V

- Refit the water/exhaust gas heat exchanger for the E.G.R. system and secure it using the bolt and the nut.- Fit the thermostat complete with gasket, pipes and sensor then tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Thermostat	Bolt	M8	(cylinder head side) 2.3 - 2.8	1.9 JTD 8V

- Connect the pipe from the thermostat to the heat exchanger and tighten the band.- Place the vacuum unit in its housing with the O-ring and secure it by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Vacuum unit	Bolt	M8	(cylinder head side) 2.7 - 3.3	1.9 JTD 8V

- Fit the air chamber assembly and tighten the nuts.- Connect the coolant return pipe to the expansion tank and de-aeration system to the thermostat.- Position the heater plugs supply wiring and secure it using the nuts.- Place the pipe from the injectors to the fuel recovery manifold back in its housing and connect it to the injectors and push home until the clips click into place.- Fit the fuel distribution manifold complete with fuel pressure sensor and tighten the nuts.- Place the new pipes from the fuel manifold ot the injectors in their housings.- Tighten the connectors for the pipes from the fuel manifold to the injector side injectors to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Pipes from fuel manifold to injectors	Connector	M12	(injector side) 2.2 - 2.4	1.9 JTD 8V

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

Component	Fastening	dia	Value (daNm)	Validity
Pipes from fuel manifold to injectors	Connector	M14	(fuel manifold side) 2.2 - 2.4	1.9 JTD 8V

- Fit the water pump rigid inlet pipe complete with gasket and tighten the bolts .- Remove the support tool.