74688 - 1016E10 SINGLE CYLINDER HEAD, removed - Overhaul

Removing ( Refitting ) 1. Position the cylinder head (1a) in a vice using the tool (1b).
DescriptionCodeFunction
1b Support1.860.470.000Cylinder head support
- Unscrew the heater plugs and remove them.1. Disconnect the engine temperature sensor wiring.
DescriptionConnector
1 I.E. engine temperature sensorK045
2. Disconnect the engine coolant pipe, thermostat side.
- Disconnect the electrical connection for the cam angle sensor.
DescriptionConnector
.Timing sensorK047
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.
DescriptionCodeFunction
1b Support for counter-torque1.860.831.000Loosen/tighten bolt fixing exhaust side driven timing pulley
DescriptionCodeFunction
1c Counter-torque1.860.848.000Loosen/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.
DescriptionCodeFunction
3b Counter-torque1.860.856.000Loosen/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.
SubjectValue
.Cyliner head inlet and exhaust shaftsmm
-End float0.10 - 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).
DescriptionCodeFunction
1b Valve support1.860.786.000Removing/refitting valves
DescriptionCodeFunction
1c Special nut1.860.787.000Removing/refitting valves
DescriptionCodeFunction
1d Support1.860.788.000Removing/refitting valves
DescriptionCodeFunction
1e Chamber1.860.840.000Removing/refitting valves
DescriptionCodeFunction
1f Lever1.860.790.000Removing/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).
DescriptionCodeFunction
1b Extractor1.860.989.000Removing valve guide oil seal
2. Remove the lower valve shim.
1. Remove the valve guides (1a) using the tool (1b).
DescriptionCodeFunction
1b Extractor1.860.395.000Valve 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.
SubjectValue
.Engine cylinder headmm
-Lower plane planarity0.1
- If the planarity of the lower cylinder head plane does not correspond to the recommended figures, regrind it without exceeding the minimum permitted height.
SubjectValue
.Engine cylinder headmm
-Minimum permitted height after regrinding140,85
- 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.
SubjectValue
.Engine cylinder headmm
-Combustion chamber volume53.26
-Volume of combustion chamber in head39.00
- 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.
SubjectValue
.Cylinder head inlet valvesmm
-Inlet valve stem diameter6.900 - 6.940
SubjectValue
.Cylinder head exhaust valvesmm
-Exhaust valve stem diameter6.900 - 6.940
- Check that the puter diameter of the hydraulic tappets corresponds to the recommended figures; if not, replace the worn components.
SubjectValue
.Hydraulic tappet casingsmm
-Outer diameter32.959 - 32.975
- Check that the diameter of the hydraulic tappet housings corresponds to the recommended figures; if not, replace the cylinder head.
SubjectValue
.Engine cylinder headmm
-Hydraulic tappet housing diameter33.000 - 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.
SubjectValue
.Cylinder head valve springs (all)mm
-Length of internal spring released39.00
-Length of external spring released46.00
SubjectValue
.Cylinder head valve springs (all)
-Length of inner spring31.20 mm
-Under a load of30.10 da N/mm2
SubjectValue
.Cylinder head valve springs (all)
-Length of inner spring23.40 mm
-Under a load of63.60 da N/mm2
SubjectValue
.Cylinder head valve springs (all)
-Length of external spring released36.80 mm
-Under a load of34.40 da N/mm2
SubjectValue
.Cylinder head valve springs (all)
-Length of outer spring27.60 mm
-Under a load of68.50 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.
SubjectValue
.Cyliner head inlet and exhaust shaftsmm
-Journal diameter26.000 - 26.015
- Check that the nominal camshaft cam lift corresponds to the recommended figures; if not, replace the worn camshaft.
SubjectValue
.Intake shaftmm
-Nominal inlet shaft cam lift9.3
SubjectValue
.Exhaust shaftmm
-Nominal exhaust shaft cam lift9.0
1. Fit the camshaft caps (1a) on the cylinder head and tighten the bolts (1b) to the recommended torque.
Value - daNmFasteningComponentØ  
1b 1.4 - 1.7 (cylinder head side)BoltCAMSHAFT CAPSM7
2. Check that the diameter of the camshaft bearings corresponds to the recommended figures; if not, replace the cylinder head.
SubjectValue
2 Engine cylinder headmm
-Diameter of camshaft support26.045 - 26.070
- Check that the outer diameter of the valve guides to be fitted corresponds to the recommended figures.
SubjectValue
.Cylinder head valve guides (all)mm
-Outer diameter13.010 - 13.021
1. Fit the valve guides (1a) using the tool (1b).
DescriptionCodeFunction
1b Fitting tool1.860.812.000Valve 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.
SubjectValue
.Cylinder head valve guides (all)mm
-Inner diameter7.022 - 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.
SubjectValue
.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).
DescriptionCodeFunction
1a Lever1.860.490.000Valve leakage test
DescriptionCodeFunction
1b Test equipment1.895.868.00Valve leakage test
- Place the lower valve shims in their housings.1. Fit the valve guide oil seal (1a) using the tools (1b) and (1c).
DescriptionCodeFunction
1b Centering1.860.813.000Fitting valve guide oil seal
DescriptionCodeFunction
1c Fitting tool1.860.454.000Fitting valve guide oil seal
1. Fit the valve (1a) and support it using the tools (1b) and (1c).
DescriptionCodeFunction
1b Valve support1.860.786.000Removing/refitting valves
DescriptionCodeFunction
1c Valve support1.860.786.000Removing/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).
DescriptionCodeFunction
4b Support1.860.788.000Removing/refitting valves
DescriptionCodeFunction
4c Chamber1.860.840.000Removing/refitting valves
DescriptionCodeFunction
4d Lever1.860.790.000Removing/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 - daNmFasteningComponentØ  
1b 1.4 - 1.7 (cylinder head side)BoltCAMSHAFT CAPSM7
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 - daNmFasteningComponentØ  
2c (Cylinder head side) 2.3 - 3.3BoltCOOLANT PUMPM8
- Place the cam angle sensor back in its housing and secure it tightening the bolts to the recommended torque.
Value - daNmFasteningComponentØ  
.2,3 - 3,3BoltCAM ANGLE SENSOR
1. Fit the exhaust side camshaft front oil seal (1a) using the tool (1b).
DescriptionCodeFunction
1b Fitting tool1.860.824.000Fitting exhaust camshaft front oil seal
1. Fit the inlet side camshaft front oil seal (1a) using the tool (1b).
DescriptionCodeFunction
1b Fitting tool1.860.844.000Fitting inlet camshaft front oil seal
- Place the timing belt side guards in their housings and secure them using the bolts.
Value - daNmFasteningComponentØ  
.0,8 - 1,2BoltTIMING BELT COVER GUARDSM6
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 - daNmFasteningComponentØ  
2a 0,8 - 1,0BoltPRESSURE PUMP CONTROL PULLEY
DescriptionCodeFunction
2b Counter-torque1.860.856.000Loosen/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 - daNmFasteningComponentØ  
4a 10.8 -13.2 (Exhaust camshaft side)BoltTIMING DRIVEN TIMING SYSTEMM12
DescriptionCodeFunction
4b Support for counter-torque1.860.831.000Loosen/tighten exhaust side camshaft drive pulley bolt
DescriptionCodeFunction
4c Counter-torque1.860.848.000Loosen/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 - daNmFasteningComponentØ  
.2.3 - 3.3 (cylinder head side)BoltTHERMOSTATM8
- 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 - daNmFasteningComponentØ  
.2.3 - 3.3 (cylinder head side)NutMANIFOLD/INLETM8
- 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 - daNmFasteningComponentØ  
.(Cylinder head side) 2.5 - 3.6-SPARK PLUGSM14
- Remove the cylinder head from the vice and place it in the housing on the support tool.
DescriptionCodeFunction
.Support1.860.470.000Cylinder head support