Single cylinder head, removed - overhaul

Operation 1016E10 · Cylinder head/s - various operations

1.6 TS

Dismantling

1. Position the tool in the vice.

2. Fit the tool.

3. Fit the tool.

4. Position the cylinder head (4a) on the supporting tools and fix it using the nuts (4b).

1. Disconnect the electrical connection from the engine coolant temperature sensor.

1. Undo the nuts (1a) and remove the complete modular inlet manifold (1b).

2. Remove the gasket.

1. Undo the bolts (1a) and remove the complete thermostat (1b).

2. Remove the gasket.

1. Undo the bolt (1a) of the exhaust side camshaft pulley, using the tools (1b) for counter-torque.

2. Remove the exhaust side camshaft pulley.

3. Undo the bolts (3a) of the inlet side camshaft pulley, using the tool (3b) for counter-torque.

4. Remove the inlet side camshaft pulley.

1. Undo the bolts (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 end float is within the recommended values using a dial gauge on a magnetic base.

If the camshaft endfloat is not within the recommended values, when reassembling the cylinder head, replace the worn components.

1. Undo the bolts (1a) and remove the camshaft caps (1b).

2. Remove the upper bearing shell for the front camshaft support, inlet side.

3. Remove the camshafts.

4. Remove the front camshaft oil seals.

5. Remove the lower bearing shell for the front camshaft support, inlet side.

6. Remove the hydraulic tappets.

1. Remove the split collars (1a) using tools (1b), (1c), (1d), (1e) and (1f).

2. Remove the upper valve shim.

3. Remove the valve springs.

Remove the valve dismantling tools.

4. Remove the valve.

Work in the same way to remove the remaining valves.

1. Remove the valve guide oil seal (1a) using the tool (1b).

2. Remove the lower valve shim.

Remove the cylinder head from the supporting tools and position it on an appropriate workbench.

1. Screw the special extraction tool (1b) in the valve seat (1a).

Turn the cylinder head upside down on the workbench.

Remove the valve seat using the extraction tool.

1. Remove valve guides (1a) using tool (1b).

Reassembling

Clean the residues of the old gasket from the lower surface of the cylinder head.

Check that the planarity of the lower cylinder head surface is within the recommended values.

1. If the planarity of the lower cylinder head surface is not within the recommended values, reface the lower cylinder head surface without exceeding the minimum permissible combustion chamber depth.

1.6 TS · 103 CV

The volume of the combustion chamber for each cylinder is given below.

1.6 TS · 120 CV

The volume of the combustion chamber for each cylinder is given below.

1.6 TS

Check that the valves do not show signs of scoring or seizing.

Check that the diameter of the valve stems is within the recommended values; if this is not the case, replace the worn valves.

1.6 TS · 103 CV

Check that the diameter of the valve stems is within the recommended values; if this is not the case, replace the valves.

1.6 TS · 120 CV

Check that the diameter of the valve stems is within the recommended values; if this is not the case, replace the valves.

1.6 TS

The taper of the valve contact band in relation to the valve bore is given below.

Check that the outer diameter of the hydraulic tappets is within the recommended values. if this is not the case, replace the worn parts.

Check that the diameter of the tappet casing housings are within the recommended values; If this is not the case, replace the cylinder head.

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

Use a torque wrench to check that the spring specifications are within specified values; if this is not the case, replace parts that have yielded.

Check that the cam journal diameters are within the recommended values; if this is not the case, replace the worn camshat.

1.6 TS · 103 CV

Check that the nominal lift of the camshaft cams is within the recommended values; if this is not the case, replace the worn camshat.

1.6 TS · 120 CV

Check that the nominal lift of the camshaft cams is within the recommended values; if this is not the case, replace the worn camshat.

1.6 TS

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

2. Check the diamter of the camshaft mounts is within specified values; If this is not the case, replace the cylinder head.

Check that the outer diameter of the valve guides to be fitted is within the recommended values.

1. Fit the valve guides (1a) using the tool (1b).

Ream the inner diameter of the valve guides to the recommended diameter.

Check that the outer diameter of the valve seats to be fitted is within the recommended values.

1. Heat the cylinder to 80° C, then fit the valve seats (1a) using a suitable tool (1b).

Regrind the valve seats to the recommended dimensions.

Grind the valve seats using a suitable tool.

Fit the cylinder head on the supporting tools and fix it using the nuts.

Fit the lower valve shim.

Fit the valve guide oil seal (1a) using the tool (1b).

1. Fit the valve (1a) and support it using the tools (1b) and (1c).

2. Fit the valve springs.

3. Fit the upper valve shim.

4. Fit the split collars (4a) using the tools (4b), (4c) and (4d).

Work in the same way when fitting the remaining valves.

Remove the valve dismantling/fitting tools.

Fit the hydraulic tappets.

Fit the lower bearing shell for the front camshaft support, inlet side.

Fit the camshafts.

Fit the upper bearing shell for the front camshaft support, inlet side.

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

2. Fit the water pump (2a) complete with new O-ring and tighten the bolts (2c) to the recommended torque.

Fit the cam angle sensor and fix it using the bolt.

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

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

1. Fit the inlet side camshaft pulley.

2. Tighten the bolts (2a) of the inlet side camshaft pulley, using the tool (2b) for counter-torque.

3. Fit the exhaust side camshaft pulley.

4. Tighten to torque the bolt (4a) on the exhaust side camshaft pulley, using the tools (4b) for counter-torque.

Fit the thermostat, complete with gasket, and fix it tightening the bolts to the recommended torque.

Fit the modular inlet manifold complete with gasket and tighten the nuts to the recommended torque.

Connect the electrical connection to the engine coolant temperature sensor.

Remove the cylinder head from the supporting tools.

Remove the cylinder head support tools from the vice and return them.

2.0 TS

1. Position the tool in the vice.

2. Fit the tool.

3. Fit the tool.

4. Position the cylinder head (4a) on the supporting tools and fix it using the nuts (4b).

Disconnect the electrical connection from the engine coolant temperature sensor.

1. Undo the nuts (1a) and remove the complete inlet manifold (1b).

2. Remove the seal.

1. Undo the bolts (1a) and remove the complete thermostat (1b).

2. Remove the seal.

1. Undo the bolt (1a) for the exhaust side driven pulley using the tools (1b) and (1c) for anti-torque.

2. Remove the exhaust side driven pulley.

3. Undo the bolts (3a) of the inlet side drive pulley, using the tool (3b) for counter-torque.

4. Remove the inlet side driven pulley.

1. Undo the bolts (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 end float is within the recommended values using a dial gauge on a magnetic base.

If the camshaft endfloat is not within the recommended values, when reassembling the cylinder head, replace the worn components.

1. Undo the bolts (1a) and remove the camshaft caps (1b).

2. Remove the upper bearing shell for the front camshaft support, inlet side.

3. Remove the camshafts.

4. Remove the front camshaft oil seals.

5. Remove the lower bearing shell for the front camshaft support, inlet side.

6. Remove the hydraulic tappets.

1. Remove the split collars (1a) using tools (1b), (1c), (1d), (1e) and (1f).

2. Remove the upper valve shim.

3. Remove the valve springs.

Remove the valve dismantling tools.

4. Remove the valve.

Work in the same way to remove the remaining valves.

1. Remove the valve guide oil seal (1a) using the tool (1b).

2. Remove the lower valve shim.

Remove the cylinder head from the supporting tools and position it on an appropriate workbench.

1. Screw the special extraction tool (1b) in the valve seat (1a).

Turn the cylinder head upside down on the workbench.

Remove the valve seat using the extraction tool.

Clean the residues of the old gasket from the lower surface of the cylinder head.

Check that the planarity of the lower cylinder head surface is within the recommended values.

1. If the planarity of the lower cylinder head surface is not within the recommended values, reface the lower cylinder head surface without exceeding the minimum permissible height for the combustion chamber.

The volume of the combustion chamber for each cylinder is given below.

Check that the valves do not show signs of scoring or seizing.

Check that the diameter of the valve stems is within the recommended values; if this is not the case, replace the worn valves.

Check that the diameter of the valve stems is within the recommended values; if this is not the case, replace the valves.

The taper of the valve contact band in relation to the valve bore is given below.

Check that the outer diameter of the hydraulic tappets is within the recommended values. if this is not the case, replace the worn parts.

Check that the diameter of the tappet casing housings are within the recommended values; If this is not the case, replace the cylinder head.

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

Use a torque wrench to check that the spring specifications are within specified values; if this is not the case, replace parts that have yielded.

Check that the cam journal diameters are within the recommended values; if this is not the case, replace the worn camshaft.

Check that the nominal lift of the camshaft cams is within the recommended values; if this is not the case, replace the worn camshaft.

1. Place the camshaft cams back in their housings in the cylinder head and secure them tightening the bolts (1b) to the recommended torque.

Check the diameter of the camshaft mounts is within specified values; If this is not the case, replace the cylinder head.

Check that the outer diameter of the valve seats to be fitted is within the recommended values.

1. Heat the cylinder to 80° C, then fit the valve seats (1a) using a suitable tool (1b).

Reface the valve seats to the recommended figure.

Position the cylinder head on the supporting tools and fix it using the nuts.

Place the lower valve shim in its housing.

1. Fit the valve guide oil seal (1a) using the tool (1b).

1. Place the valve (1a) back in its housing and support it using the tools (1b) and (1c).

2. Place the valve springs in their housings.

3. Place the upper valve shim in its housing.

4. Place the cotters (4a) in their housings using the tools (4b), (4c) and (4d).

Work in the same way when fitting the remaining valves.

Remove the valve dismantling/fitting tools.

Place the hydraulic tappets in their housings.

Place the inlet side camshaft front support lower half-bearing back in its housing.

Place the camshafts back in their housings.

Place the inlet side camshaft front support upper half-bearing back in its housing.

1. Place the camshaft cams (1a) back in their housing and secure them tightening the bolts (1b) to the recommended torque.

Check that the camshaft end float is within the recommended values using a dial gauge on a magnetic base.

2. Place the water pump (2a), complete with a new O-Ring (2b), back in its housing and secure it tightening the bolts (2c) to the recommended torque.

Place the cam angle sensor back in its housing and fix it using the bolt.

1. Place the front camshaft oil seal, exhaust side (1a) back in its housing using the tool (1b).

1. Place the front camshaft oil seal, inlet side (1a) back in its housing using the tool (1b).

Fit the inlet side driven pulley and fix it using the bolts without tightening them.

Fit the exhaust side driven pulley and fix it with the bolt without tightening it.

Place the thermostat, complete with gasket, back in its housing and fix it tightening the bolts to the recommended torque.

Place the inlet manifold, complete with gasket, back in its housing and fix it tightening the nuts to the recommended torque.

Connect the electrical connection to the engine coolant temperature sensor.

Remove the cylinder head from the support tools.

Remove the cylinder head support tools from the vice and return them.

1.9 JTD 8V

Dismantling

1. Position the tool in the vice.

2. Fit the tool.

3. Fit the tool.

4. Position the cylinder head (4a) on the supporting tools and fix it using the nuts (4b).

1. Undo the bolts (1a) and remove the water pump rigid inlet pipe (1b).

2. Remove the gasket.

1. Undo the connectors (1a) and (1b) and remove the pipes from the fuel manifold to the injectors (1c).

When refitting, use new pipes from the fuel manifold to the injectors.

2. Undo the nuts (2a) and remove the fuel distribution manifold (2b) complete with fuel pressure sensor (2c).

3. Manually push the springs (3a) and disconnect the pipe from the injectors to the fuel recovery manifold (3b), injectors 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 system vent pipe from the thermostat.

4. Undo the nuts (4a) and remove the air chamber (4b), complete with E.G.R. valve (4c) and throttle casing (4d).

1. Undo the bolts (1a) and remove the vacuum unit (1b) complete with O-ring.

2. Loosen the band (2a) and disconnect the pipe from the thermostat to the heat exchanger (2b), 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 bolt (1a) for the driven pulley using the tools (1b).

2. Remove the driven pulley.

3. Undo the bolts (3a) and remove the cam angle sensor (3b).

4. Undo bolts (4a) and remove water pump (4b) complete with O-ring (4c).

1. Undo nuts (1a) and remove injector bracket (1b).

2. Remove the injectors (2a) complete with seals (2b).

3. Remove the injector bracket support pads.

4. Remove the heater plugs.

Check that the end float of the camshaft is within the recommended values using a dial gauge.

If the end float of the camshaft is not within the recommended values, when reassembling the cylinder head, replace the worn components.

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 wooden board on the cylinder head to support the valves and bolt in place.

Refit the cylinder head in the vice.

1. Remove the split collars (1a) using the tools (1b), (1c) and (1d).

2. Remove the upper valve shim.

3. Remove the valve spring.

1. Remove the valve guide oil seal (1a) using the tool (1b).

2. Remove the lower shim.

Work in the same way on the other valves.

Remove the cylinder head from the vice.

Remove the wooden board and recover the valves.

Remove the cylinder head from the support tools.

Position the cylinder head on the workbench.

1. Screw the special extraction tool (1b) in the valve seat (1a).

Turn the cylinder head upside down on the workbench.

1. Remove the valve seat (1a) using the extraction tool (1b).

Work in the same way on the other valves.

To replace the valve guides, see op. 1016E14.

Reassembling

Clean the residues of the old gasket from the lower surface of the cylinder head.

Check that the planarity of the lower cylinder head surface is within the recommended values.

1. If the planarity of the lower cylinder head surface is not within the recommended values, regrind the lower cylinder head surface without exceeding the minimum permissible height.

Check that the valves do not show signs of scoring or seizing.

Check that the diameter of the valve stems is within the recommended values; if this is not the case, replace the worn valves.

Check that the outer diameter of the tappet casings is within the recommended values; if this is not the case, replace the worn parts.

Check that the diameter of the tappet casing seats is within the recommended values; If this is not the case, replace the cylinder head.

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

Use a torque wrench to check that the spring specifications are within specified values; if this is not the case, replace parts that have yielded.

Check that the cam journal diameters are within the recommended values; if this is not the case, replace the worn camshaft.

Check that the nominal lift of the camshaft cams is within the recommended values; if this is not the case, replace the worn camshaft.

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

2. Check the diameter of the camshaft mounts is within specified values; If this is not the case, replace the cylinder head.

Check that the outer diameter of the valve seats to be fitted is within the recommended values.

1. Fit the valve seats (1a) using a suitable tool (1b).

1. Regrind the valve seats to the recommended dimension.

Grind the valve seats using a suitable tool.

Temporarily fit the valves.

1. Check that the valve recess in relation to the cylinder head (1a) is within the recommended values, using a tool (1b) fitted with a dial gauge.

If the valve recess in relation to the cylinder head plane is not within the recommended value, regrind the valve seats.

Place a suitable wooden board between the support tools and the cylinder head to support the valves.

Fit the cylinder head, complete with valves, on the support tools and fix it using the nuts.

Fit the lower shim.

1. Fit the valve guide oil seals (1a) using the tools (1b) and (1c).

Fit the valve spring.

Fit the upper valve shim.

1. Fit the split collars (1a) using the tools (1b), (1c) and (1d).

Work in the same way on the other valves.

Remove the cylinder head from the vice.

Remove the wooden board 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.

Spread LOCTITE 573 on the surfaces where camshaft caps 1 and 5 come into contact with the cylinder head.

Fit the camshaft journal lubrication pipe.

2. Tighten the camshaft cap bolts to the specified torque.

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

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

1. Fit the injector bracket support pads.

2. Fit injectors (2a) complete with seals (2b).

3. Fit injector brackets (3a) and tighten nuts (3b) to torque.

4. Position the connectors for the pipe from the injectors to the fuel recovery manifold (4a) on the corresponding injector seats and fully insert them until the click of the spring (4b) is heard.

1. Fit the water pump (1a), complete with a new O-ring (1b), and tighten the bolts (1c) to torque.

2. Fit the cam angle sensor (2a) and tighten the bolts (2b).

3. Fit the driven pulley.

4. Tighten the bolt for the driven pulley (4a) to the recommended torque usign the tools (4b).

Check that the valve clearance, with the valves in the closed position, is within the recommended values. if not replace the valve clearance adjustment shims as described below.

1. Lower the tappet in question using the tool.

2. Fit the tool.

Remove the tool.

Extract the valve clearance adjustment pad and replace it with another of a suitable size.

Remove the tool.

1. Place the water/exhaust gas heat exchanger for the E.G.R. system (1a) back in its housing and secure it using the bolt (1b) and the nut (1c).

2. Fit the thermostat (2a), complete with gasket (2b), pipes and sensor, then tighten the bolts (2c) to the recommended torque.

3. Connect the pipe from the thermostat to the heat exchanger (3a) and tighten the band (3b).

4. Fit the vacuum unit (4a), complete with O-ring and tighten the bolts (4b) to the recommended torque.

1. Fit the complete air chamber (1a) and tighten the nuts (1b).

Connect the coolant return pipe to the expansion tank and the system vent pipe to the engine thermostat.

Position the heater plugs supply cable and fix it using the nuts.

2. Place the pipe from the injectors to the fuel recovery manifold (2a) back in its housing and connect it to the injectors pressing the connectors into position until the springs (2b) click into place.

3. Fit the fuel distribution manifold (3a), complete with fuel pressure sensor (3b) and tighten the nuts (3c).

4. Place the new pipes from the fuel manifold to the injectors back in their housings.

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

6. Tighten the connectors for the pipes from the fuel manifold to the manifold side injectors to the recommended torque using the tool.

Fit the water pump rigid inlet pipe, complete with gasket, and tighten the bolts.

Remove the cylinder head from the support tools.

Remove the cylinder head support tools from the vice and return them.

1.9 JTD 16V

Dismantling

UPPER CYLINDER HEAD

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

1. Undo the bolts (1a) and remove the engine oil filler (1b).

2. Remove the gasket.

1. Undo bolts (1a) and remove vacuum unit (1b).

2. Remove the gasket.

1. Undo the bolts (1a) and remove the cam angle sensor (1b).

Check that the end float of the camshaft is within the recommended values using a dial gauge.

If the camshaft endfloat is not within the recommended values, when reassembling the cylinder head, replace the worn components.

1. Remove the plugs (1a) and fit the camshaft timing tools (1b) in the upper cylinder head.

Check that the tools are correctly inserted in the housings in the camshafts.

1. Undo the camshaft sprocket fixing bolts.

1. Undo the bolt (1a) and remove the exhaust side camshaft toothed drive pulley (1b).

Remove the camshaft timing tools from the camshaft housing.

1. Release the camshafts (1a) as necessary and remove the camshaft sprockets (1b).

1. Using a suitable drift, extract the inlet side camshaft (1a) and the plug (1b).

2. Using a suitable drift, extract the exhaust side camshaft (2a) and the oil seal (2b).

Remove the exhaust side camshaft oil seal.

1. Undo and remove the engine oil lubrication duct plugs.

Remove the support tool, complete with upper cylinder head from the vice and separate them.

LOWER CYLINDER HEAD

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

2. Remove the hydraulic tappets.

3. Undo the bolts (3a) and remove the thermostat (3b).

Remove the gasket.

1. Undo the bolts (1a) and remove the water pump (1b).

2. Remove the gasket.

1. Place a wooden board on the cylinder head surface to support the valves and bolt in place.

1. Remove the cotters (1a) using tools (1b) and (1c).

2. Remove the upper valve shim.

3. Remove the valve spring.

4. Remove the shim (for the exhaust valves only).

5. Remove the valve guide oil seal with built-in lower valve shim.

Work in the same way on the other valves.

Remove the wooden board and recover the valves.

Remove the lower cylinder head from the support tool.

Replace the valve guides - 1016E14 single cylinder head valve guides - replace during operation 1016e10.

Reassembling

Clean the residues of the old gasket from the lower surface of the lower cylinder head.

Check that the planarity of the lower cylinder head surface is within the recommended values.

1. If the planarity of the lower cylinder head surface is not within the recommended values, regrind it without exceeding the minimum permissible height.

Check that the valves do not show signs of scoring or seizing.

Check that the diameter of the valve stems is within the recommended values; if this is not the case, replace the worn valves.

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

Use a torque wrench to check that the valve spring specifications are within specified values; if this is not the case, replace parts that have yielded.

Check that the cam journal diameters are within the recommended values; if this is not the case, replace the worn camshaft(s).

Check that the nominal lift of the camshaft cams is within the recommended values; if this is not the case, replace the worn camshaft(s).

1. Check the diameter of the camshaft mounts is within specified values; If this is not the case, replace the cylinder head.

The outer diameter of the valve seats should be as follows.

1. Regrind the valve seats to the recommended dimension.

Grind the valve seats using a suitable tool.

LOWER CYLINDER HEAD

Position the lower cylinder head in the vice using the tool.

Fit the valves in their seats, then support them using the wooden board and secure them using bolts.

1. Refit the valve guide oil seal (1a) in its housing using the tool (1b).

1. Place the shim back in its housing (exhaust valves only).

2. Place the valve spring back in its housing.

3. Place the upper valve shim back in its housing.

4. Place the split cotters (4a) back in their housings using the tools (4b) and (4c).

Work in the same way on the other valves.

Remove the wooden board for supporting the valves from the cylinder head plane.

1. Place the water pump (1a), complete with gasket (1b), back in its housing and tighten the bolts (1c) to the recommended torque.

1. Place the thermostat (1a), complete with gasket, back in its housing and secure it tightening the bolts (1b) to the recommended torque.

2. Place the hydraulic tappets in their housings.

Remove the lower cylinder head from the support tool.

UPPER CYLINDER HEAD

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

Tighten the engine oil lubrication duct plugs.

Place the camshafts back in their housings.

Place the camshaft gears back in their housings and secure them without tightening the bolts.

1. Fit the camshaft timing tools.

Check that the tools are correctly inserted in the housings in the camshafts.

1. Tighten the camshaft sprocket fixing bolts to the recommended torque.

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

Fit the inlet side camshaft plug.

Fit the exhaust side timing drive pulley and fix it with the bolt without tightening it.

1. Place the cam angle sensor (1a) back in its housing and secure it tightening the bolt (1b) to the recommended torque.

1. Place the vacuum unit (1a), complete with gasket (1b), back in its housing and secure it tightening the bolts (1c) to the recommended torque.

1. Place the engine oil filler (1a), complete with gasket (1b), back in its housing and secure it tightening the bolts (1c) to the recommended torque.

Remove the support tool, complete with upper cylinder head from the vice and separate them.