SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

Operation 1016E10 · CYLINDER HEAD/S - VARIOUS OPERATIONS

1.4 16v

Removing

1. Position the cylinder head (1a) in the vice supporting it using the support tool (1b).

2. Unscrew the spark plugs and remove them.

3. Undo the bolts (3a) and remove the thermostat (3b) complete with O-ring.

1. Undo the nut (1a) and remove the moving timing belt tensioner (1b).

1. Fit the valve retaining tool beneath the cylinder head.

2. Fit the cotters (2a) using the tools (2b) and (2c).

3. Fit the upper valve shims.

4. Remove the valve springs.

5. Remove the valves.

1. Use the tool (1a) to remove the oil seals (1b) from the valve guides.

2. Fit the lower valve shims.

- Remove the valve retaining tool and keep the valves.

- Loosen the vice, remove the cylinder head and place it on the bench.

- Remove the cylinder head support tool.

Op. 1016E14 VALVE GUIDES IN SINGLE CYLINDER HEAD - REPLACE DURING OP. 1016E10

Refitting

- De-carbonize and clean the valve seats and ducts.

- Clean any residues of the old gasket from the lower cylinder head plane.

- Check that the cylinder head plane flatness is within the recommended values.

- If necessary, flatten the lower cylinder head surface; it is permitted to remove 0.1 mm of material from the minimum cylinder head height (factory value).

1. Check that the refacing has not changed any of the combustion chambers in the areas or else the head must be replaced.

- Also check all the combustion chambers proceeding as follows:

1. Fit the valves and spark plugs provisionally. Take a graduated burette containing a known amount of engine oil.

2. Rest a glass plate on the cylinder head with holes corresponding to the combustion chambers.

3. Fill the combustion chamber completely, taking care not to pour oil outside the combustion chamber.

- Wait about 10 minutes to allow the oil to decant.

- Measure the amount of oil remaining in the burette and then calculate the difference between this and the amount of oil used initially with the burette full. The difference is the volume of the chamber.

- Check that this value is within specified values, otherwise replace the cylinder head.

- Check that the valve stem does 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.

- Check that the diameter of the valve head corresponds to the recommended figures; if not, replace the valves.

- Check that the inner diameter of the valve guide and the clearance between it and the valve are within specified values, otherwise replace the valve guide.

- If necessary, replace the valve guides, refer to

Op. 1016E14 VALVE GUIDES IN SINGLE CYLINDER HEAD - REPLACE DURING OP. 1016E10

- Using special equipment, check that the valve spring specifications are within the recommended values; if this is not the case, replace the components that do not comply.

1. Fit the lower valve shims (1a); place the oil seals (1b) on the valve guides, positioning the drift guide (1c) on the valve stem fitted provisionally in its seat, then fit a new oil seal on the drift.

2. Fit the oil seal in its housing using the fitting tool.

- Refit the valves, springs, upper plates and caps using the same equipment as for the dismantling.

- Position the timing belt moving tensioner in its housing and secure it without tightening the nut.

- Place the thermostat in its housing with the new O-ring and secure it by tightening the bolts to the recommended torque.

- Fit the spark plugs and tighten them to the recommended torque.

- Undo the nuts and remove the cylinder head from the support tool.

1.9 JTD 16v

Removing

CAMSHAFT HOUSING

1. Position the camshaft housing (1a) in a vice using the tool (1b).

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

2. Remove the gasket.

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

2. Remove the gasket.

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

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

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

1. Undo the bolts securing the camshaft gears.

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

- Remove the camshaft timing tools from the cylinder head extension.

1. Withdraw camshafts (1a) as far as necessary and remove camshaft gears (1b).

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

2. Using a suitable drift, extract 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).

1. Loosen the band (1a), unscrew the nut (1b) and the bolts (1c), then remove rigid fluid inlet pipe to water pump assembly (1d).

- Remove the gasket.

1. Undo bolts (1a) and (1b) and remove water/exhaust gas heat exchanger for E.G.R. system assembly (1c).

1. Loosen the collar and disconnect the degassing pipe from the thermostat.

1. Undo nuts (2a) and remove intake manifold assembly (2b).

- Remove the gasket.

1. Remove the hydraulic tappets.

2. Undo bolts (2a) and remove thermostat (2b).

- Remove the gasket.

1. Undo bolts (1a) and remove 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.

1. Remove half-cones (1a) using tools (1b) and (1c).

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 built-in lower valve shim.

- Carry out the same operations on the other valves.

- Remove the wooden stand and keep the valves.

Remove the lower cylinder head from the support tool.

- Replace the valve guides

Op. 1016E14 VALVE GUIDES IN SINGLE CYLINDER HEAD - REPLACE DURING OP. 1016E10

Refitting

- Clean any residues of the old gasket from the lower cylinder head plane.

- Check that the flatness of the lower cylinder head lower plane corresponds to the recommended values.

1. If the lower surface flatness of the lower cylinder head is not within specified values, grind from the nominal head height and then fit a new gasket with the number of notches determined as described below.

a - The head may be levelled to 0.1 m if starting from a gasket with no references and using a new gasket with one reference.

b - The head may be levelled to 0.2 m if starting from a gasket with no references and using a new gasket with two references.

c - The head may be levelled to 0.1 m if starting from a gasket with one reference and using a new gasket with two references.

When within limit conditions (head gasket with 2 notches before levelling), the lower cylinder head surface cannot be levelled.

- Check that the valves do not show signs of grooves or meshing.

- Check that the diameter of the valve stems corresponds to the recommended figures; if not, replace the worn valves.

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

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

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

- Check that the nominal camshaft cam lift corresponds to the recommended figures; if not, replace the worn camshaft.

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

- The outer diameter of the valve housings is as follows.

1. Grind the valve seats to the recommended size.

- 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 the seats, then support them using the wooden stand and secure with suitable bolts.

1. Place valve guide oil seal (1a) in position using tool (1b).

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 half-cones (4a) in their housings using tools (4b) and (4c).

- Carry out the same operations on the other valves.

- Remove the wooden stand for supporting the valves from the cylinder head plane.

1. Position water pump (1a), complete with gasket (1b), in its housing and secure it by tightening bolts (1c) to the recommended torque.

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

2. Place the hydraulic tappets in their housings.

- Place the intake manifold gasket in its housing.

- Replace the intake manifold in its housing and secure it by tightening the nuts to the recommended torque.

- Connect the degassing pipe to the thermostat and secure with the band.

- 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.

- 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.

CAMSHAFT HOUSING

1. Position the camshaft housing (1a) in a vice using the tool (1b).

- Tighten the engine oil lubrication duct plugs.

- Place the camshafts in their housings.

- Refit 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.

1. Tighten the camshaft gear bolts to the recommended torque.

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

- Fit the inlet side camshaft plug.

- Place the exhaust side camshaft toothed drive pulley in its housing and secure it without tightening the bolt.

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

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

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

- Remove the support tool complete with cylinder head extension from the vice and separate them.

1.9 JTD 8v

Removing

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

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.

- 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).

2. Remove the valve upper shim.

3. Remove the valve spring.

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

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

- 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.

1. If the lower surface flatness of the lower cylinder head is not within specified values, grind from the nominal head height and then fit a new gasket with the number of notches determined as described below.

a - The head may be levelled to 0.1 mm if starting with a gasket with no references and using a new gasket with one reference.

b - The head may be levelled to 0.2 mm if starting with a gasket with no references and using a new gasket with two references.

c - The head may be levelled to 0.1 mm if starting with a gasket with one reference and using a new gasket with two references.

When within limit conditions (head gasket with 2 references before levelling), the lower head surface cannot be levelled.

- 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.

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

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

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

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

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

- Check that the nominal camshaft cam lift corresponds to the recommended figures; if not, replace the worn camshaft.

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

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

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

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

1. Grind the valve seats to the recommended size.

- 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.

- 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).

- Fit the valve spring.

- Fit the valve upper shim.

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

- 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.

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

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

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.

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.

- Fit the cam angle sensor and tighten the bolts.

- Fit the driven toothed pulley and tighten the bolt to the recommended torque.

- 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.

1. Lower the tappet in question using the tool.

2. Fit the tool.

- Remove the tool.

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

- Remove the tool.

- 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.

- 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.

- 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.

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

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

- Remove the support tool.

1.4 16v TJet

Removing

1. Position the cylinder head (1a) in the vice supporting it using the support tool (1b).

2. Unscrew the spark plugs and remove them.

3. Undo the bolts (3a) and remove the thermostat (3b) complete with O-ring.

1. Undo the nut (1a) and remove the moving timing belt tensioner (1b).

1. Fit the valve retaining tool beneath the cylinder head.

2. Remove the cotters (2a) using the tools (2b) and (2c).

3. Fit the upper valve shims.

4. Remove the valve springs.

5. Remove the valves.

1. Use the tool (1a) to remove the oil seals (1b) from the valve guides.

2. Fit the lower valve shims.

- Remove the valve retaining tool and keep the valves.

- Loosen the vice, remove the cylinder head and place it on the bench.

- Remove the cylinder head support tool.

Op. 1016E14 VALVE GUIDES IN SINGLE CYLINDER HEAD - REPLACE DURING OP. 1016E10

Refitting

- De-carbonize and clean the valve seats and ducts.

- Clean any traces of the old gasket from the lower cylinder head surface.

- Check that the cylinder head plane flatness is within the recommended values.

- If necessary, flatten the lower cylinder head surface; it is permitted to remove 0.1 mm of material from the minimum cylinder head height (factory value).

1. Check that the refacing has not changed any of the combustion chambers in the areas or else the head must be replaced.

- Also check all the combustion chambers proceeding as follows:

1. Fit the valves and spark plugs provisionally. Take a graduated burette containing a known amount of engine oil.

2. Rest a glass plate on the cylinder head with holes corresponding to the combustion chambers.

3. Fill the combustion chamber completely, taking care not to pour oil outside the combustion chamber.

- Wait about 10 minutes to allow the oil to decant.

- Measure the amount of oil remaining in the burette and then calculate the difference between this and the amount of oil used initially with the burette full. The difference is the volume of the chamber.

- Check that this value is within specified values, otherwise replace the cylinder head.

- Check that the valve stem does 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.

- Check that the diameter of the valve head corresponds to the recommended figures; if not, replace the valves.

- Check that the inner diameter of the valve guide and the clearance between it and the valve are within specified values, otherwise replace the valve guide.

- If necessary, replace the valve guides, refer to

Op. 1016E14 VALVE GUIDES IN SINGLE CYLINDER HEAD - REPLACE DURING OP. 1016E10

- Using special equipment, check that the valve spring specifications are within the recommended values; if this is not the case, replace the components that do not comply.

1. Fit the lower valve shims (1a); place the oil seals (1b) on the valve guides, positioning the drift guide (1c) on the valve stem fitted provisionally in its seat, then fit a new oil seal on the drift.

2. Fit the oil seal in its housing using the fitting tool.

- Refit the valves, springs, upper plates and caps using the same equipment as for the dismantling.

- Position the timing belt moving tensioner in its housing and secure it without tightening the nut.

- Place the thermostat in its housing with the new O-ring and secure it by tightening the bolts to the recommended torque.

- Fit the spark plugs and tighten them to the recommended torque.

- Undo the nuts and remove the cylinder head from the support tool.