Single cylinder head, removed - overhaul

Operation 1016E10 · Cylinder head/s - various operations

1.2 8v

Op. 1036B14 CAMSHAFT IN CYLINDER HEAD - R.R. WITH HEAD REMOVED

1. Remove the mechanical tappets with shims.

1. Fit valve retainer tool (1a) beneath the cylinder head.

1. Remove the cotters (1a) using the tool (1b).

2. Fit the upper valve shims.

3. Remove the valve springs.

1. User pliers (1a) to remove oils seals (1b) from the valve guides.

2. Fit the lower valve spring shims.

Remove the valve retainer fitted previously and remove the valves.

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

2. Remove the spark plugs.

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

De-carbonize and clean the valve seats and ducts.

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

1. Check cylinder head flatness and 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).

After flattening, check that combustion chamber volume is within specified values 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.

If the combustion chamber volume is not within specified values, remove material from the arrowed points.

Check that the valve stem does not show signs of scoring or binding.

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

Check that the thickness of the cylindrical section of the valve head is within specified values.

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

1. 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 guide with reference to op.

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

1. In the event of valve and valve guide replacement, grind the valve seats to specified values (1a), (1b), (1c) and (1d).

When the operation is complete, clean the valve seats thoroughly.

Using an appropriate tool, 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.

1. Check that the nominal camshaft cam lift (1a) corresponds to the recommended figures; if not, replace the worn camshaft. Also measure the diameter of shaft (1b) and the height of each cam (1c).

Check that the outer diameter of the mechanical tappets corresponds to the recommended figures; if not, replace the worn components.

Check that the diameter of the cylinder head camshaft tappet sleeve housings corresponds to the recommended figures; if not, replace the cylinder head.

Position the thermostat, complete with a new gasket, and secure it tightening the bolts to the recommended torque.

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

Fit the moving timing belt tensioner and secure it with the nut without tightening.

1. Fit valve retaining tool (1a) after positioning the valves in their seats.

1. Fit the lower valve shims.

2. Fit the valve guide oil seal (2a) using the tool (2b).

1.6 16v

Fit the valve springs, the upper valve plates and the half-cones using the same tool as for the removal.

Remove the flywheel lock fitted previously.

Remove the camshaft tappet sleeves with shims.

Op. 1036B14 CAMSHAFT IN CYLINDER HEAD - R.R. WITH HEAD REMOVED.

Removing

1. Position the cylinder head in the vice supporting it using a suitable tool.

2. Remove the spark plugs using the tool.

1. With the tools (1a), (1b), (1c), (1d) and (1e) assembled as illustrated in the diagram, compress the valve springs.

2. Release the cotters (2a), caps (2b) and springs (2c), then, removing the tool, release the inlet and exhaust valves (2d) from the cylinder head.

1. User pliers (1a) to remove oils seals (1b) from the valve guides.

Refitting

De-carbonize and clean the valve seats and ducts.

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

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

If the planarity of the cylinder head plane is not within the recommended values, regrind the head plane.

1. When the cylinder head has been reground, check that the minimum height between the reference plane inside the combustion chamber and the cylinder head plane is within the recommended values using a dial gauge (1a) and tool (1b).

The minimum permitted height after refacing is 12.5 mm

Depending on the planarity value measured, the cylinder head can be refaced until it reaches the minimum permitted value

If the value measured is within the tolerance, but close to the minimum permitted figure, refacing the cylinder head may alter the specifications of the actual cylinder head because it could produce too great an increase in the compression ratio resulting in engine knock.

Also check the volume of all the combustion chambers by carrying out the following procedure.

1. Fit the valves and spark plugs provisionally and use a graduated test tube 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.

De-carbonize the valves removing the combustion residues.

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

Check that the thickness in the part in contact with the valve seat is within the recommended values.

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

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

Check that the contact angle with the valve seat for both valves is within the recommended values or else the valve has to be replaced.

Using special equipment, check that the valve spring specifications in the different load conditions have not changed or else they must be replaced.

Regrind the valve seats to the recommended measurements for a length of around 2 mm.

Ream the valve guide inner diameter using a suitable reamer.

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

If necessary, replace the valve guides, refer to

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

1. Fit the oil seals (1a) on the valve guides, positioning the intaller (1b) on the valve stem fitted provisioinally in its seat, then fit a new oil seal on the drift.

2. Remove the installer and use a drift to press-fit the oil seal in its seat.

Refit the valves, springs, cotters and caps using the same equipment as for the dismantling.

Carry out a seal test on the valves with reference to operation

Valve leakage test

Remove the cylinder head from the vice.

Remove the cylinder head support tool fitted earlier.

1. Remove the hydraulic tappets from the camshaft housing taking care to place them on a suitable surface making a note of their fitting position in the camshaft housing.

Do not turn the tappets upsidedown to prevent part of the fuel in them from escaping.

1. Fit the support tool (1a) on the camshaft housing (1b) and place it in a vice.

1. Undo the nut (1a) and remove the rear cover (1b).

Release the camshaft complete with oil seal from the housing.

Measure the diameters of the supports for the camshaft housings checking that the values measured correspond to the recommended figures or else the damaged camshaft housing has to be replaced.

Measure the camshaft bearings checking that the figures correspond to the recommended values or else the damaged camshaft has to be replaced.

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

Also check that the surfaces of the cams and the bearings should not show signs of wear, grooves or seizing.

Fit the camshafts in the camshaft housing bearing in mind that the matching of the two components must not exceed the recommended clearance.

1. Fit the new oil seal (1a) on the camshaft housings using the tool (1b).

Measure the diameters of the tappet housings checking that the values measured correspond to the recommended figures or else the camshaft housing has to be replaced.

1. Measure the diameters of the tappets checking that the values measured correspond to the recommended figures or else the tappets have to be replaced.

Fit the hydraulic tappets in the special housings in the camshaft housing.

Calculate the tappet clearance with the housing in the cylinder head extension checking that the figures are within the recommended values.

1.3 JTD 16V

Removing

CYLINDER HEAD EXTENSION

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

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

2. Remove the gasket.

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

4. Remove the joint.

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

Temporarily remove the tool fitted previously to the exhaust camshaft.

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. Remove plug (1a) and fit tool (1b) on the intake side camshaft.

Fit the tool and position with its millings horizontal. Ensure it fits nto the seat on the camshaft.

2. Undo the bolts fixing the camshaft gears.

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

2. Release the camshafts (2a), as necessary and remove the camshaft gears (2b).

Completely remove the camshafts.

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

CYLINDER HEAD

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

2. Remove the exhaust manifold gasket.

3. Unscrew the glow plugs and remove.

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

2. Remove the valve rockers.

3. Remove the hydraulic tappets.

4. Remove the cylinder head extension locating bushes.

1. Loosen the collars and remove the coolant delivery sleeve from the thermostat to the coolant/exhaust gas heat exchanger for the EGR system.

2. Undo the bolts (2a) and remove the thermostat (2b) complete with O-ring.

3. Undo and remove the engine oil pressure warning light switch.

1. Loosen the collar securing the exhaust gas/coolant heat exchanger for the EGR system, air chamber side.

2. Undo the bolts (2a) and remove the water/exhaust gas heat exchanger for the E.G.R. system (2b).

3. Remove gaskets (3a) and (3b).

1. Release the engine oil vapour recirculation pipe for the retaining collars on the air capacity chamber.

2. Unscrew bolts (2a) and remove the engine oil vapour separator (2b) complete with engine oil vapour recirculation pipe (2c).

1. Undo the bolts (1a) and remove the air chamber (1b) complete with pressure relief sensor.

2. Remove the gasket.

1. Fit a wooden stand on the cylinder head plane to support the valves and secure it using bolts.

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

2. Remove the valve upper shim.

3. Remove the valve spring.

Carry out the same operations on the other valves.

Remove the wooden stand and recover the valves.

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

2. Fit the lower valve shims.

Remove the cylinder head from the support tool.

Replace the valve guide

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

Refitting

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

Clean traces of the oil gasket off the mating surfaces between the cylinder head and the cylinder head extension.

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

If 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.

The head may be levelled to 0.1 m if starting from a gasket with 0 notches and using a new gasket with 1 notch.

The head may be levelled to 0.2 m if starting from a gasket with 0 notches and using a new gasket with 2 notches.

The head may be levelled to 0.1 m if starting from a gasket with 1 notch and using a new gasket with 2 notches.

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

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

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 when 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/s.

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

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

1. Grind the valve seats to the recommended size.

Grind the valve seats using a suitable tool.

CYLINDER HEAD

Position the cylinder head in the vice using the tool.

Fit the valves in the seats, then support them using the wooden stand and secure it using suitable bolts.

Place the lower valve shims in their housings.

1. Fit the valve guide oil seals (1a) in their seats using the tool (1b).

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).

Carry out the same operations on the other valves.

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

1. Refit the air chamber (1a) complete with gasket (1b) and pressure relief sensor back in its housing and secure it tightening the bolts (1c) to the recommended torque.

Replace the engine oil vapour separator wiht engine oil vapour recirculation pipe in its seat and secure with bolts.

Fasten the engine oil vapour recirculation pipe to the retaining collars on the air capacity chamber.

1. Replace the exhaust gas/water heat exchanger for the EGR valve (1a) with gaskets (1b) and (1c) in its seat, then secure by tightening bolts (1d) to the specified torque.

2. Tighten the collar securing the exhaust gas/coolant heat exchanger for the EGR system, air chamber side.

1. Place the engine oil pressure warning light switch in its housing and tighten it to the recommended torque.

2. Place the thermostat (2a) in its housing with the o-ring and secure it by tightening the bolts (2b) to the recommended torque.

3. Replace the coolant delivery sleeve from the thermostat to the coolant/exhaust gas heat exchanger for the EGR system and secure with the relevant collars.

Refit the upper cylinder head locating bushes in their seats.

Place the hydraulic tappets in their housings.

Position the hydraulic tappets with the oil channel hole turned toward the outside of the cylinder head: this position brings the hole into communication with the oil duct on the lower cylinder head.

Place the lower valve rockers in their housings.

Remove the cylinder head from the support tool.

1. Refit the glow plugs and tighten them to the recommended torque.

2. Place the exhaust manifold gasket in its housing.

3. Place the air conditioning compressor mounting (3a) in its housing and secure it by tightening the nuts (3b) to the recommended torque.

CYLINDER HEAD EXTENSION

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

Place the camshafts in their housings.

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

1. Fit the camshaft timing tools.

Fit the tools and position with their millings horizontal. Ensure they fit into the seats on the camshafts.

2. Tighten the camshaft gear fixing bolts to the recommended torque.

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

1. Position the pressure pump (1a), complete with coupling (1b) and a new o-ring, in its housing and secure it tightening the bolts (1c) to the recommended torque.

2. Place the vacuum pump (2a), complete with gasket (2b), back in its housing and secure it tightening the bolts (1c) to the recommended torque.

Follow the order shown in the figure for each tightening sequence. The tightening to 2.0 daNm is performed in two stages: a pretightening to 0.5 daNm followed by an additional tightening of 1.8 -2.2 daNm.

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

1.9 DIESEL

Place the head on the workbench.

1. Use the nut and counternut to unscrew the stud.

2. Fit the tool (2a) on the cylinder head (2b) and secure it using the nuts (2c).

Place the tool in the vice.

1. Undo the bolts (1a) and remove the vacuum pump (1b) complete with gasket.

2. Undo the bolts (2a) and remove the thermostat (2b) complete with pipe, sensors and o-ring.

1. Disconnect the diesel return pipes (1a) and injectors (1b).

2. Remove the heater plugs.

1. Undo the lockring (1b), using the tool (1a), and remove the combustion prechambers (1c).

1. Undo the toothed driven pulley bolt (1a) using the tool (1b).

2. Remove the toothed driven pulley.

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

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.

When removing, mark the camshaft caps with a progressive number to define their installation position.

4. Remove the camshaft.

5. Remove the camshaft front oil seal.

6. Remove the cups complete with valve clearance adjustment pads.

When removing, mark the cups with a progressive number to define their installation position.

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.

Lock the cylinder head in the vice.

1. Remove the cotters (1a) using the tool (1b).

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.

Release the cylinder head from the vice and position on the workbench.

Remove the wooden stand and recover the valves.

Mark the valves with a progressive number to define their installation position.

Remove the support tool from the cylinder head.

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

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

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

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.

Check that the valves do not show signs of scoring 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 mechanical tappets corresponds to the recommended figures; if not, replace the worn components.

Check that the diameter of the tappet seats corresponds to the recommended figures; if not, replace the cylinder head.

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 in their original position 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.

Undo the bolts and remove the camshaft caps.

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

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

The valve guides should be fitted after the cylinder head has been heated to a temperature of 80° - 100°C.

Ream the valve guide bore to the recommended figure.

Temporarily fit the valves.

1. Check the clearance between the valve stem and valve guide.

Grind the valve seats to the required values if they are ground, or replace the valves or valve guides

Grind the valve seats using a suitable tool.

Temporarily fit the valves.

1. Check that the change in the combustion prechamber surface in relation go the cylinder head surface is within specified values, using the tool with dial gauge.

Fit the support tool on the cylinder head and secure it using the nuts.

Position a suitable wooden stand on the cylinder head plane to support the valves and secure it using bolts.

Fit the cylinder head, complete with valves, in the vice.

Fit the lower shim.

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

1. Press-fit the valve guide oil seals (1a) using the tool (1b).

Fit the valve spring.

Fit the valve upper shim.

1. Fit the cotters (1a) using the tool (1b).

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 in their position prior to removal.

Fit the camshaft.

1. Fit the camshaft caps in their position prior to removal.

Apply LOCTITE 573 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).

Fit the combustion prechamber, centring using the tool (dummy plug), then secure with the lockrings using the specific tightening tool.

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

2. Fit the injectors and tighten them to torque.

3. Fit the diesel return pipes.

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

2. Fit the toothed driven pulley.

3. Tighten the toothed driven pulley bolt (3a) to the recommended torque using the tools (3b).

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 to lock the cup in lowered position.

Remove the tool.

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

Remove the tool.

Remove the seal.

1. Fit the thermostat (1a) complete with pipes and sensors and tighten the bolts (1b) to the recommended torque.

2. Fit the vacuum pump (2a) complete with gasket and tighten the bolts (2b) to the recommended torque.

1.9 JTD 8V

Remove the cylinder head from the vice.

Unscrew the bolts and remove the mounting tool.

Removing

Place the cylinder head on the workbench.

1. Use the nut and counternut to unscrew the stud.

2. Fit the tool (2a) on the cylinder head (2b) and secure it using the nuts (2c).

Place the tool in the vice.

1. Loosen the manifold side connectors for the pipes from the fuel manifold to the injectors.

2. Undo the injector side connectors for the pipes from the fuel manifold to the injectors.

3. Undo the nuts (3a) and remove the fuel distribution manifold (3b) complete with fuel pressure sensor and pipes (3c).

4. Remove clips (4a) and withdraw the fuel return pipe to lubricate injectors (4b).

Undo the nuts and disconnect the supply wiring from the glow plugs.

Disconnect the coolant return pipe to the expansion tank and de-aeration system from the thermostat.

5. Undo the nuts (5a) and remove the air intake manifold assembly (5b).

1. Undo the bolts (1a) and disconnect the water/exhaust gas heat exchanger for the E.G.R. system (1b) from the EGR system solenoid.

2. Undo the fixing bolts (2a) and remove the E.G.R. system solenoid valve (2b).

3. Remove the bracket.

1. Release the vacuum pipe from the fastening bands.

2. Disconnect the vacuum pipe from the air valve on the electropneumatically-controlled throttle body.

3. Loosen the band and disconnect the engine oil vapour recovery pipe from the cam cover.

4. Loosen the band securing the air intake sleeve to the electropneumatically-controlled throttle body.

1. Undo the bolts (1a) and remove the electropneumatically-controlled throttle body (1b).

2. Remove the gasket.

Unscrew the bolt securing the water/exhaust gas heat exchanger for the EGR system to the cylinder head.

1. Unscrew the nut securing the water/exhaust gas heat exchanger for the EGR system to the cylinder head.

2. Undo the bolt (2a) and the nut (2b) and remove the thermostat (2c) together with the water/exhaust gas heat exchanger for the E.G.R. system (2d).

3. Remove the thermostat gasket.

1. Undo the bolts (1a) and remove the vacuum pump (1b) complete with gasket.

1. Undo the toothed driven pulley bolt (1a) using the tool (1b).

2. Remove the toothed driven pulley.

3. Undo the bolts (3a) and remove the timing 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.

When removing, mark the camshaft caps with a progressive number to define their installation position.

4. Remove the camshaft.

5. Remove the camshaft front oil seal.

6. Remove the cups complete with valve clearance adjustment pads.

When removing, mark the cups with a progressive number to define their installation position.

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.

Lock the cylinder head in the vice.

1. Remove the cotters (1a) using the tool (1b).

2. Remove the valve upper shim.

3. Remove the valve spring.

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

2. Remove the lower shim.

Carry out the same operations on the other valves.

Release the cylinder head from the vice and position on the workbench.

Remove the wooden stand and recover the valves.

Mark the valves with a progressive number to define their installation position.

Remove the support tool from the cylinder head.

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

Refitting

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

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

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.

Check that the valves do not show signs of scoring 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 cups corresponds to the recommended figures; if not, replace the worn components.

Check that the diameter of the cup seats corresponds to the recommended figures; if not, replace the cylinder head.

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

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 in their original position 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.

Undo the bolts and remove the camshaft caps.

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

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

The valve guides should be fitted after the cylinder head has been heated to a temperature of 80° - 100°C.

Ream the valve guide bore to the recommended figure.

Temporarily fit the valves.

1. Check the clearance between the valve stem and valve guide.

Grind the valve seats to the required values if they are ground, or replace the valves or valve guides

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 corresponds to the recommended figures using the tool 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.

Fit the support tool on the cylinder head and secure it using the nuts.

Position a suitable wooden stand on the cylinder head plane to support the valves and secure it using bolts.

Fit the cylinder head, complete with valves, in the vice.

Fit the lower shim.

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

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 tool (1b).

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 in their position prior to removal.

Fit the camshaft.

1. Fit the camshaft caps in their position prior to removal.

Apply LOCTITE 573 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. Fit the fuel return pipe to lubricate injectors (4a) and secure with clips (4b).

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

2. Fit timing sensor (2a) and tighten bolts (2b).

3. Fit the toothed driven pulley.

4. Tighten the toothed driven pulley bolt (4a) to the recommended torque using the tool (4b).

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 to lock the cup in lowered position.

Remove the tool.

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

Remove the tool.

Remove the seal.

1. Fit the thermostat (1a) complete with pipes and sensors and tighten the bolts (1b) to the recommended torque.

2. Fit the vacuum pump (2a) complete with gasket and tighten the bolts (2b) to the recommended torque.

1. Refit the water/exhaust gas heat exchanger for the E.G.R. system (1a) with thermostat (1b) complete with gasket (1c)..

2. Tighten pin (2a) and bolt (2b) securing the thermostat to the recommended torque.

3. Tighten the nut securing the water/exhaust gas heat exchanger for the E.G.R. system to the cylinder head.

Tighten the bolts securing the water/exhaust gas heat exchanger for the E.G.R. system to the cylinder head.

Refit the electrical wiring in its seat and connect the electrical connections to the injectors.

Connect the coolant intake pipe and the coolant outlet pipe to the EGR exhaust gas heat exchanger, then tighten the collars.

Connect the coolant return pipe to the engine coolant reservoir to the thermostat and tighten the band.

Connect the coolant delivery pipe to the climate control system heater to the thermostat and tighten the band.

Connect the outlet pipe from the climate control system heater to the T-connector and the delivery pipe to the water pump liquid rigid inlet pipe, then tighten the collars.

Connect the radiator upper coolant inlet hose to the radiator and tighten the band.

Connect the electrical connection to the engine coolant temperature sensor.

Tighten the bolts securing the water/exhaust gas heat exchanger for the E.G.R. system to the exhaust manifold.

Secure the turbocharger vane position actuator control solenoid to the protection on the gearbox.

Connect the electrical connection to the turbocharger vane position actuator solenoid valve.

1. Refit the electro-pneumatically operated throttle casing (1a) complete with gasket (1b) back in its housing and secure it tightening the bolts (1c) to the recommended torque.

Tighten the band securing the air intake sleeve to the electropneumatically-controlled throttle body.

Connect the engine oil vapour recovery pipe to the cam cover and tighten the band.

Connect the vacuum pipe to the air valve on the electropneumatically-controlled throttle body.

Secure the vacuum pipe to the fastening bands.

Place the E.G.R. system solenoid valve in its housing complete with bracket and fasten it tightening the bolts to the recommended torque.

Connect the water/exhaust gas heat exchanger for the E.G.R. system to the EGR system solenoid and tighten the bolts.

1. Fit the intake air manifold assembly (1a) and tighten the nuts (1b).

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.

2. Connect the fuel return pipe to lubricate injectors (2a) to the fuel manifold and secure with clips (2b).

3. Fit the fuel rail (3a) complete with pipes and fuel pressure sensor (3b) and tighten the nuts (3c).

4. Using a fixed wrench, bring the connectors of the pipes from the fuel rail to the injectors, injector side, into contact, then tighten to the specified torque using a fork-type torque wrench.

5. Tighten the connectors (5a) for the pipes from the fuel manifold to the manifold side injectors to the recommended torque using tool (5b).

Remove the cylinder head from the vice.

Unscrew the bolts and remove the mounting tool.

Retighten the stud.

1.4 8v

Removing

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

- Unscrew the bolt and remove the toothed driven pulley.

- Undo the nut and remove the mobile timing belt tensioner.

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

2. Remove the camshaft.

3. Remove the camshaft front oil seal.

1. Remove the tappet sleeves with shims.

1. Remove the spark plugs.

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

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

2. Fit the upper valve shims.

3. Remove the valve springs.

1. Use tool (1a) to remove oil seals (1b).

2. Fit the lower valve shims.

- Replace the valve guides

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

Refitting

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

Op. 1016E38 SINGLE CYLINDER HEAD OR (ONE) L OR R, REMOVED - GRINDING

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

- Check that the measurements for the valve springs are within the recommended values.

- Clean the valve seats thoroughly.

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

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

- Check that the diameter of the cylinder head camshaft tappet sleeve housings corresponds to the recommended figures; if not, replace the cylinder head.

- Check that the diameter of the cylinder head camshaft tappet sleeve housings corresponds to the recommended figures; if not, replace the cylinder head.

- Fit the thermostat complete with a new gasket and secure it using the bolts.

- Fit the moving timing belt tensioner and secure it with the nut without tightening.

- Fit the valve retaining tool after positioning the valves in their seats.

1. Fit the lower valve shims.

2. Fit the valve guide oil seals (2a) using the tool (2b).

- Fit the valve springs, the upper valve plates and the half-cones using the same tool as for the removal.

- Remove the valve retaining tool fitted previously.

- Fit the camshaft tappet sleeves with shims.

- Fit the camshaft on the cylinder head.

- Fit the camshaft caps and secure them tightening the bolts to the recommended torque.

- Fit the oil seal with the tool.

- Fit the toothed driven pulley by tightening the bolt provisionally.