SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

Operation 1016E10 · CYLINDER HEAD/S - VARIOUS OPERATIONS

1.9 Multijet

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 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 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 tappets 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.

1.3 Multijet

Removing

CYLINDER HEAD EXTENSION

1. Position the camshaft housing (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 on the exhaust side 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 positioning it with the millings horizontal and checking that it is correctly inserted in the housing in the camshaft.

2. Undo the bolts fixing the camshaft gears.

1. Remove the camshaft timing tools for 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 camshaft housing 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).

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 keep 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 VALVE GUIDES IN SINGLE CYLINDER HEAD - REPLACE DURING OP. 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 planarity of the lower cylinder head plane corresponds to the recommended values.

- 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.

- 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 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 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 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. 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.

- Refit the air chamber complete with gasket and pressure relief sensor back in its housing and secure it tightening the bolts 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.

- Place the exhaust gas/water heat exchanger for the E.G.R. system complete with gasket back in its housing and secure it by tightening the bolts to the specified torque.

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

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

- 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 camshaft housing locating bushes in their seats in the cylinder head.

Before fitting the locating bushes, check that the height is 13 mm.

- 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 valve rockers in their housings.

- Remove the cylinder head from the support tool.

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

- Place the exhaust manifold gasket in its housing.

- Place the air conditioning compressor mounting in its housing and secure it by tightening the nuts 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 caps 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.

- Place the cam angle sensor back in its housing and secure it tightening the bolt 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 unit (2a), complete with gasket (2b), back in its housing and secure it tightening the bolts (2c) 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 camshaft housing from the vice and separate them.

1.2 8v, 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 VALVE GUIDES IN SINGLE CYLINDER HEAD - REPLACE DURING OP. 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.

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.