Single cylinder head, removed - overhaul

Operation 1016E10 · Cylinder head/s - various operations

1.2 16v

Dismantling

1. Position the cylinder head in the vice, supporting it with a suitable tool (1a).

2. Use a suitable wrench to remove the spark plugs

1.4 16v

Dismantling

1. Position the cylinder head in the vice (1a), supporting it with a suitable tool (1b).

2. Use a suitable wrench to remove the spark plugs

1.6 16v

Dismantling

1. Position the cylinder head in the vice (1a), supporting it with a suitable tool (1b).

2. Using the tool (2a), remove the spark plugs (2b).

2.4 20v

Dismantling

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

1.9 JTD 8v

Dismantling

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

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

3. Remove the gasket.

1.9 JTD 16v

Dismantling

CAMSHAFT HOUSING

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

1.2 16v

1. Remove the thermostat and the gasket underneath using the fixing bolts.

1.4 16v

1. Remove the thermostat and the gasket underneath using the fixing bolts.

1.6 16v

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

2. Remove the cotters (2a), caps (2b) and springs (2c), then remove the tool to remove the inlet and exhaust valves (2d) from the head.

2.4 20v

Undo and remove the spark plugs.

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

2. Disconnect the coolant return pipe to the engine coolant reservoir, thermostat side.

1.9 JTD 8v

Take the cylinder head to the workbench.

1. Undo the stud using the nut and locknut.

2. Fit tool (2a) to cylinder head (2b) and secure using nuts (2c).

1.9 JTD 16v

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

2. Remove the gasket.

1.2 16v

1. Undo the nut and remove the automatic timing drive belt tensioner.

1.4 16v

1. Undo the nut and remove the automatic timing drive belt tensioner.

1.6 16v

1. Using pliers (1a), remove the oil seals (1b) from the valve guides.

2.4 20v

1. Disconnect the earth lead from the cylinder head.

2. Disconnect the electrical connection for the cam angle sensor.

3. Undo the nuts (3a) and remove the inlet manifold (3b), complete with modular inlet manifold (3c) and butterfly casing (3d).

Remove the inlet manifold gasket.

1.9 JTD 8v

Position the tool in the vice.

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

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

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

Fully undo the connectors previously loosened and detach the pipes from fuel manifold to fuel injectors from the fuel manifold.

Use new piping from from fuel manifold to injectors upon reassembly.

4. Manually push the springs (4a) and disconnect the pipe from the injectors to the fuel recovery manifold (4b), 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.

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

1.9 JTD 16v

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

2. Remove the gasket.

1.2 16v

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

2. Remove the cotters (2a), caps (2b) and springs (2c), then remove the tool to remove the inlet and exhaust valves (2d) from the head.

1.4 16v

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

2. Remove the cotters (2a), caps (2b) and springs (2c), then remove the tool to remove the inlet and exhaust valves (2d) from the head.

1.6 16v

Reassembling

De-carbonize and clean the valve seats and ducts.

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.

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

1. After regriding the cylinder head, use a dial gauge (1a) and tool (1b) to check that the minimum height between the reference plane inside the combustion chamber and the cylinder head surface is within the recommended value.

The minimum permissible height after refacing is 12.5 mm.

2.4 20v

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

Remove the gasket.

1.9 JTD 8v

Disconnect the supply pipe from the thermostat to the water return manifold to the pump, manifold side.

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

2. Remove the gasket.

1.9 JTD 16v

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

1.2 16v

1. Using pliers (1a), remove the oil seals (1b) from the valve guides.

2. Remove the lower valve shims.

1.4 16v

1. Using pliers (1a), remove the oil seals (1b) from the valve guides.

2. Remove the lower valve shims.

1.6 16v

According the planarity figure measured, the cylinder head can be refaced until the minimum permissible value is reached.

If the value measured is within the tolerance, but close to the minimum permissible value, the operation of refacing the head could alter the functional characteristics of the actual cylinder head because it could cause an excessive increase in the compression ratio with consequent detonation.

Also check the volume of all the combustion chambers following the procedure described below.

1. Temporarily fit the valves and spark plugs and use a graduated test tube containing a known quantity of engine oil.

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

3. Complete the filling of the combustion chamber, taking care that no oil comes out of the combustion chamber.

Wait for around 10 minutes to allow the decantation of the oil.

Measure the quantity of oil remaining in the test tube and then calculate the difference between it and the quantity of oil used initially when the test tube was full; this value corresponds to the volume of the chamber.

Check that this figure corresponds to the recommended values, or else the cylinder head has to be replaced.

2.4 20v

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

2. Remove the timing driven pulley, exhaust side.

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

4. Remove the timing driven pulley, inlet side.

5. Undo the bolts (5a) and remove the timing belt side protections (5b).

1.9 JTD 8v

1. Undo the bolt (1a) for the driven pulley using the tools (1b).

2. Remove the toothed 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).

1.9 JTD 16v

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.

1.2 16v

Reassembling

De-carbonize and clean the valve seats and ducts.

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.

If necessary, reface the lower cylinder head surface; it is permissible to remove 0.1 mm of material over and above the minimum cylinder head height (factory dimension).

1.4 16v

Reassembling

De-carbonize and clean the valve seats and ducts.

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.

If necessary, reface the lower cylinder head surface; it is permissible to remove 0.1 mm of material over and above the minimum cylinder head height (factory dimension).

1.6 16v

Remove the combustion residues from the valves.

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

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

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

Check that the diameter of the valve head is within the recommended values; if this is not the case, 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 a special instrument, check that the valve spring specifications in the various load conditions have not changed; otherwise they must be replaced.

2.4 20v

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).

1.9 JTD 8v

1. Undo and remove the heater plugs.

2. Undo the nuts on the brackets securing the fuel injectors with their wiashers.

1.9 JTD 16v

1. Undo the camshaft sprocket fixing bolts.

1.2 16v

1. Check that the levelling operation has not changed any combustion chamber in areas (1a). Otherwise replace the head.

1.4 16v

1. Check that the levelling operation has not changed any combustion chamber in areas (1a). Otherwise replace the head.

1.6 16v

2.4 20v

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.

1.9 JTD 8v

1. Remove the injectors (1a), complete with gaskets and mounting brackets (1b), using the tool (1c).

Remove the injector bracket support pads.

1.9 JTD 16v

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

1.2 16v

Also check all the combustion chambers following the procedure described below.

• Fit valves and spark plugs provisionally. Take a graduated burette containing a known amount of engine oil.
• Rest a glass sheet with four holes corresponding to the combustion chambers on the cylinder head.
• Complete the filling of the combustion chamber, taking care that no oil comes out of the combustion chamber.

Wait for around 10 minutes to allow the decantation of the oil.

Measure the quantity of oil remaining in the burette and then calculate the difference between it and the quantity of oil used initially when the burette was full; this value corresponds to the volume of the chamber.

Check that this figure corresponds to the recommended values, or else the cylinder head has to be replaced.

1.4 16v

Also check all the combustion chambers following the procedure described below.

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

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

3. Complete the filling of the combustion chamber, taking care that no oil comes out of the combustion chamber.

Wait for around 10 minutes to allow the decantation of the oil.

Measure the quantity of oil remaining in the burette and then calculate the difference between it and the quantity of oil used initially when the burette was full; this value corresponds to the volume of the chamber.

Check that this figure corresponds to the recommended values, or else the cylinder head has to be replaced.

1.6 16v

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

Ream the internal diameter of the valve guide, using a suitable reamer.

Check that the value of the valve guide internal diameter after refacing and the clearance with the valve are within the recommended values or else the valve guide has to be replaced.

If necessary, replace the valve guides referring to op. 1016E14 single cylinder head valve guides - replace during operation 1016e10.

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

Using a drift, fit the oil seal in the housing and remove the drift.

2.4 20v

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.

1.9 JTD 8v

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.

1.9 JTD 16v

Remove the camshaft timing tools from the camshaft housing.

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

1.2 16v

Check that the valve stem does 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 thickness of the cylindrical part of the valve head is within the recommended values.

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

1. Check valve guide bore and valve clearance are within the recommended values or else the valve guide has to be replaced.

If necessary, replace the valve guides referring to op. 1016E14 single cylinder head valve guides - replace during operation 1016e10.

1.4 16v

Check that the valve stem does 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 thickness of the cylindrical part of the valve head is within the recommended values.

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

1. Check valve guide bore and valve clearance are within the recommended values or else the valve guide has to be replaced.

If necessary, replace the valve guides referring to op. - 1016E14 single cylinder head valve guides - replace during operation 1016e10.

1.6 16v

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

Remove the cylinder head from the vice.

Remove the support tool fitted initially from the cylinder head.

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

Do not turn the tappets upsidedown or else they fluid they contain will escape.

2.4 20v

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 tools used for dismantling the valves.

4. Remove the valve.

Work in the same way to remove the remaining valves.

1.9 JTD 8v

Remove the cylinder head from the vice.

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

Refit the cylinder head in the vice.

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

2. Remove the upper valve shim.

3. Remove the valve spring.

1.9 JTD 16v

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.

1.2 16v

Grind the valve seats if the valves and valve guides are replaced.

Clean the valve seats thoroughly when the operation is complete.

1.4 16v

Grind the valve seats if the valves and valve guides are replaced.

Clean the valve seats thoroughly when the operation is complete.

1.6 16v

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

2.4 20v

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

2. Remove the lower valve shim.

1.9 JTD 8v

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 support tools and recover the valves.

1.9 JTD 16v

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

1.2 16v

Use the appropriate tool to check that the characteristics of the springs are within the recommended values; if this is not the case, replace parts that have yielded.

1. Fit the lower valve shims (1a); position the oil seals (1b) on the valve guides, using the drift (1c) on the stem pf the valve temporarily fitted in the seat, then fit the new oil seal on the drift.

2. Fit the oil seal in its seat using drift (2a).

1.4 16v

Use the appropriate tool to check that the characteristics of the springs are within the recommended values; if this is not the case, replace parts that have yielded.

1. Fit the lower valve shims (1a); position the oil seals (1b) on the valve guides, using the drift (1c) on the stem pf the valve temporarily fitted in the seat, then fit the new oil seal on the drift.

2. Fit the oil seal in the housing using the drift illustrated.

1.6 16v

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

Remove the camshaft, complete with oil seal, from the housing.

2.4 20v

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

1.9 JTD 8v

Position the cylinder head on the workbench.

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

1.9 JTD 16v

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.

1.2 16v

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

Fit the timing belt tensioner.

Fit the thermostat and gasket.

Remove the cylinder head from the vice.

Remove the cylinder head support tool.

1.4 16v

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

Fit the timing belt tensioner.

Fit the thermostat and gasket.

Remove the cylinder head from the vice.

Remove the cylinder head support tool.

1.6 16v

Measure the diameters of the camshaft housing supports, checking that the figures correspond to the recommended values; if this is not the case, replace the damaged camshaft housing.

Measure the camshaft bearings, checking that the values correspond to the recommended figures; if this is not the case, replace the damaged camshaft.

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

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

Fit the camshafts in the camshaft housings, taking into account that the recommended clearance should not be exceeded.

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

2.4 20v

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.

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.

1.9 JTD 8v

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.

1.9 JTD 16v

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

2. Remove the gasket.

1.6 16v

Measure the diameters of the tappet housings, checking that the values correspond to the recommended figures; if this is not the case, replace the camshaft housing.

1. Measure the diameters of the tappets, checking that the values are within the recommended figures; if this is not the case, replace the tappets.

2.4 20v

When the cylinder head has been refaced, check that the volume of the combustion chamber (with the valve and spark plugs temporarily fitted) is within the recommended values.

1.9 JTD 8v

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

1.9 JTD 16v

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

1.6 16v

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

Calculate the tappet clearance with seat in the camshaft housing, checking that the values correspond to the recommended figures.

2.4 20v

If the volume of the combustion chamber is not within the recommended figures, restore it by removing material from the inside of the combustion chamber at the points shown by the arrows.

1.9 JTD 8v

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.

1.9 JTD 16v

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.

2.4 20v

De-carbonize the valves and check that the stem does not show signs of grooves.

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 guide is within the recommended values; if this is not the case, replace the valve guides.

The diameter of the valve guide is checked with the guide fitted in the head.

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 hydraulic tappets in the cylinder head is within the recommended values; If this is not the case, replace the cylinder head.

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 surfaces of the camshaft bearings and cams do not show signs of wear, grooves or seizing; if this is not the case, replace the camshafts.

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

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. 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.

1.9 JTD 8v

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.

With the valve guide fitted in the head, check that the diameter is within the recommended values, if this is not the case, replace the valve guides.

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

Check that the diameter of the cup 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.

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. 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.

1.9 JTD 16v

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.

2.4 20v

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

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

Before fitting the new valve guides, heat the cylinder head in the oven to a temperature of 80 - 100 °C.

1.9 JTD 8v

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).

1.9 JTD 16v

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.

2.4 20v

In the case of slight distortions suffered during fitting, ream the inner diameter of the valve guides to the recommended value.

Regrind the valve seats each time the valves or the valve guides are replaced.

1. Regrinding a valve seat with the cutter at 44° 30'.

Reduce the valve seat from above with the cutter at 20° and from below with the cutter at 75°, until the width of the band in contact with the valves is correct.

1.9 JTD 8v

1. Regrind the valve seats to the recommended dimension.

1.9 JTD 16v

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.

2.4 20v

Measure the contact line of each valve against its seat; if the contact is not centred, make the appropriate reductions as described above.

1. Temporarily fit the valves and the spark plugs and carry out the valve compression leakage test using tools (1a) and (1b).

1.9 JTD 8v

Grind the valve seats using a suitable tool.

Temporarily fit the valves.

1. Check that the valve recess in relation to the cylinder head is within the recommended values, using a tool 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.

1.9 JTD 16v

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

1. Regrind the valve seats to the recommended dimension.

2.4 20v

Fit the lower valve shims back in their housings.

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

1.9 JTD 8v

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).

1.9 JTD 16v

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).

2.4 20v

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

2. Place the valve springs back in their housings.

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

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

Work in the same way when fitting the remaining valves.

Remove the tools used for refitting the valves.

1.9 JTD 8v

Fit the valve spring.

Fit the upper valve shim.

Work in the same way on the other valves.

1.9 JTD 16v

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.

2.4 20v

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

Place the camshafts back in their housings.

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

1. Place the camshft caps (1a) back in their housings and secure them tightening the bolts (1b) to the recommended torque.

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

1.9 JTD 8v

Remove the cylinder head from the supporting tools.

Remove the wooden board supporting the valves from the support tools.

Refit the cylinder head on the support tools.

Fit the cups complete with valve clearance adjustment pads.

Fit the camshaft.

1. Fit the camshaft caps.

Fit the camshaft journal lubrication pipe.

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

1.9 JTD 16v

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.

2.4 20v

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

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

1.9 JTD 8v

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

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

1.9 JTD 16v

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.

2.4 20v

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

1.9 JTD 8v

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.

1.9 JTD 16v

Remove the lower cylinder head from the support tool.

CAMSHAFT HOUSING

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

2.4 20v

Place the timing belt side guards back in their housings and secure them using the bolts.

1. Place the inlet side timing driven pulley back in its housing.

2. Tighten th bolts (2a) for the inlet side timing driven pulley to the recommended torque using the tool (2b) for counter-torque.

3. Place the exhust side timing driven pulley back in its housing.

4. Tighten the bolt (4a) for the exhaust side timing driven pulley to the recommended torque using the tools (4b) and (4c) for counter-torque.

1.9 JTD 8v

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).

1.9 JTD 16v

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.

2.4 20v

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

Refit the inlet manifold gasket.

Place the inlet manifold, complete with modular inlet manifold and butterfly casing, back in its housing, then secure it tightening the nuts to the recommended torque.

Connect the electrical connection for the cam angle sensor.

Connect the earth lead to the cylinder head.

Connect the coolant return pipe to the engine coolant reservoir, thermostat side.

Connect the electrical connection to the engine coolant temperature sensor.

Place the spark plugs back in their housings and tighten them to the recommended torque.

Remove the cylinder head from the vice and place the support tool back in its housing.

1.9 JTD 8v

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 (smaller for a smaller clearance and larger for a larger clearance).

Remove the tool.

1.9 JTD 16v

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

1.9 JTD 8v

1. Fit the gasket.

2. Fit the thermostat (2a), complete with pipes and sensors, and tighten the bolts (2b) to torque.

3. Fit the vacuum unit (3a), complete with O-ring, and tighten the bolts (3b) to torque.

1.9 JTD 16v

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

1.9 JTD 8v

1. Fit the gasket.

2. Fit the water pump rigid inlet pipe (2a) and tighten the bolts (2b).

Connect the supply pipe from the thermostat to the water return manifold to the pump, manifold side.

1.9 JTD 16v

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.

1.9 JTD 8v

1. Fit air intake manifold assembly (1a) and tighten 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. Connect the fuel return pipe for lubricating the injectors to the fuel manifold.

Fit new pipes from fuel manifold to fuel injectors on the fuel manifold without tightening the relevant connectors.

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

4. Tighten the injector side connectors to the recommended torque.

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

1.9 JTD 16v

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.

1.9 JTD 8v

Remove the cylinder head from the supporting tools.

1.9 JTD 16v

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.