SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

Operation 1016E10 · CYLINDER HEAD/S - VARIOUS OPERATIONS

1.9 JTS, 2.2 JTS

Removing

1. Position the cylinder head in the vice using the support tool.

1. Disconnect the pipes (1a) and remove the three-way connector (1b).

1. Undo the nuts (1a) and remove the lifting bracket (1b).

2. Undo the fastenings (2a) and remove the pressure pump (2b).

3. Undo the bolts (3a) and remove the two timing sensors (3b).

4. Undo the fastenings and remove the camshaft rear cap cover.

- Mark the position of the camshafts.

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

The rear inlet side camshaft cap has silicon sealant therefore a plastic hammer should be used for the removal.

2. Remove the camshafts.

- Remove the camshaft front oil seals.

1. Remove the tappet rocker arms.

2. Remove the hydraulic tappets.

1. Fit the valve support under the head.

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

2. Remove the valve upper shim.

3. Remove the valve spring.

1. Remove the valve guide oil seals (1a) with built in lower shim and the valve (1b).

Refitting

- Clean the contact surfaces between the cylinder head and the crankcase.

COMBUSTION CHAMBER WITH THE POINT FOR MEASURING THE DEPTH SHOWN

- The lower cylinder head plane can be refaced if the flatness is not within the recommended values.

- The refacing does not have to be carried out for lower flatness values.

- The refacing is not permitted for higher flatness values.

- After refacing it is necessary to check that the minimum depth for each combustion chamber is 12.75 mm (at the point shown in the diagram above) in order to guarantee the minimum combustion chamber volume.

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

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

1. Temporarily position the valve (1a) in the seat and fit the tool (1b) for centering the valve guide oil seal (1c) on it.

2. Fit the valve guide oil seal using the tool.

- Position the spring and the upper shim on the valve.

- Place the cotters back in their housings using the tools.

- Carry out the same operations to refit the remaining bolts.

- Place the camshafts in their housings.

- Place the camshaft caps in their housings and secure them tightening the bolts to the recommended torque.

- Place the two timing sensors in their housings and tighten the bolts to the recommended torque.

- Place the pressure pump in position and tighten the fastenings to torque.

- Connect the pipes and fit the three-way fuel connector.

1.9 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 engine oil filler (1b).

2. Remove the gasket.

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

2. Remove the gasket.

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

1. Remove the plugs (1a) and fit camshaft timing tools (1b) on the camshaft housing.

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

1. Undo the bolts fixing the camshaft gears.

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

Remove the camshaft timing tools from the cylinder head extension.

1. Wtihdraw the camshafts (1a), as far as necessary and remove the camshaft gears (1b).

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

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

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

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

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

- Remove the gasket.

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

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

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

- Remove the gasket.

1. Remove the hydraulic tappets.

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

Remove the gasket.

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

2. Remove the gasket.

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

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

2. Remove the valve upper shim.

3. Remove the valve spring.

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

5. Remove the valve guide oil seal with integrated lower valve shim.

Carry out the same operations on the other valves.

Remove the wooden stand and recover the valves.

Remove the lower 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.

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 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 bearings 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.

The outer diameter of the valve seats is as follows.

1. Grind the valve seats to the recommended size.

Grind the valve seats using a suitable tool.

LOWER CYLINDER HEAD

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

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

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

1. Place the shim in position (for exhaust valves only).

2. Fit the valve spring in its seat.

3. Refit the upper valve shim.

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

Carry out the same operations on the other valves.

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

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

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

2. Place the hydraulic tappets in their housings.

- Place the intake manifold gasket in its housing.

- Replace the air conditioning compressor mounting in its housing and secure it by tightening the nuts to the recommended torque.

- Connect the degasing pipe to the thermostat and secure with the collar.

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

- Replace the water pump rigid inlet pipe, complete with gasket, in position and secure it using the bolts, the nut and the collar.

Remove the lower cylinder head from the support tool.

CYLINDER HEAD EXTENSION

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

Tighten the engine oil lubrication duct plugs.

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.

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

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

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

Fit the intake side camshaft plug.

Refit the exhaust side camshaft toothed pulley and secure by screwing in the bolt without tightening.

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

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

1. Place the engine oil filler fitting (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 cylinder head extension from the vice and separate them.

1.9 JTD 8V

Removing

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

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

2. Remove the gasket.

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

Use new pipes from the fuel manifold to the injectors when refitting.

2. Undo the nuts (2a) and remove the fuel distribution manifold (3b) complete with fuel pressure sensor and pipes (2c).

3. Manually push the clips (3a) and disconnect the pipe from the injectors to the fuel recovery manifold (3b), injector side, and remove it.

- Undo the nuts and disconnect the supply wiring from the heater plugs.

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

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

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

2. Loosen the retaining band (2a) and disconnect the pipe (2b) from the thermostat to the oil heat exchanger, heat exchanger side.

3. Undo the bolts (3a) and remove the thermostat (3b) complete with pipe and sensor.

4. Remove the gasket.

5. Undo the bolt (5a) and the nut (5b) and remove the water/exhaust gas heat exchanger for the E.G.R. system (5c).

1. Undo the driven toothed pulley bolt.

2. Remove the toothed driven pulley.

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

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

1. Undo the nuts (1a) and remove the brackets (1b) for the injectors.

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

3. Remove the injector bracket support pads.

4. Remove the heater plugs.

- Check that the camshaft endfloat is within the recommended values using a dial gauge.

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

1. Undo the camshaft cap bolts.

2. Remove the camshaft support lubrication pipe.

3. Remove the camshaft caps.

4. Remove the camshaft.

5. Remove the camshaft front oil seal.

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

- Remove the cylinder head from the vice.

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

- Refit the cylinder head in the vice.

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

2. Remove the valve upper shim.

3. Remove the valve spring.

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

2. Remove the lower shim.

- Carry out the same operations on the other valves.

- Remove the cylinder head from the vice.

- Remove the wooden stand and keep the valves.

- Remove the cylinder head from the support tools.

- Position the cylinder head on the workbench.

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

- Turn the cylinder head upsidedown on the workbench.

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

- Carry out the same operations on the other valve seats.

- For the replacement of the valve guides

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

Refitting

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

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

1. If the 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.

1.8

Removing

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

1. Undo the protective plugs.

2. Undo the bolts and remove the pullies.

1. Undo bolts (1a) and remove timing belt inner guard (1b).

1. Undo bolts (1a) and remove phase transformer solenoid valves (1b).

- Undo the bolts and remove the engine lifting brackets.

1. Undo bolts (1a) and remove timing sensors (1b).

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

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

The camshaft caps are numbered from 2 to 5, inlet side and from 6 to 9, exhaust side. The front cap, which is the same for both camshafts, is number 1.

The bolts securing the camshaft caps should be loosened in a spiral sequence, starting from the caps on the outside, in the following order: 5 - 2 - 4 - 3.

Mark the fitting position of the camshafts.

1. Remove camshafts (1a) and oil seals (1b).

1. Remove the tappet cups.

1. Unscrew the spark plugs and remove them.

1. Fit the tool in the lower part of the cylinder head.

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

2. Remove the shim.

3. Remove the valve spring.

- Carry out the same operations for removing the remaining valves.

- Remove the valve support fitted previously.

4. Remove the valves.

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

- Carry out the same operations for removing the remaining oil seals.

- Remove the cylinder head from the support tool.

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

Refitting

- Thoroughly clean the matching surfaces between the cylinder head and the engine block.

- Check that the planarity of the lower cylinder head plane is within the recommended values. If this is not the case, replace the cylinder head (the cylinder head lower plane cannot be reground).

- Fit the cylinder head support tool and place the assembly in a vice.

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

1. Check that the width of the valve bore in the cylinder head is within the recommended values.

2. Check that the angle of the valve bore in the cylinder head is within the recommended values.

- If the values are not within the recommended limits, replace the cylinder head.

3. Check that the diameter of the valve head corresponds to the recommended figures.

4. Check that the angle of the valve head is within the recommended values.

5. Check that the diameter of the valve stem corresponds to the recommended figures.

- If the values are not within the recommended limits, replace the valves.

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

- Place the valves in their seats and support them using the support tool.

- Fit the valve guide oil seal using the tool.

- Fit the springs and the shim.

- Position the lever fitted with an adaptor, compress the valve spring and fit the cotters.

- Proceed in a similar way and fit the remaining oil seals, springs, shims and cotters.

- Undo the bolts and remove the valve support tool.

- Fit the mechanical tappet cups.

- Fit the inlet and exhaust side camshafts, following the position marked during the dismantling.

- Fit two new oil seals on the camshafts, having lubricated them with engine oil.

- Apply a bead of silicon sealant to the matching surfaces of the camshaft front cap.

- Place the camshaft front cap in position using the two centering bushes.

- Place the camshaft caps in position, following the progressive numbers indicated during the removal.

- Tighten to the recommended torque the bolts fixing the camshaft caps, following the spiral sequence from the inside towards the outside.

1. Use a feeler gauge to check that the valve clearance is within the specified limits with the valves closed.

- If the tappet clearance is not within the recommended tolerance, remove the camshaft involved and replace the cups, selecting the size according to the required clearance.

The tappet cups are graded according to size and therefore the Spare Parts list should be consulted for selecting the new cup to be fitted. The code is on the cup crown.

- After fitting the new cups, repeat the procedure for checking the tappet clearance.

- Fit the timing belt inner guard and secure it using the bolts.

1. Fit tool (1a) in special splining on camshafts (1b).

1. Place toothed driven pullies (1a) and (1b) in position.

2. Fit the tool on the toothed driven pullies.

Fit the inlet side template first and then the exhaust side one.

- Tighten the bolts fixing the pullies to the recommended torque.

3. Tighten the sealing plugs with new O-rings.

- Remove the templates used for timing.

- Place the thermostat unit in its housing complete with a new O-ring and tighten the fixing bolts.

- Place the inlet and exhaust side timing sensors in position and secure them using the bolts.

- Place the inlet and exhaust side phase transformer solenoid valves in position and secure them using the bolt.

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

- Place the engine lifting brackets in their housings and secure them using the bolts.

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

- Remove the support tool from the vice.

2.4 JTD 20V

Removing

CAMSHAFT HOUSING

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

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

2. Remove the gasket.

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

2. Remove the gasket.

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

1. Remove plugs (1a) and fit camshaft timing tools (1b) on the camshaft housing.

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

1. Undo the bolts fixing the camshaft gears.

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

Remove the camshaft timing tools from the cylinder head extension.

1. Wtihdraw the camshafts (1a), as far as necessary and remove the camshaft gears (1b).

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

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

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

LOWER CYLINDER HEAD

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

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

- Remove the gasket.

- Loosen the band and disconnect the degassing pipe from the thermostat.

1. Loosen the collar and disconnect the E.G.r. exhaust gas pipe, heat exchanger side.

2. Undo the nuts (2a) and remove the air chamber (2b) complete with E.G.R. valve (2c) and throttle body (2d).

- Remove the gasket.

- Remove the hydraulic tappets.

1. Loosen the band (1a), undo the bolts (1a) and remove the thermostat (1b) complete with O-ring.

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

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

2. Remove the gasket.

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

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

2. Remove the valve upper shim.

3. Remove the valve spring.

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

5. Remove the valve guide oil seal with integrated lower valve shim.

Carry out the same operations on the other valves.

Remove the wooden stand and recover the valves.

Remove the lower cylinder head from the support tool.

Replace the valve guide

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

Refitting

LOWER CYLINDER HEAD

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 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 bearings 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.

The outer diameter of the valve seats is as follows.

1. Grind the valve seats to the recommended size.

Grind the valve seats using a suitable tool.

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

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

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

1. Place the shim in position (for exhaust valves only).

2. Fit the valve spring in its seat.

3. Refit the upper valve shim.

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

Carry out the same operations on the other valves.

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

- Refit the water pump, complete with gasket, in its housing and secure it tightening the bolts to the recommended torque.

- Place the engine oil heat exchanger for the E.G.R system in its housing and secure it to the cylinder head tightening the bolts to the recommended torque.

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

- Place the hydraulic tappets in their housings.

- Connect the water return pipe from the E.G.R. heat exchanger and secure it using the band.

- Place the intake manifold gasket in its housing.

- Replace the air chamber complete with E.G.R. valve in its housing and secure it by tightening the nuts to the recommended torque.

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

- Place the water pump rigid return pipe, complete with gasket, in position and tighten the bolts.

- Connect the the flexible water return pipe from the E.G.R. heat exchanger to the water pump rigid return pipe and secure it using the band.

Remove the lower cylinder head from the support tool.

CAMSHAFT HOUSING

- Position the camshaft housing in the vice using the tool.

Tighten the engine oil lubrication duct plugs.

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.

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

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

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

Fit the intake side camshaft plug.

Refit the exhaust side camshaft toothed pulley and secure by screwing in the bolt without tightening.

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

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

1. Place the engine oil filler fitting (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 cylinder head extension from the vice and separate them.