Single cylinder head, removed - overhaul

Operation 1016E10 · Cylinder head/s - various operations

1.1

Dismantling

- 1036B14 overhead camshaft - r r on vehicle - with cylinder head removed

1. Remove the camshaft tappet cases with shims.

1.2 8v

Dismantling

Carry out op. 1036B14

1. Remove the camshaft tappet cases with shims.

1.3 JTD 16v

Dismantling

UPPER CYLINDER HEAD

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

1.1

1. Fit the valve retainer beneath the cylinder head.

1.2 8v

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

1.3 JTD 16v

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

2. Remove the gasket.

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

4. Remove the coupling.

1.1

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

2. Remove the upper valve shims.

3. Remove the valve springs.

1.2 8v

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

2. Remove the upper valve shims.

3. Remove the valve springs.

1.3 JTD 16v

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

1.1

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

2. Remove the lower valve shims.

1.2 8v

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

2. Remove the lower valve shims.

1.3 JTD 16v

Temporarily remove the tool fitted previously on the exhaust side camshaft.

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

Fit the tool positioning it with the references in a horizontal direction and checking that it is correctly inserted in the housing in the camshaft.

2. Undo the camshaft sprocket fixing bolts.

1.1

Remove the valve retaining tool fitted previously and remove the valves.

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

2. Remve the engine coolant temperature sender unit

3. Remove the spark plugs.

1.2 8v

Remove the valve retaining tool fitted previously and remove the valves.

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

2. Remove the spark plugs.

1.3 JTD 16v

1. Remove the camshaft timing tools from the camshaft housing.

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

Remove the camshafts completely.

1.1

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

2. Undo the attachments and remove the cable mount bracket.

1.2 8v

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

1.3 JTD 16v

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

CYLINDER HEAD

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

2. Remove the exhaust manifold gasket.

3. Undo and remove the heater plugs.

1.1

Reassembling

Descale and clean the valve seats and ducts.

Clean the residues of the old gasket from the lower surface of the cylinder head.

If necessary, reface the lower cylinder head surface without exceeding the minimum permitted cylinder head height.

1.2 8v

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

1.3 JTD 16v

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

2. Remove the valve rocker arms.

3. Remove the hydraulic tappets.

4. Remove the camshaft housing centring bushes.

1.1

After levelling, check that combustion chamber volume is with specified limits by fitting the valves and spark plugs provisionally.

1.2 8v

After levelling, check that combustion chamber volume is with specified limits as follows.

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.

1.3 JTD 16v

1. Loosen the bands and remove the coolant supply hose from the thermostat to the E.G.R. system exhaust gas/water heat exchanger.

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.

1.1

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

1.2 8v

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

1.3 JTD 16v

1. Loosen the collar fixing the E.G.R. system exhaust gas/coolant heat exchanger, air chamber side.

2. Undo the bolt (2a) and remove the E.G.R. system exhaust gas/heat exchanger assembly (2b).

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

1.1

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.

1.2 8v

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.

1.3 JTD 16v

1. Release the engine oil vapour recirculation pipe from the fastening band on the air chamber.

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

1.1

If necessary, grind the valves to an angle of 45° 30' 5'

If necessary, grind the valve stem surface, removing as little material as possible.

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

1.2 8v

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

Clean the valve seats thoroughly when the operation is complete.

1.3 JTD 16v

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

2. Remove the gasket.

1.1

Check that the endfloat between the valve steam and seats is within the specified values; if this is not the case, replace the worn parts (for valve guide replacement, see op. 1016E14).

1.2 8v

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.

Check that the diameter of the camshaft journals is within the recommended values; if this is not the case, replace the worn 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.

Check that the diameter of the camshaft tappet casing housings are within the recommended values; if this is not the case, replace the worn parts.

Check that the diameter of the camshaft tappet casing housings are within the recommended values; If this is not the case, replace the cylinder head.

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

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

Fit the timing moving tensioner and fix it using the nut without tightening it.

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

1.3 JTD 16v

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

1.1

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

1.2 8v

1. Fit the lower valve shim.

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

1.3 JTD 16v

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

2. Remove the upper valve shim.

3. Remove the valve spring.

1.1

Detect the valve abutment line in the seats. If the contact is not centred, repeat the valve guide grinding operation.

Dress the valves in their seats after spreading the contact surfaces with abrasive paste and using a special tool wtih sucker.

Clean the valves and valve seats thoroughly when the operation is complete.

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 diameter of the camshaft journals is within the recommended values; if this is not the case, replace the worn 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.

Check that the diameter of the camshaft tappet casing housings are within the recommended values; if this is not the case, replace the worn parts.

Check that the diameter of the camshaft tappet casing housings are within the recommended values; If this is not the case, replace the cylinder head.

1. Fit the cable bracket and secure.

2. Fit the thermostat (2a), complete with a new gasket, and fix it tightening the bolts to the recommended torque.

1.2 8v

Refit the valve springs, upper valve shims and cotters using the same tools as used for the dismantling.

Remove the valve retainer removed previously.

Fit the camshaft tappet cases with shims.

- 1036B14 overhead camshaft - r r on vehicle - with cylinder head removed

1.3 JTD 16v

Work in the same way on the remaining valves.

Remove the wooden board and recover the valves.

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

2. Remove the lower valve shims.

1.1

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

2. Fit the engine coolant temperature sending unit and tighten it to the recommended torque.

3. Fit the timing belt moving tensioner (3a) and fix it tightening the bolt (3b) to the recommended torque.

1.3 JTD 16v

Remove the cylinder head from the support tool.

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

1.1

1. Fit the flywheel retaining tool after positioning the valves in their seats.

1.3 JTD 16v

Reassembling

Clean the residues of the old gasket from the lower surface of the cylinder head.

Clean the residues of the old gasket from the matching surfaces between the cylinder head and the camshaft housing.

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 it starting from the nominal height of the head and, at the end of the operation, positioning a new gasket with the number of references indicated below.

The head can be reground by 0.1 mm if starting with a gasket with 0 references and using a new gasket with 1 reference.

The head can be reground by 0.2 mm if starting with a gasket with 0 references and using a new gasket with 2 references.

The head can be reground by 0.1 mm if starting with a gasket with 1 reference and using a new gasket with 2 references.

If the limit condition is reached (head gasket with 2 references before regrinding), the cylinder head lower plane cannot be reground.

1.1

1. Fit the lower valve shim.

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

1.3 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.

1.1

1. Fit the valve springs.

2. Fit the upper valve shims.

3. Fit cotters (3a) using tool (3b).

1.3 JTD 16v

1. Regrind the valve seats to the recommended dimension.

1.1

Remove the valve retainer removed previously.

Fit the camshaft tappet cases with shims.

- 1036B14 overhead camshaft - r r on vehicle - with cylinder head removed

1.3 JTD 16v

Grind the valve seats using a suitable tool.

CYLINDER HEAD

Position the 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.

Fit the lower valve shims back in their housings.

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

1. Place the valve spring back in its housing.

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

3. Place the split cotters (3a) back in their housings using the tools (3b) and (3c).

Work in the same way on the remaining valves.

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

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

Place the engine oil vapour separator, complete with engine oil recirculation pipes, back in its housing and fix it using the bolts.

Fasten the engine oil vapour recirculation pipe to the band on the air chamber.

1. Place the E.G.R. system exhaust gas/water heat exchanger (1a) back in its housing complete with gaskets (1b) and (1c), then secure it tightening the bolts (1d) to the recommended torque.

2. Tighten the collar fixing the E.G.R. system exhaust gas/water heat exchanger, air chamber side.

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

2. Refit the thermostat (2a), complete with O-ring, back in its housing and tighten the bolts (2b) to the specified torque.

3. Refit the coolant supply hose between the thermostat and the E.G.R. system exhaust gas/water heat exchanger and secure it using the bands.

Place the camshaft housing centering bushes back in their seats.

Place the hydraulic tappets in their housings.

Position the hydraulic tappets with the oil port facing the outside of the cylinder head: this position places the above mentioned port in contact with the oil duct in the lower cylinder head.

Place the valve rocker arms back in their housings.

Remove the cylinder head from the support tool.

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

2. Place an exhaust manifold gasket in the housing.

3. Place the exhaust manifold (3a) back in its housing and fix it tightening the nuts (3b) to the recommended torque.

UPPER CYLINDER HEAD

Position the camshaft housing in the vice using the tool.

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.

Fit the tool positioning it with the millings in a horizontal position and checking that it is correctly inserted in the housings in the camshafts.

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

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

1. Place the pressure pump (1a), complete with coupling (1b) and new O-ring, back in its housing and fix 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 (1c) to the recommended torque.

Follow the order shown in the diagram for each tightening sequence. Tighten to 2.0 daNm in two stages: an initial stage of 0.5 daNm following tightening to 1.8 - 2.2 daNm.

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