Single cylinder head, removed - overhaul

Operation 1016E10 · Cylinder head/s - various operations

1.2 8v

Dismantling

Carry out op. 1036B14

1. Remove the camshaft tappet cases with shims.

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

1.3 JTD

Dismantling

CAMSHAFT HOUSING

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

1.2 8v

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

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.

1.3 JTD

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.

1.2 8v

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

2. Remove the upper valve shims.

3. Remove the valve springs.

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.

1.3 JTD

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

1.2 8v

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

2. Remove the lower valve shims.

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.

1.3 JTD

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 gear fixing bolts.

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.

1.2 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.

1.3 JTD

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.

1.2 8v

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

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).

1.3 JTD

Remove the support tool, complete with camshaft housing, 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.

1.2 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).

1.2 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.

1.3 JTD

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 centering bushes.

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.

1.2 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.

1.3 JTD

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.

1.2 8v

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

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.

1.3 JTD

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).

1.2 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.

1.2 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.

1.3 JTD

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).

1.2 8v

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

Clean the valve seats thoroughly when the operation is complete.

1.2 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.

1.3 JTD

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

2. Remove the gasket.

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.

1.2 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.

1.3 JTD

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

1.2 8v

1. Fit the lower valve shim.

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

1.3 JTD

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

2. Remove the upper valve shim.

3. Remove the valve spring.

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

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.

Remove the cylinder head from the support tool.

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

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.

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. Regrind the valve seats to the recommended dimension.

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 pips, 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 beetween 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.

CAMSHAFT HOUSING

Positino 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 gear fixing bolts to the recommended torque.

1. Plact 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 camshaft housing, from the vice and separate them.