Procedures

1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

Engines: 2.0 16V, 2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V

Engines: 2.0 16V

Removing

- Fit the tool to the cylinder head and secure in the vice.

	Description	Code	Function
.	Support	1.860.470.000	Cylinder head in vice

1. Check that the 10 mm diameter reference pin is correctly inserted.2. Undo the gear retaining bolt.3. Remove the gear.- Remove the 10 mm diameter reference pin.

Engines: 2.0 16V

- Remove the spark plugs.- Remove the press-fitted lubrication pipe and the sealing rings.1. Unscrew nuts (1a) securing the camshaft caps in the order shown and remove caps (1b).2. Remove the camshaft.

Engines: 2.0 16V

1. Remove tappets (1a) and calibrated valve clearance pads (1b).

Engines: 2.0 16V

1. Fit the tool beneath the cylinder head.

	Description	Code	Function
1	Valve retaining base	1.860.804.000	Valve retention

2. Remove semicones (2a) from the valve using tools (2b).

	Description	Code	Function
2b	Tool	1.860.644.000	Removing/refitting valves

	Description	Code	Function
2b	Tool	1.860.644.030	Removing/refitting valves

3. Remove upper plate (3a), spring (3b) and lower plate (3c) in order.- Repeat the operation for all valves.- Remove the tool.

	Description	Code	Function
.	Valve retaining base	1.860.804.000	Valve retention

4. Remove all valves.

Engines: 2.0 16V

1. Remove the valve stem sealing ring using the tool.

	Description	Code	Function
1	Extractor	1.860.792.000	Valve guide oil seals

- Repeat the operation for all valve stem sealing rings.

Engines: 2.0 16V

1. Remove the filter from the lubricant delivery channel to the cylinder head.

Engines: 2.0 16V

1. Remove the valve guide from its seat using the tool.

	Description	Code	Function
1	Drift	1.860.395.000	Valve guide extraction

Engines: 2.0 16V

- Remove the cylinder head from the tool.

	Description	Code	Function
.	Support	1.860.470.000	Cylinder head in vice

Engines: 2.0 16V

Refitting

Removing

- Clean all ducts thoroughly.1. Check the lower surface and ensure that flatness is within specified limits.

	Subject	Value
1	CYLINDER HEAD	mm
-	Flatness	0,05

Engines: 2.0 16V

- Fit the camshaft and caps provisionally.- Tighten the nuts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	1,6	Nut	CAMSHAFT CAPS	-

1. Check that cylinder head height is within recommended limits.

	Subject	Value
1	CYLINDER HEAD	mm
-	Height	140,95 - 141,05

- Remove the caps and camshaft.- If cylinder head flatness and/or height are not within specified limits, grind the lower surface to reduce the height to the specified value.

	Subject	Value
.	CYLINDER HEAD	mm
-	Cylinder head height reduction	0,20

Engines: 2.0 16V

1. Grind the intake valve seats using a suitable tool.

	Subject	Value
1a	VALVE SEATS
-	Contact band angle with intake valve	45°

	Subject	Value
1b	VALVE SEATS
-	Intake port outlet angle	65°

	Subject	Value
1c	VALVE SEATS
-	Intake port intake angle	25°

2. Grind the exhaust valve seats using a suitable tool.

	Subject	Value
2a	VALVE SEATS
-	Contact band angle with intake valve	45°

	Subject	Value
2b	VALVE SEATS
-	Exhaust port outlet angle	65°

	Subject	Value
2c	VALVE SEATS
-	Exhaust port intake angle	20°

	Subject	Value
.	VALVE SEATS	mm
-	Intake valve contact band width	1,70
-	Exhaust valve contact band width	2,20

Engines: 2.0 16V

1. Check contact between valve and seat is correct after grinding.

Engines: 2.0 16V

- If it is not possible to obtain centred, even contactg between valve and seat, replace the valve seat.1. Whenever necessary, replace the valve seats using new oversize valve seats to restore the initial conditions.

	Subject	Value
1a	VALVE SEATS	mm
-	Intake valve seat housing diameter, 1st oversize	42,3
-	Intake valve seat housing diameter, 2nd oversize	42,5

	Subject	Value
1a	VALVE SEATS	mm
-	Exhaust valve seat housing diameter, 1st oversize	36,3
-	Exhaust valve seat housing diameter, 2nd oversize	36,5

	Subject	Value
1b	VALVE SEATS	mm
-	Intake valve seat housing height	15,98
-	Exhaust valve seat housing height	15,25

	Subject	Value
1c	VALVE SEATS	mm
-	Intake valve seat diameter, 1st oversize	42,4
-	Intake valve seat diameter, 2nd oversize	42,6

	Subject	Value
1c	VALVE SEATS	mm
-	Exhaust valve seat diameter, 1st oversize	36,4
-	Exhaust valve seat diameter, 2nd oversize	36,6

	Subject	Value
1d	VALVE SEATS	mm
-	Oversize intake valve seat height	8,40
-	Oversize exhaust valve seat height	7,35

Engines: 2.0 16V

- Ream the valve guide seats using a suitable tool.

	Subject	Value
.	VALVE GUIDES	mm
-	Valve guide seat diameter, 1st oversize	13,195 - 13,227
-	Valve guide seat diameter, 2nd oversize	13,495 - 13,527

1. Press-fit new valve guides (1a) from the top of the cylinder head using tool (1b).

	Description	Code	Function
1b	Fitting tool	1.870.751.000	Valve guide fitting

Engines: 2.0 16V

1. Check that valve guide position is within specified limits.

	Subject	Value
1	VALVE GUIDES	mm
-	Gap between intake valve guide - lower cylinder head surface	43,65 - 44,35
-	Gap between exhaust valve guide - lower cylinder head surface	38,05 - 38,75

Engines: 2.0 16V

- Ream the valve guides using an appropriate tool

	Subject	Value
.	VALVE GUIDES	mm
-	Valve guide bore	8,000 - 8,022

1. Check that the valve specifications are within specified limits; if not, replace the valves.

	Subject	Value
1a	INLET VALVES	mm
-	Stem diameter	7.965 - 7,980

	Subject	Value
1b	INLET VALVES	mm
-	Head diameter	41,4 - 41,8

	Subject	Value
1c	INLET VALVES	mm
-	Height	108,8, mm

	Subject	Value
1d	INLET VALVES
-	Contact angle	45°

	Subject	Value
1a	EXHAUST VALVES	mm
-	Stem diameter	7.955 - 7,970

	Subject	Value
1b	EXHAUST VALVES	mm
-	Head diameter	34,3 - 34,7

	Subject	Value
1c	EXHAUST VALVES	mm
-	Height	108,4

	Subject	Value
1d	EXHAUST VALVES
-	Contact angle	45°30'

Engines: 2.0 16V

- Fit the valves and spark plugs provisionally as described later.1. Carry out a valve leak test using tools (1a) and (1b).

	Description	Code	Function
1a	Lever	1.860.490.000	Valve leakage test

	Description	Code	Function
1b	Sealing pad with pressure gauge	1.895.868.000	Valve leakage test

Engines: 2.0 16V

- Using a torque wrench, check that the valve spring specifications meet specified limits; if not, replace the springs.

	Subject	Value
.	EXTERNAL VALVE SPRING
-	Length	54,5 mm
-	Under a load of	0 daN

	Subject	Value
.	EXTERNAL VALVE SPRING
-	Length	42,5 mm
-	Under a load of	39 daN

	Subject	Value
.	EXTERNAL VALVE SPRING
-	Length	31,0 mm
-	Under a load of	85 daN

- Fit the tool to the cylinder head and secure in the vice.

	Description	Code	Function
.	Support	1.860.470.000	Cylinder head in vice

- Fit a new filter in the lubricant delivery channel to the cylinder head.1. Fit all the valve in their valve guides.2. Fit the tool beneath the cylinder head.

	Description	Code	Function
2	Valve retaining base	1.860.804.000	Valve retention

Engines: 2.0 16V

1. Fit the sealing ring (1a) into its seat using tool (1b).

	Description	Code	Function
1b	Fitting tool	1.860.313.000	Valve guide oil seal fitting.

Engines: 2.0 16V

- Repeat the operation for all rings.1. Fit the lower plate (1a), spring (1b) and upper plate (1c) in order, respecting the marks made upon disassembly.2. Fit semicones (2a) and settle in their seats using tools (2b).

	Description	Code	Function
2b	Tool	1.860.644.030	Removing/refitting valves

	Description	Code	Function
2b	Tool	1.860.644.000	Removing/refitting valves

Engines: 2.0 16V

- Repeat the operation for all valves.1. Fit the calibrated pads to adjust the clearance. Ensure they are fitted in the correct direction.2. Fit the tappets in their housing.

Engines: 2.0 16V

1. Fit the camshaft.2. Fit the camshaft caps (2a) and tighten retaining nuts (2b) to the specified torque in the order shown.

	Value - daNm	Fastening	Component	Ø
2b	1,6	Nut	CAMSHAFT CAPS	-

Engines: 2.0 16V

- Fit the timing gear provisionally.1. 1. Position each cam upright and check the clearance is within specified limits.

	Subject	Value
.	VALVE TAPPETS	mm
-	Inlet valve clearance check	0,15 - 0,25
-	Exhaust valve clearance check	0,35 - 0,45

Engines: 2.0 16V

- if not as specified, remove the camshaft caps, camshaft and tappets.- Remove a calibrated pad and measure its thickness.- Calculate the difference between the measured clearance and the specified clearance for each pad.- Calculate the thickness of the pad to be fitted by adding the thickness of the current pad to the calculated difference (including the + or - sign).- Repeat the procedure for all calibrated pads.- Fit the tappets.1. Fit the camshaft.2. Fit the camshaft caps (2a) and tighten retaining nuts (2b) to the specified torque in the order shown.

	Value - daNm	Fastening	Component	Ø
2b	1,6	Nut	CAMSHAFT CAPS	-

Engines: 2.0 16V

1. Press-fit the lubrication pipe (1a) and the sealing rings (1b).

Engines: 2.3 JTD 16V

Removing

Refitting

1. Position the cylinder head in the vice supporting it using a suitable tool.

	Description	Code	Function
1	Support	1.860.470.000	Cylinder head in vice

2. Undo the bolts (2a) and the nuts (2b).3. Undo the bolts (3a) and remove the connector (3b) from the cylinder head.4. Remove the seal.5. Remove the heat exchanger for the EGR (5a) and the gaskets (5b).

Engines: 2.3 JTD 16V

1. Undo the bolt (1a) and remove the fixed timing belt tensioner (1b).

Engines: 2.3 JTD 16V

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

Engines: 2.3 JTD 16V

1. Undo the bolts (1a) and remove the intake manifold (1b).2. Remove the seal.

Engines: 2.3 JTD 16V

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

Engines: 2.3 JTD 16V

- Position the tool for supporting the valves in the lower part of the cylinder head.

	Description	Code	Function
1	Valve retaining base	1.860.804.000	Valve retention

1. Compress the valve springs using the special tool.

	Description	Code	Function
1	Tool	99360260	Valve spring compression

2. Release the cotters (2a), caps (2b) and springs (2c), then, removing the tools, release the valves (2d) from the cylinder head.

Engines: 2.3 JTD 16V

1. Remove the oil seals (1b) from the valve guides using pliers (1a).

	Description	Code	Function
1a	Extractor	1.860.989.000	Valve guide oil seal extraction

Engines: 2.3 JTD 16V

See in Op. 1016E14

Engines: 2.3 JTD 16V

Refitting

Removing

- De-carbonize and clean the valve seats and ducts.- Clean any residues of the old gasket from the lower cylinder head plane.- Check that the planarity of the lower cylinder head plane corresponds to the recommended values.

	Subject	Value
.	Cylinder head	mm
-	Lower plane planarity	0.1

- 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.

	Subject	Value
.	INLET VALVES	mm
-	Stem diameter	5.985 - 6,000

	Subject	Value
.	EXHAUST VALVES	mm
-	Stem diameter	5.975 - 5.990

See in Op. 1016E14- Using a torque wrench, check that the spring specifications correspond to the recommended figures; if not, replace the worn components.

	Subject	Value
.	VALVE SPRINGS	mm
-	Length	45
-	Under a load of	23.1 - 25.5

	Subject	Value
.	VALVE SPRINGS	mm
-	Length	35
-	Under a load of	50.9 - 55.7

1. Grind the valve seats at (1a), (1b) and (1c) using a suitable tool.

	Subject	Value
1a	VALVE SEATS
-	Contact band angle with inlet/exhaust valve	44° 25' - 44° 35'

Engines: 2.3 JTD 16V

- Check that the valve recess in relation to the cylinder head plane corresponds to the recommended figures using the tool fitted with a magnetic base.

	Description	Code	Function
.	Dial gauge support	1.870.404.000	Valve recess in cylinder head plane measurement

- If the valve recess in relation to the cylinder head plane does not correspond to the recommended figures, regrind the valve seats once again.- Fit all the valves in the correct positions.- Position the tool for supporting the valves in the lower part of the cylinder head.

	Description	Code	Function
.	Valve retaining base	1.860.804.000	Valve retention

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

	Description	Code	Function
.	Fitting tool	1.860.993.000	Fitting oil seals on valve stems

Engines: 2.3 JTD 16V

- Fit the valve springs and shims.- Compress the valve springs and fit the cotters using the special tool.

	Description	Code	Function
.	Tool	99360260	Valve spring compression

- Remove the tools used for fitting the valves.

	Description	Code	Function
.	Valve retaining base	1.860.804.000	Valve retention

	Description	Code	Function
.	Tool	99360260	Valve spring compression

- Position the brackets and tighten the fixing bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.5	Bolt	HOISTS	M8 X 1.25

- Fit a new gasket, position the intake manifold and tighten the fixing bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.5	Bolt	INLET MANIFOLD	M8 X 1.25

- Position the thermostat and tighten the fixing bolts.- Fit the fixed timing belt tensioner and tighten the retaining bolt to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2.5	Bolt	FIXED TENSIONER	M8 X 1.25

- Fit the new gaskets, position the EGR heat exchanger and tighten the fixing bolts and nuts.- Connect the EGR heat exchanger connector to the cylinder head and tighten the fixing bolt.- Remove the cylinder head from the vice.- Remove the support tool.

	Description	Code	Function
1	Support	1.860.470.000	Cylinder head in vice

Engines: 2.0 JTD 8V

Removing

Refitting

1. Fit the tool on the cylinder head and secure the tool on a vice.

	Description	Code	Function
1	Support	1.860.470.000	Cylinder head in vice

Engines: 2.0 JTD 8V

1. Undo bolts (1a) and remove pulley (1b) using tool (1c).

	Description	Code	Function
1c	Counter-torque	1.860.776.000	Timing pulley lock

Engines: 2.0 JTD 8V

1. Undo central nut (1a) and remove flange (1b) using tool (1c).

	Description	Code	Function
1c	Counter-torque	1.860.776.000	Timing pulley lock

Engines: 2.0 JTD 8V

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

Engines: 2.0 JTD 8V

- Remove the fuel return pipe from the injector.1. Undo nut (1a) securing the injector bracket.2. Remove injector (2a), sealing ring (2b), washer (2c), bracket (2d) and support dowel (2e).- Repeat the operation for all the injectors.3. Remove spark plug supply lead (3a) and spark plugs (3b).

Engines: 2.0 JTD 8V

1. Undo the twelve bolts in the order indicated.

Engines: 2.0 JTD 8V

1. Remove the cylinder head extension (1a), camshaft (1b) and oil sealing ring (1c).

Engines: 2.0 JTD 8V

1. Remove rocker (1a) and tappet (1b).- Repeat the operation for all rocker-tappet assemblies.

Engines: 2.0 JTD 8V

1. Fit the tool beneath the cylinder head.

	Description	Code	Function
1	Valve retaining base	1.860.804.000	Valve retention

2. Remove half-cones (2a) from the valve using tools (2b).

	Description	Code	Function
2b	Tool	1.860.644.000	Removing/refitting valves

	Description	Code	Function
2b	Tool	1.860.877.000	Removing/refitting valves

3. Remove upper plate (3a), spring (3b) and lower plate (3c) in order.- Repeat the operation for all the valves.- Remove the tool.

	Description	Code	Function
.	Valve retaining base	1.860.804.000	Valve retention

4. Remove all the valves.

Engines: 2.0 JTD 8V

1. Remove valve stem sealing ring (1a) using tool (1b).

	Description	Code	Function
1b	Extractor	1.860.989.000	Valve guide oil seal extraction

- Repeat the operation for all the valve stem sealing rings.

Engines: 2.0 JTD 8V

1. Remove the lubrication circuit check valve.

Engines: 2.0 JTD 8V

1. Remove the valve guides from their seats using the tool.

	Description	Code	Function
1	Extractor	1.860.939.000	Valve guide extraction

Engines: 2.0 JTD 8V

- Remove the cylinder head from the tool.

	Description	Code	Function
.	Support	1.860.470.000	Cylinder head in vice

Engines: 2.0 JTD 8V

Refitting

Removing

- Clean all the ports thoroughly.1. Check the lower surface and check that flatness is within specified limits.

	Subject	Value
1	CYLINDER HEAD	mm
-	Flatness	0,05

Engines: 2.0 JTD 8V

1. Check that the cylinder head height is within the recommended limits.

	Subject	Value
1	CYLINDER HEAD	mm
-	Height	132,95 - 133,05

- if cylinder head flatness and/or height are not within the specified limits, grind the lower surface without exceeding the minimum pemitted height.

	Subject	Value
.	CYLINDER HEAD	mm
-	Minimum permitted height	132,55 - 132,65

Engines: 2.0 JTD 8V

1. Grind the intake valve seats using a suitable tool.

	Subject	Value
1a	VALVE SEATS
-	Contact band angle with intake valve	45°

	Subject	Value
1b	VALVE SEATS
-	Intake port outlet angle	65°

	Subject	Value
1c	VALVE SEATS
-	Intake port intake angle	25°

2. Grind the exhaust valve seats using a suitable tool.

	Subject	Value
2a	VALVE SEATS
-	Contact band angle with intake valve	45°

	Subject	Value
2b	VALVE SEATS
-	Exhaust port intake angle	25°

	Subject	Value
.	VALVE SEATS	mm
-	Intake valve contact band width	1,00

	Subject	Value
.	VALVE SEATS	mm
-	Exhaust valve contact band width	2,25

Engines: 2.0 JTD 8V

1. Check the correct contact between the valve and seat after grinding.

Engines: 2.0 JTD 8V

- If it is not possible to achieve centred, uniform contact between valve and seat, replace the valve seat.- Ream the valve guide seats using a suitable tool.

	Subject	Value
.	VALVE GUIDES	mm
-	Oversize valve guide seat diameter	12,398 - 12,521

1. Press-fit new and oversize valve guides (1a) from the upper part of the cylinder head using tool (1b).

	Description	Code	Function
1b	Fitting tool	1.870.768.000	Valve guide fitting

Engines: 2.0 JTD 8V

1. Check that valve guide position is within specified limits

	Subject	Value
1	VALVE GUIDES	mm
-	Distance between valve guide - lower cylinder head surface	34,50 - 35,50

Engines: 2.0 JTD 8V

- Ream the valve guides using a suitable tool.1. Check that the valve specifrications correspond to the recommended limits; if not, replace the valves.

	Subject	Value
1a	INLET VALVES	mm
-	Stem diameter	5,971 - 5,985

	Subject	Value
1b	INLET VALVES	mm
-	Head diameter	35,5 - 35,7

	Subject	Value
1c	INLET VALVES	mm
-	Height	106,78 - 107,18

	Subject	Value
1d	INLET VALVES	mm
-	Contact angle	45° - 45° 7'30"

	Subject	Value
1a	EXHAUST VALVES	mm
-	Stem diameter	5,961 - 5,975

	Subject	Value
1b	EXHAUST VALVES	mm
-	Head diameter	33,7 - 33,9

	Subject	Value
1c	EXHAUST VALVES	mm
-	Height	107,18 - 106,78

	Subject	Value
1d	EXHAUST VALVES	mm
-	Contact angle	45° - 45°7'30"

Engines: 2.0 JTD 8V

1. Check that valve protrusion (1a) in relation to the cylinder head surface meets specified limits using tool (1b).

	Description	Code	Function
1b	Dial gauge support	1.870.404.000	Injector projection from cylinder head plane measurement

	Subject	Value
.	CYLINDER HEAD VALVES (ALL)	mm
-	Protrusion from lower cylinder head surface	0,20

Engines: 2.0 JTD 8V

- Repeat the operation for each valve.- Fit the valves, injectors and glow plugs provisionally as described below.1. Test the valve seal using tool (1a) and (1b).

	Description	Code	Function
1a	Lever	1.860.490.000	Valve leakage test

	Description	Code	Function
1b	Sealing pad with pressure gauge	1.895.868.000	Valve leakage test

Engines: 2.0 JTD 8V

- Using a torque wrench, check that the spring specifications correspond to the recommended figures; if not, replace the worn springs.

	Subject	Value
.	EXTERNAL VALVE SPRING
-	Length	37,0 mm
-	Under a load of	24,700-27,300 daN

	Subject	Value
.	EXTERNAL VALVE SPRING
-	Length	27,7 mm
-	Under a load of	43,225-47,775 daN

- Fit the cylinder head extension together with the camshaft as described below.- Tighten the ten retaining bolts to the specified torque as described below.

	Value - daNm	Fastening	Component	Ø
.	1,0	Bolt	CYLINDER HEAD EXTENSION FASTENERS	-

1. Check that the axial clearance is within specified limits.

	Subject	Value
1	CAMSHAFT INTAKE AND EXHAUST	mm
-	End float	0,08 - 0,38

Engines: 2.0 JTD 8V

- Remove the bolts, cylinder head extension and camshaft.- Fit the tool on the cylinder head and secure the tool on a vice.

	Description	Code	Function
.	Support	1.860.470.000	Cylinder head in vice

- Fit the lubrication circuit check valve.1. Fit all the valves in the valve guide.2. Fit the tool beneath the cylinder head.

	Description	Code	Function
2	Valve retaining base	1.860.804.000	Valve retention

Engines: 2.0 JTD 8V

1. Fit sealing ring (1a) into its seat using tool (1b).

	Description	Code	Function
1b	Fitting tool	1.860.993.000	Fitting oil seals on valve stems

Engines: 2.0 JTD 8V

- Repeat the operation for all the rings.1. Fit lower plate (1a), spring (1b) and upper plate (1c) in order, respecting the marks made upon disassembly.2. Fit semicones (2a), taking care to settle in their seats using tools (2b).

	Description	Code	Function
2b	Tool	1.860.644.000	Removing/refitting valves

	Description	Code	Function
2b	Tool	1.860.877.000	Removing/refitting valves

Engines: 2.0 JTD 8V

- Repeat the operation for all the valves.- Fit the tappet and rockers, respecting the marks made upon disassembly.- Repeat the operation for all rocker-tappet assemblies.1. Apply silicone sealant to the cylinder head extension mating surfaces.

	Description	Qty.	Component	Type	Classification
.	DOW CORNING, 7091	-	CYLINDER HEAD EXTENSION	Silicone sealant	-

Engines: 2.0 JTD 8V

- Fit the cylinder head extension together with the camshaft.1. Tighten the twelve bolts (1a) to the specified torque in the order indicated.

	Value - daNm	Fastening	Component	Ø
1	1,0	Bolt	CYLINDER HEAD EXTENSION FASTENERS	-

Engines: 2.0 JTD 8V

1. Lubricate and, if necessary, replace the seals (1a) and the oil filter (1b).2. Fit the vacuum unit and tighten the bolts (2a) and the nut (2b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2a	4,3	Bolt	BRAKING SYSTEM BRAKES	-

	Value - daNm	Fastening	Component	Ø
2b	4,3	Nut	BRAKING SYSTEM BRAKES	-

Engines: 2.0 JTD 8V

1. Fit the oil sealing ring (1a) using the tool (1b)

	Description	Code	Function
1b	Fitting tool	1.860.990.000	Camshaft front oil seal

Engines: 2.0 JTD 8V

- Fit the camshaft pulley flange, centring the drive tooth.- Tighten the central flange retaining nut to the specified torque using the tool.

	Description	Code	Function
.	Counter-torque	1.860.776.000	Timing pulley lock

	Value - daNm	Fastening	Component	Ø
.	4,3	Nut	TIMING PULLEY FLANGE	-

- Check spark plug continuity using a multimeter.1. Fit spark plugs (1a), tighten to the specified torque and fit spark plug supply lead (1b).

	Value - daNm	Fastening	Component	Ø
1a	2,3	Spark plug	GLOW PLUGS	-

2. Fit the shim (2a), sealing ring (2b) and injector (2c) in order3. Fit support dowel (3a), bracket (3b) and tighten nut (3c) to the specified torque.

	Value - daNm	Fastening	Component	Ø
3c	2,3	Nut	INJECTORS(DIESEL)	-

- Repeat the operation for all the injectors.4. Fit the fuel return pipe.

Engines: 2.8 JTD 8V

- Proceed with the DISMANTLING.- Place the head on a workbench.1. Fit the tool (1a) on the cylinder head (1b) and secure it using the nuts (1c), then place the tool (1a) in a vice.

	Description	Code	Function
1a	Counter-torque	1.860.765.001	Loosen/tighten auxiliary shaft toothed drive pulley bolt

Engines: 2.8 JTD 8V

1. Fit the tool.

	Description	Code	Function
1	Counter-torque	1.860.765.001	Loosen/tighten toothed timing drive pulley bolt

2. Undo the fixing bolts (2a) and remove the driven timing pulley (2b).3. Undo the fixing nuts (3a) and remove the front cover (3b).

Engines: 2.8 JTD 8V

1. Undo the nuts fixing the camshaft caps.2. Remove the camshaft caps.3. Remove the camshaft.4. Remove the tappets.

Engines: 2.8 JTD 8V

1. Undo the nuts (1a) and remove the fuel distribution manifold cover (1b).2. Remove the fuel distribution manifold.

Engines: 2.8 JTD 8V

1. Undo the bolts (1a) and remove the thermostat unit (1b).2. Remove the seal.3. Undo the fixing bolts (3a) and remove the bracket (3b).4. Undo the fixing bolts (4a) and remove the cover (4b).5. Undo the fixing nuts (5a) and remove the bracket (5b).

Engines: 2.8 JTD 8V

- 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 tool (1b).

	Description	Code	Function
1b	Tool	1.860.644.000	Removing/refitting valves

2. Remove the valve upper shim.3. Remove the outer valve spring (3a) and the inner one (3b).

Engines: 2.8 JTD 8V

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

	Description	Code	Function
1b	Extractor	1.860.989.000	Valve guide oil seal extraction

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 support tool from the cylinder head.

	Description	Code	Function
.	Support	1.860.470.000	Cylinder head in vice

Engines: 2.8 JTD 8V

See in Op. 1016E14- Proceed with the REASSEMBLY- 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.

	Subject	Value
.	Cylinder head	mm
-	Lower plane planarity	0.1

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.

	Subject	Value
1	Cylinder head	mm
-	Minimum permitted height	149,5 - 149,7

Engines: 2.8 JTD 8V

- 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.

	Subject	Value
.	Cylinder head valves (all)	mm
-	Stem diameter	7,985 - 8,000

See in Op. 1016E14- Check that the tappet outer diameter corresponds to the recommended figures; if not, replace the tappets with oversize ones.

	Subject	Value
.	Cylinder head camshaft tappet cases	mm
-	Outer diameter	43,950 - 43,970
-	Outer diameter oversize	44,150 - 44,170

- Check that the diameter of the tappet housings corresponds to the recommended figures; if not, replace the cylinder head.

	Subject	Value
.	Engine cylinder head	mm
-	Tappet housing diameter	44,000 - 44,025
-	Tappet housing diameter oversize	44,200 - 44,225

- Using a torque wrench, check that the spring specifications correspond to the recommended figures; if not, replace the worn components.

	Subject	Value
.	Inner valve spring
-	Length mm	33,5
-	under a load of daN	15,4 - 17,4

	Subject	Value
.	Inner valve spring
-	Length mm	23,5
-	under a load of daN	28,5 - 38,5

	Subject	Value
.	Inner valve spring
-	Length mm	38,5
-	under a load of daN	41,3 - 46,3

	Subject	Value
.	Inner valve spring
-	Length mm	28,5
-	under a load of daN	73,4 - 81,4

1. Reface the valve seats to the recommended figure using a suitable tool.

	Subject	Value
1	Cylinder head valve seats (all)
-	Contact band angle with inlet valve	29° 55' - 30° 05'
-	Contact band angle with exhaust valve	44° 55' - 45° 05'

	Subject	Value
2	Cylinder head valve seats (all)
-	Inlet/exhaust manifold outlet angle	20°

	Subject	Value
3	Cylinder head valve seats (all)
-	Inlet/exhaust manifold inlet angle	75°

Engines: 2.8 JTD 8V

- Temporarily fit the injectors.1. Check that the injector projection in relation to the cylinder head plane (1a) corresponds to the recommended figures using the tool (1b) fitted with a dial gauge.

	Subject	Value
.	Injectors (DIESEL)	mm
-	Projection from cylinder head plane	2,230 - 2,690

	Description	Code	Function
1b	Dial gauge support	1.870.404.000	Injector projection from cylinder head plane measurement

2. If the projection of the injectors in relation to the cylinder head plane does not correspond to the recommended figures, fit an approriate oversize washer in the injector seat.

Engines: 2.8 JTD 8V

- Remove the injectors.- 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.

	Subject	Value
1a	Cylinder head valves (all)
-	Valve recess in relation to cylinder head plane	mm
-	inlet	1,2 - 1,5
-	exhaust	1,0 - 1,3

	Description	Code	Function
1b	Dial gauge support	1.870.404.000	Valve recess in cylinder head plane measurement

- If the valve recess in relation to the cylinder head plane does not correspond to the recommended figures, regrind the valve seats once again.

Engines: 2.8 JTD 8V

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

	Subject	Value
.	INTAKE AND EXHAUST CAMSHAFT
-	Nominal cam lift	mm
-	inlet	9,5
-	exhaust	10,5

- Check that the diameter of the camshaft bearings corresponds to the recommended figures; if not, replace the worn camshaft with an oversize one.

	Subject	Value
.	INTAKE AND EXHAUST CAMSHAFT	mm
-	Journal diameter	33,934 - 33,950

	Subject	Value
.	INTAKE AND EXHAUST CAMSHAFT	mm
-	Journal diameter oversize	0,20

- Fit the camshaft caps (1a) on the cylinder head and tighten the nuts (1b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	1,8	Nut	CAMSHAFT SUPPORTS	M8

- Check that the camshaft support diameter corresponds to the recommended figures; if not, proceed with the regrinding using the recommended oversize.

	Subject	Value
.	Camshaft caps	mm
-	Support diameter	33,985 - 34,015

	Subject	Value
.	Camshaft caps	mm
-	Support diameter oversize	0,20

- Fit the support tool on the cylinder head and secure it using the nuts.

	Description	Code	Function
.	Support	1.860.470.000	Cylinder head in vice

- Fit all the valves.- Position a suitable wooden stand on the cylinder head plane to support the valves and secure it using bolts.- Fit the cylinder head, complete with valves, in the vice.- Fit the lower shim.1. Fit the valve guide oil seal (1a) using the tool (1b).

	Description	Code	Function
1b	Fitting tool	1.860.313.000	Valve guide oil seal fitting.

Engines: 2.8 JTD 8V

1. Fit the inner valve spring (1a) and the outer one (1b).2. Fit the valve upper shim.3. Fit the cotters (3a) using the tool (3b).

	Description	Code	Function
3b	Tool	1.860.644.000	Removing/refitting valves

Engines: 2.8 JTD 8V

- 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 tappets complete with valve clearance adjustment pads.- Fit the camshaft.1. Fit the camshaft caps.2. Tighten the camshaft cap bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	1,8	Nut	CAMSHAFT SUPPORTS	M8

Engines: 2.8 JTD 8V

1. Fit the front oil seal on the camshaft cover (1a) using the tools (1b) and (1c).

	Description	Code	Function
1b	Fitting tool	1.860.623.000	Camshaft front oil seal fitting

	Description	Code	Function
1c	Grip	1.870.007.000	Camshaft front oil seal fitting

2. Fit the front cover applying sealant and tighten the fixing nuts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2	0.75	Nut	INLET AND EXHAUST CAMSHAFT FRONT COVER	M6

3. Fit the bracket tightening the fixing nuts.4. Fit the cover applying sealant and tightening the fixing bolts.5. Fit the bracket tightening the fixing nuts.

Engines: 2.8 JTD 8V

- Fit the tool.

	Description	Code	Function
.	Counter-torque	1.860.765.001	Loosen/tighten toothed timing drive pulley bolt

- Fit the toothed driven pulley and tighten the fixing bolts to the recommended torque.

	Value - daNm	Fastening	Component	Ø
.	2,5	Bolt	TIMING DUCT PULLEY	M8

- Remove the tool.

	Description	Code	Function
.	Counter-torque	1.860.765.001	Loosen/tighten toothed timing drive pulley bolt

1. 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.

	Subject	Value
.	Cylinder head valves (all)
-	Inlet valves clearance in closed position	mm
-	inlet	0,45 - 0,55
-	exhaust	0,45 - 0,55

2. Lower the tappet in question using the tool.

	Description	Code	Function
2	Lever	1.860.443.000	Lower tappets

3. Fit the tool.

	Description	Code	Function
3	Lever	1.860.724.001	Keep tappets lowered

- Remove the tool.

	Description	Code	Function
.	Lever	1.860.443.000	Lower tappets

4. Remove the valve clearanance adjustment plate and replace it with a one of a suitable thickness.- Remove the tool.

	Description	Code	Function
.	Lever	1.860.724.001	Keep tappets lowered

Engines: 2.8 JTD 8V

1. Remove the seal.2. Fit the thermostat (2a) complete with pipes and tighten the bolts (2b) to the recommended torque.

	Value - daNm	Fastening	Component	Ø
2b	1,8	Bolt	THERMOSTAT	M8

Engines: 2.8 JTD 8V

- Fit the fuel distribution manifold complete with pipes and fuel pressure sensor and tighten the nuts.- Remove the cylinder head from the vice.- Remove the support tool from the cylinder head.

	Description	Code	Function
.	Support	1.860.470.000	Cylinder head in vice