1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL - Alfa - 156 - eLearn

3239084 - 1016E10 single cylinder head, removed - overhaul

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

1. Fit the tool on the engine block.

	Name	Country
1	Mount	1.860.470.001

Position the cylinder head in the vice using the support tool fitted previously.1. Disconnect the electrical connection from the engine coolant temperature sensor.

	Name	Connector
1	Engine temperature sender unit	K36

2. Release the electrical wiring (2a) from the band (2b).

1. Disconnect the electrical connection from the fuel pressure regulator.

	Name	Connector
1	Fuel pressure regulator	N77

2. Disconnect the electrical connection from the fuel pressure sensor.

	Name	Connector
2	Fuel pressure sensor	K83

3. Disconnect the electrical connection from the throttle body integrated with the D.V.L.

	Name	Connector
3	Throttle body actuator	N75

1. Disconnect the electrical connection from the variable valve timing electro-magnet.2. Disconnect the electrical connection from the enablement solenoid of the changeover device actuator.

	Name	Connector
2	Variable geometry control solenoid	L15

3. Remove the electrical wiring (3a) after having released it from the fastenings (3b) on the modular intake manifold. 4. Loosen the band and disconnect the coolant return pipe to the coolant reservoir from the thermostat, then remove.

1. Release the electrical wiring from the retaining bands.2. Disconnect the electrical connection from the fuel vapour recovery solenoid.

	Name	Connector
2	Fuel vapour recovery solenoid	L10

1. Disconnect the electrical connections from the injectors.

	Name	Connector
1	Injector	N70

2. Remove the electrical wiring (2a) after having released it from the fastening bands (2b).

1. Undo the bolts securing the modular intake manifold brackets.

1. Loosen bands (1a) and remove the modular intake manifold assembly (1b).

1. Undo connectors (1a) and remove the high pressure fuel pipe (1b).

The high pressure fuel pipe must be replaced at each reassembly.

1. Undo bolts (1a) and remove fuel manifold pipe assembly (1b).

1. Undo the nuts (1a) and remove the inlet manifold (1b).2. Remove the gasket.

1. Remove the connectors with O-rings from the injectors.2. Undo nuts (2a) and remove the injectors (2b) with brackets (2c).

1. Undo the bolts (1a) and remove the thermostat (1b) complete with O-Ring (1c).

1. Undo the bolts (1a) and remove the high-pressure fuel pump (1b) complete with O-ring (1c).

1. Undo the bolts (1a) and remove the water pump (1b) complete with O-Ring (1c).

1. Loosen the bolt (1a) for the exhaust side timing driven pulley using tool (1b) for counter-torque.

	Name	Country
1b	Spanner for camshaft pulley rotation	1.860.831.002

2. Remove the exhaust side driven toothed pulley.

1. Undo the bolts (1a) of the timing driven pulley, inlet side, using the tool (1b) for counter-torque.

	Name	Country
1b	Counter-torque	1.860.856.001

2. Remove the timing driven pulley, inlet side.

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

Check that the camshaft end float is within the recommended values using a dial gauge on a magnetic base.

	Measurement		Value
-	Camshaft end float (mm)		0.10 ÷ 0.23

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

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

The front cap has silicone sealant, so a plastic hammer should be used for its removal.

2. Remove the upper bearing shell for the front camshaft support, inlet side.3. Remove the camshafts.4. Remove the front camshaft oil seals.5. Remove the lower bearing shell for the front camshaft support, inlet side. 6. Remove the hydraulic tappets, grading them.

1. Place the exhaust side camshaft in a vice fitted with protective jaws.2. Unscrew the pressure pump drive sleeve and remove.

1. Remove the calibrated jet used to lubricate the high pressure fuel pump control coupling.

1. Remove the split collars (1a) using tools (1b), (1c), (1d), (1e) and (1f).

	Name	Country
1b	Valve supports	1.820.011.000

	Name	Country
1c	Special nut	1.820.049.000

	Name	Country
1d	Mount	1.821.124.000

	Name	Country
1e	Chamber	1.821.205.000

	Name	Country
1f	Lever	1.821.058.000

2. Remove the upper valve shim.3. Remove the valve springs.Remove the valve dismantling tools.4. Remove the valve.Work in the same way to remove the remaining valves.

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

	Name	Country
1b	Extractor	1.860.989.000

2. Remove the lower valve shims.

Reassembling ( Dismantling

) Clean any residues of sealant from the matching surfaces of the cylinder head and front journal cap. Check that the planarity of the lower cylinder head surface is within the recommended values.

	Measurement		Value
-	Cylinder head lower plane planarity (mm)		0.1

1. If the planarity of the lower cylinder head surface is not within the recommended values, reface the lower cylinder head surface without exceeding the minimum permissible height for the combustion chamber.

	Measurement		Value
1	Combustion chamber minimum permissible height (mm)		12.8 ÷ 13.2

The volume of the combustion chamber for each cylinder is given below.

	Measurement		Value
-	Combustion chamber volume (c.c.)		38.2

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.

	Measurement		Value
-	Valve stem diameter (mm)	Exhaust	6.960 ÷ 6.975
Inlet	6.975 ÷ 6.990

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

	Measurement		Value
-	Valve head diameter (mm)	Exhaust	28.2
Intake	33.7

The taper of the valve contact band in relation to the valve bore is given below.

	Measurement		Value
-	Valve contact band taper (-)		45° 30'

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

	Measurement		Value
-	Hydraulic tappeter outer diameter (mm)		32.959 ÷ 32.975

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

	Measurement		Value
-	Diameter of hydraulic tappet seats (mm)		33.000 ÷ 33.025

Check that the length of the uncompressed valve springs is within the recommended values.

	Measurement		Value
-	Valve spring length released (mm)	External	46.0
Internal	39.0

Use a torque wrench to check that the spring specifications are within specified values; if this is not the case, replace parts that have yielded.

	Measurement		Value
-	Outer valve spring height (mm)		35.0
	Check load (daN)	25.0 ÷ 27.4

	Measurement		Value
-	Outer valve spring height (mm)		24.4
	Check load (daN)	49.4 ÷ 53.4

	Measurement		Value
-	Inner valve spring height (mm)		28.7
	Check load (daN)	11.6 ÷ 12.6

	Measurement		Value
-	Inner valve spring height (mm)		18.1
	Check load (daN)	23.6 ÷ 25.6

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

	Measurement		Value
-	Camshaft bearing diameter (mm)		26.000 ÷ 26.015

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

	Measurement		Value
-	Camshaft nominal cam lift (mm)	Exhaust	10.2
Intake	10.6

1. Place the camshaft cams back in their housings in the cylinder head and secure them tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CAMSHAFT SUPPORTS	M7	(Cylinder head side) 1.4 ÷ 1.7

Check the diameter of the camshaft mounts is within specified values; If this is not the case, replace the cylinder head.

	Measurement		Value
-	Camshaft bearing diameter (mm)		26.045 - 26.070

If necessary, grind the valve seats to the specified height.

	Measurement		Value
-	Angle"a" valve seat upper band (-)		150°

	Measurement		Value
-	Angle "b" contact band with valves (-)		90° ± 10?

	Measurement		Value
-	Angle "c" valve seat lower band (-)		30°

	Measurement		Value
-	Width "L" contact band with valves (mm)	Exhaust	1.0
Intake	0.8

Refit the support tool to the cylinder head.

	Name	Country
-	Mount	1.860.470.001

Position the cylinder head in the vice using the support tool fitted previously.Fit the lower valve shims back in their housings.1. Position valve (1a) in its seat temporarily and fit the valve guide oil seal locating tool (1b).

	Name	Country
1b	Drift	1.860.814.001

2. Fit the valve guide oil seal by hand, then remove the locating tool. 3. Drive home the valve guide oil seal using the tool.

	Name	Country
3	Fitting tool	1.860.812.000

Work in the same way when fitting the remaining valve guide oil seals.

1. Place the valve (1a) back in its housing and support it using the tools (1b) and (1c).

	Name	Country
1b	Valve supports	1.820.011.000

	Name	Country
1c	Special nut	1.820.049.000

2. Place the valve springs back in their housings.3. Place the upper valve shim back in its housing.4. Place the split cotters (4a) back in their housings using the tools (4b), (4c) and (4d).

	Name	Country
4b	Mount	1.821.124.000

	Name	Country
4c	Chamber	1.821.205.000

	Name	Country
4d	Lever	1.821.058.000

Work in the same way when fitting the remaining valves.Remove the valve dismantling/fitting tools.

Refit the calibrated jet used to lubricate the fuel high pressure pump drive coupling.1. Place the exhaust side camshaft in a vice fitted with protective jaws.2. Refit the pressure pump drive sleeve in its seat on the camshaft and tighten to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2	-	PRESSURE PUMP DRIVE SPIGOT	M12	(Exhaust camshaft side) 8.2 ÷ 10.0

Place the hydraulic tappets in their housings.Place the inlet side camshaft front support lower bearing shell back in its housing. Place the camshafts back in their housings.Place the inlet side camshaft front support upper bearing shell back in its housing.1. Place the camshft caps (1a) back in their housings and secure them tightening the bolts (1b) to the recommended torque.

Apply silicone sealant between the front cap and the cylinder head.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CAMSHAFT SUPPORTS	M7	(Cylinder head side) 1.4 ÷ 1.7

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

	Name	Country
1b	Fitting tool	1.821.228.000

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

	Name	Country
1b	Fitting tool	1.821.252.000

Place the cam angle sensor back in its housing and fix it using the bolts. Place the inlet side driven toothed pulley back in its housing and fix it without tightening the bolt. Place the exhaust side driven toothed pulley back in its housing and fix it without tightening the bolt.1. Place water pump (1a), complete with O-ring (1b), back in its housing and fix it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	COOLANT PUMP	M8	(Cylinder head side) 2.3 ÷ 2.8

1. Place the high-pressure fuel pump (1a) in its seating complete with O-ring (1b) and fix it tightening the bolts (1c) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	HIGH PRESSURE FUEL PUMP	M6	(Cylinder head side) 0.8 ÷ 1.0

1. Refit thermostat (1a), complete with O-ring (1b) and secure by tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	THERMOSTAT	M8	(Cylinder head side) 2.3 ÷ 2.8

1. Refit injectors (1a) with brackets (1b) and secure by tightening nuts (1c) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1c	Self-locking nut	INJECTORS	M6	(Intake manifold side) 0.5 ÷ 0.6

2. Refit the connectors with O-rings into their seats on the injectors.

1. Refit inlet manifold (1a), complete with gasket (1b), back in its housing and secure by tightening nuts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Nut	INLET MANIFOLD	M8	(Cylinder head side) 2.3 ÷ 2.8

1. Refit the fuel manifold (1a) and secure it by tightening bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	FUEL MANIFOLD	M9	(Intake manifold side) 3.9 ÷ 4.7

1. Place a new fuel high-pressure pipe (1a) in its seating and secure it by tightening the connectors (1b) and (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Connector	FUEL HIGH PRESSURE PIPE	M10	(High pressure pump side) 1.2 ÷ 1.6

	Fastening	Component	Ø	Value(daNm)
1c	Connector	FUEL HIGH PRESSURE PIPE	M12	(Fuel manifold pipe side) 2.0 ÷ 2.4

Refit the modular intake manifold assembly and tighten the bands. Tighten the modular intake manifold bracket bolts.Place the electrical wiring back in its housing and fix it to the bands. Connect the electrical connections to the injectors.Connect the electrical connection to the fuel vapour recovery solenoid valve.Fix the electrical wiring using the bands.Refit the coolant return pipe to the supply reservoir, connect to the thermostat and tighten the band. Refit the electrical wiring and secure to the modular intake manifold.Connect the electrical connection from the enablement solenoid of the changeover device actuator. Connect the electrical connection to the variable valve timing electro-magnet.Connect the electrical connection to the throttle body integrated with the D.V.L. Connect the electrical connection to the fuel pressure sensor. Connect the electrical connection to the fuel pressure regulator. Secure the electrical wiring to the band.Connect the electrical connection to the engine coolant temperature sensor. Remove the cylinder head from the support tool.

	Name	Country
-	Mount	1.860.470.001

Place the water pump rigid inlet pipe, complete with gasket, back in its housing and secure it using the bolts.