1016E22 R CYLINDER HEAD - OVERHAUL - Alfa - 156 - eLearn

3239070 - 1016E22 r cylinder head - overhaul

) 1. Position the tool in the vice.

	Name	Country
1	Mount	1.820.012.000

2. Fit the tool (2a) complete with tool (2b).

	Name	Country
2a	Mount	1.820.050.000

3. Position the cylinder head (3a) on the supporting tools and fix it using the nuts (3b).

1. Undo the bolts (1a) and remove the intake pipes (1b).2. Undo the bolts (2a) and remove the fuel distribution manifold (2b) complete with fuel injectors (2c).3. Remove the air intake manifold (3a) complete with gasket (3b).

1. Undo the bolts (1a) and remove the automatic timing belt tensioner (1b).2. Undo the bolt (2a) and remove the fixed timing belt tensioner (2b).

1. Slacken the bolts (1a) on the camshaft pullies using the tools (1b) for counter-torque.

	Name	Country
1b	Counter-torque	1.822.146.000

1. Remove the camshaft pullies (1a) using the tool (1b).

	Name	Country
1b	Timing pullies extractor	1.860.954.000

1. Undo the bolts (1a) and remove the timing belt cover (1b).2. Undo the nuts (2a) and remove the reaction rod support (2b).

1. Undo the bolt (1a) and remove the coolant outlet connector from the right cylinder head (1b).2. Undo the bolt (2a) and remove the timing senor (2b), complete with O-Ring (2c).

	Name	Connector
2b	Timing sensor	K47

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

	Measurement		Value
-	End float (mm)		0.060 - 0.201

If the value of the camshaft end float is not within the recommended values, when reassembling, replace the worn components.1. Undo the bolts (1a) and remove the camshaft caps (1b).2. Remove the camshafts.3. Remove the front camshaft oil seals.4. Remove the hydraulic tappets.5. Remove the spark plug housing gaskets.

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 tools used for dismantling the valves.4. Remove the valve.Work in the same way to remove the remaining valves.

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

	Name	Country
1b	Extractor	1.821.208.000

2. Remove the lower spring washer (2a) and the lower valve shim (2b).

Remove the cylinder head from the supporting tools and position it on an appropriate workbench.1. Screw the special extraction tool (1b) in the valve seat (1a).Turn the cylinder head upside down on the workbench.Remove the valve seat using the extraction tool.

1. Remove the valve guides (1a) using the tool (1b).

	Name	Country
-	Extractor	1.821.176.000

Reassembling ( Dismantling

) Clean the residues of the old gasket from the lower surface of the cylinder head.1. Check that the planarity of the lower cylinder head surface is within the recommended values.

	Measurement		Value
1	Flatness of bottom surface (mm)		0.05

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.

	Measurement		Value
1	Minimum permissible height after refacing (mm)		134.85 - 135.15

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
-	Stem diameter (mm)		6.965 - 6.980

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

	Measurement		Value
-	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 valve springs is within the recommended values.

	Measurement		Value
-	Free length- Exterior (mm)		45

	Measurement		Value
-	Free length - Interior (mm)		42

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
-	Laden (daN)		21.9 - 23.1
	Length (mm)	32.5

	Measurement		Value
-	Laden (daN)		43.1 - 45.0
	Length (mm)	23

	Measurement		Value
-	Laden (daN)		12.4 - 13.1
	Length (mm)	30.5

	Measurement		Value
-	Laden (daN)		24.0 - 26.0
	Length (mm)	21

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

	Measurement		Value
-	Journal diameter (mm)		25.959 - 26.980

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

	Measurement		Value
-	Nominal cam lift (mm)		9.30

1. Fit the camshaft caps on the right cylinder head in accordance with the sequence indicated in the figure.

1. Tighten the camshaft cap bolts to torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	CAMSHAFT CAPS	M8	1.8 - 2.0

2. 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)		27.010 - 27.036

Check that the outer diameter of the valve guides to be fitted is within the recommended values.

	Measurement		Value
-	Inlet outer diameter (mm)		12.040 - 12.051 (*)
	Oversize (mm)	0.20

	Measurement		Value
-	Exhaust outer diameter (mm)		12.050 - 12.068 (*)
	Oversize (mm)	0.20

1. Fit the valve guides (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.821.207.000

Ream the inner diameter of the valve guides to the recommended diameter.

	Measurement		Value
-	Inner diameter (mm)		7.000 - 7.015

Check that the outer diameter of the valve seats to be fitted is within the recommended values.

	Measurement		Value
-	Inlet outer diameter (mm)		34.600 - 34.616
	Oversize (mm)	0.3

	Measurement		Value
-	Exhaust outer diameter (mm)		30.100 - 30.110
	Oversize (mm)	0.3

1. Heat up the cylinder head to 100-120° C, then fit the valve seats (1a) using a suitable tool (1b).

1. Reface the valve seats to the recommended figure.

	Measurement		Value
1	Valve contact band taper (mm)		90° ± 20?

Grind the valve seats using a suitable tool.

Fit the cylinder head on the supporting tools and fix it using the nuts.Fit the lower valve shim and lower spring washer.1. Fit the valve guide oil seal (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.821.206.000

1. Fit the valves (1a) for the cylinder head in question and support them 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. Fit the valve springs.3. Fit the upper valve shims.4. Fit the split collars (4a) 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 tools used for fitting valves.

1. Fit the spark plug housing gaskets.2. Fit the hydraulic tappets.3. Fit the camshafts.

1. Fit the camshaft caps on the right cylinder head in accordance with the sequence indicated in the figure.

Tighten the camshaft cap bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAMSHAFT CAPS	M8	1.8 - 2.0

1. Fit the camshaft front oil seals (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.860.948.000

Fit the cam angle sensor complete with O-ring and fix it using the bolt.

	Name	Connector
-	Timing sensor	K47

Fit the coolant outlet connector on the cylinder head and fix it using the bolt.Fit the reaction rod mounting and fix it using the nuts.Fit the timing belt cover and fix it using the bolts.1. Fit the camshaft pullies.2. Tighten the bolts (2a) on the camshaft pullies to torque using the tools (2b).

	Name	Country
2b	Counter-torque	1.822.146.000

	Fastening	Component	Ø	Value(daNm)
2a	Bolt	TIMING GEAR DRIVEN PULLEYS	M10	6.8 ÷ 8.4

Fit the timing belt fixed tensioner and fix it using the bolt.Fit the automatic timing belt tensioner and fix it using the bolts, without tightening them.Fit the inlet manifold complete with gasket.Fit the fuel distribution manifold complete with fuel injectors and fix it using the bolts.Fit the inlet ducts and fix them using the bolts.Remove the cylinder head from the support tools.Remove the cylinder head support tools from the vice and return them.