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

3239070 - 1016E22 r cylinder head - overhaul

) 1. Position the cylinder head (1a) in the vice, using the tools (1b), (1c) and (1d).

	Name	Country
1b	Mount	1.820.012.000

	Name	Country
1c	Mount	1.820.050.000

	Name	Country
1d	-	1.860.952.000

1. Undo the bolts (1a) and remove the fuel manifold (1b), complete with injectors (1c).2. Undo the nuts (2a) and remove the bracket on the engine for the reaction rod (2b).

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

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

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)		0.060 ÷ 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.

1. Remove the spark plug housing gaskets.2. Remove the spark plugs.

1. Remove the split collars (1a) for the cylinder in question 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 shims.3. Remove the valve springs.Remove the tools used for dismantling the valves.4. Remove the valves.Work in the same way to remove the remaining valves.

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

	Name	Country
1b	Extractor	1.821.208.000

2. Remove the lower spring washers (2a) and the lower valve shims (2b).

Remove the cylinder head from the supporting tools and position it on an appropriate workbench.1. Remove valve guides (1a) using tool (1b).

	Name	Country
1b	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.

If necessary, both cylinder head should be refaced.

	Measurement		Value
1	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.

The minimum permitted cylinder head height should never be exceeded or else the actual cylinder head has to be replaced.

	Measurement		Value
1	Minimum permitted cylinder head height (mm)		134.85 ÷ 135.15

De-carbonize the valves and check that the stem does not show signs of grooves 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)		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
-	Hydraulic tappeter outer diameter (mm)		32.959 ÷ 32.975

Check that the diameter of the tappet casing housings are within the recommended values.

	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
-	Valve spring length released (mm)	External	45.0
Internal	42.0

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)		32.5
	Check load (daN)	21.9 ÷ 23.1

	Measurement		Value
-	Outer valve spring height (mm)		23.0
	Check load (daN)	43.1 ÷ 45.0

	Measurement		Value
-	Inner valve spring height (mm)		30.5
	Check load (daN)	12.4 ÷ 13.1

	Measurement		Value
-	Inner valve spring height (mm)		21.0
	Check load (daN)	24.0 ÷ 26.0

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

The surfaces of the camshaft bearings should not show signs of wear, grooves or seizing or else the shafts have to be replaced.

	Measurement		Value
-	Camshaft bearing diameter (mm)		26.959 ÷ 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 camshafts.

The surfaces of the camshaft bearings should not show signs of wear, grooves or seizing or else the shafts have to be replaced.

	Measurement		Value
-	Camshaft nominal cam lift (mm)		9.30

Place the camshaft caps back in their housings in the right cylinder head in accordance with the sequence indicated in the figure.

1. Tighten the camshaft cap bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	CAMSHAFT CAPS/	M8	(Cylinder head side) 1.8 ÷ 2.0

2. Check the diameter of the camshaft mounts is within specified values.

	Measurement		Value
2	Camshaft bearing diameter (mm)		27.010 ÷ 27.036

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

	Measurement		Value
-	Valve guide outer diameter (mm)	Intake	12.040 ÷ 12.051

	Measurement		Value
-	Valve guide outer diameter oversize (mm)	Intake	0.20

Inlet valve guides are available from the Parts Dept. with an outer diameter of 12.053 12.064 mm.

	Measurement		Value
-	Valve guide outer diameter (mm)	Exhaust	12.050 ÷ 12.068

	Measurement		Value
-	Valve guide outer diameter oversize (mm)	Exhaust	0.20

Exhaust valve guides are available from the Parts Dept. with an outer diameter of 12.064 12.082 mm.

Check that the diameter of the valve guide seat is within the recommended values. if this is not the cse, ream the seats depending on the valve guide oversize.

	Measurement		Value
-	Valve guide bore diameter (mm)		12.000 ÷ 12.018

1. Place the valve guides (1a) back in their seats using the fitting tool (1b).

Using the above mentioned tool guarantees the correct valve guide projection.

	Name	Country
1b	Fitting tool	1.821.207.000

1. Ream the new valve guides using a suitable tool for calibrating the openings to the correct diameter.

	Measurement		Value
1	Valve guide internal diameter (reaming) (mm)		7.000 ÷ 7.015

1. Reface the valve seats to the recommended figure.

	Measurement		Value
1	Contact band angle with valves (-)		90° ± 20?

Grind the valve seats using a suitable tool.

Use SIPAL Arexons abrasive or a similar product to grind the valve seats.

Positino the cylinder head in the vice using the tools.

	Name	Country
-	Mount	1.820.012.000

	Name	Country
-	Mount	1.820.050.000

	Name	Country
-	-	1.860.952.000

Place the lower valve shims and the lower spring seals back in their housings.1. Place the valve guide oil seals (1a) back in their housings using the tool (1b).

	Name	Country
1b	Fitting tool	1.821.206.000

1. Place the valves (1a) for the cylinder in question back in their seats 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. Place the valve springs back in their seats.3. Place the upper valve shims back in their housings.4. Place the cotters (4a) for the valves for the cylinder in question bakc 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

Remove the tools used for fitting valves.Work in the same way when fitting the remaining valves.1. Place the spark plugs back in their housings and tighten them to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	-	SPARK PLUGS	M14	(Cylinder head side) 2.4 ÷ 3.0

1. Carry out the valve leakage test using the tools (1a) and (1b).

	Name	Country
1a	Lever	1.860.490.000

	Name	Country
1b	Test instrument	1.895.868.000

1. Place the spark plug housing seals back in their housings.2. Place the hydraulic tappets in their housings.3. Place the camshafts back in their housings.

Place the camshaft caps back in their housings in the right cylinder head following the sequence shown in the diagram.

Tighten the bolts fixing the camshaft caps to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	CAMSHAFT CAPS/	M8	(Cylinder head side) 1.8 ÷ 2.0

1. Place the camshaft front oil seals (1a) back in their housings using the tool (1b).

	Name	Country
1b	Fitting tool	1.860.948.000

Place the bracket back in its housing and secure it using the bolt.Fit the timing belt mobile tensioner and fix it using the bolts without tightening them.1. Place the intake manifold (1a), complete with gasket (1b), back in its housing and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	INLET MANIFOLD	M8	(Cylinder head side) 1.9 ÷ 2.3

1. Place the bracket on the engine for the reaction rod (1a) back in its housing and fix it tightening the nuts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	REACTION LINK BRACKET ON ENGINE	M10	(Cylinder head side) 4.5 ÷ 5.5

Place the fuel manifold, complete with injectors, back in its housing and fix it using the bolts.Remove the cylinder head from the support tools.