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

3239084 - 1016E10 single cylinder head, removed - overhaul

CAMSHAFT HOUSING1. Position the upper cylinder head (1a) in the vice using the tool (1b).

	Name	Country
1b	Mount	1.860.470.001

1. Undo the bolts (1a) and remove the engine oil filler (1b).2. Remove the gasket.

1. Undo bolts (1a) and remove vacuum unit (1b).2. Remove the gasket.

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

Check that the end float of the camshaft is within the recommended values using a dial gauge.If the camshaft endfloat is not within the recommended values, when reassembling the cylinder head, replace the worn components.1. Remove the plugs (1a) and fit the camshaft timing tools (1b) in the camshaft housing.

Check that the tools, marked with the letter 'A', are correctly inserted in the housings in the camshafts.

	Name	Country
1b	Gauge	1.870.896.900

1. Undo the camshaft gear fixing bolts.

1. Undo the bolt (1a) and remove the exhaust side camshaft toothed drive pulley (1b).

Remove the camshaft timing tools from the camshaft housing.

	Name	Country
-	Gauge	1.870.896.900

1. Release the camshafts (1a) as necessary and remove the camshaft gears (1b).

1. Using a suitable drift, extract the inlet side camshaft (1a) and the plug (1b).2. Using a suitable drift, extract the exhaust side camshaft (2a) and the oil seal (2b).Remove the exhaust side camshaft oil seal.

1. Undo and remove the engine oil lubrication duct plugs.

Remove the support tool, complete with camshaft housing, from the vice and separate them.LOWER CYLINDER HEAD.1. Position the lower cylinder head (1a) in the vice using the tool (1b).

	Name	Country
1b	Mount	1.860.470.001

2. Remove the hydraulic tappets.3. Undo the bolts (3a) and remove the thermostat (3b).Remove the gasket.

1. Undo the bolts (1a) and remove the water pump (1b).2. Remove the gasket.

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

	Name	Country
1	Stand	1.860.804.001

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

	Name	Country
1b	Lever	1.860.644.001

	Name	Country
1c	Chamber	1.870.890.000

2. Remove the upper valve shim.3. Remove the valve spring.4. Remove the shim (for the exhaust valves only).5. Remove the valve guide oil seal with built-in lower valve shim.Work in the same way on the other valves.

Remove the wooden board and recover the valves.

	Name	Country
-	Stand	1.860.804.001

Remove the lower cylinder head from the support tool.

	Name	Country
-	Mount	1.860.470.001

Replace the valve guides - 1016E14 single cylinder head valve guides - replace during operation 1016e10 . Clean the residues of the old gasket from the lower surface of the lower cylinder head.Check that the planarity of the lower cylinder head surface is within the recommended values.1. If the planarity of the lower cylinder head surface is not within the recommended values, regrind it without exceeding the minimum permissible height.

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.HYDRAULIC TAPPET CHECKCheck 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.

The outer diameter of the valve seats should be as follows.1. Regrind the valve seats to the recommended dimension.

Grind the valve seats using a suitable tool.Temporarily fit the valves.1. Check that the valve recess in relation to the cylinder head (1a) is within the recommended values, using a tool (1b) fitted with a dial gauge.

	Name	Country
1b	Dial gauge mounting	1.870.404.001

If the valve recess in relation to the cylinder head plane is not within the recommended value, regrind the valve seats OR REPLACE THEM.

LOWER CYLINDER HEAD.Position the lower cylinder head in the vice using the tool.

	Name	Country
-	Mount	1.860.470.001

Fit the valves in their seats, then support them using the wooden board and secure them using bolts.

	Name	Country
-	Stand	1.860.804.001

1. Refit the valve guide oil seal (1a) in its housing using the tool (1b).

	Name	Country
1b	Fitting tool	1.870.897.100

1. Place the shim back in its housing (exhaust valves only).2. Place the valve spring back in its housing.3. Place the upper valve shim back in its housing.4. Place the split cotters (4a) back in their housings using the tools (4b) and (4c).

	Name	Country
4b	Lever	1.860.644.001

	Name	Country
4c	Chamber	1.870.890.000

Work in the same way on the other valves.

Remove the wooden board for supporting the valves from the cylinder head plane.

	Name	Country
-	Stand	1.860.804.001

1. Place the water pump (1a), complete with gasket (1b), back in its housing and tighten the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	-	-	-	-

1. Place the thermostat (1a), complete with gasket, back in its housing and secure it tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	-	-	-	-

2. Place the hydraulic tappets in their housings.

Remove the lower cylinder head from the support tool.

	Name	Country
-	Mount	1.860.470.001

CAMSHAFT HOUSING1. Position the upper cylinder head (1a) in the vice using the tool (1b).

	Name	Country
1b	Mount	1.860.470.001

Tighten the engine oil lubrication duct plugs.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.

Check that the tools, marked with the letter 'A', are correctly inserted in the housings in the camshafts.

	Name	Country
1	Gauge	1.870.896.900

1. Tighten the camshaft gear fixing bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	-	-	-	-

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

	Name	Country
1b	Fitting tool	1.870.896.800

Fit the inlet side camshaft plug.Fit the exhaust side timing drive pulley and fix it with the bolt without tightening it.1. Plact the cam angle sensor (1a) back in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	-	-	-	-

1. Place the vacuum unit (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	-	-	-	-

1. Place the engine oil filler (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	-	-	-	-

Remove the support tool, complete with camshaft housing, from the vice and separate them.