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

125000908 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

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

1. Fit the tool on the cylinder head.

	Description	Code
1	Support	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.

	Description	Connector
1	Engine temperature sending unit	See K36 ENGINE TEMPERATURE SENDER UNIT ( CONNECTORS )

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

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

	Description	Connector
1	Fuel pressure regulator	See N77 FUEL PRESSURE REGULATOR ( CONNECTORS )

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

	Description	Connector
2	Fuel pressure sensor	See K83 FUEL PRESSURE SENSOR

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

	Description	Connector
3	Throttle body actuator	See N75 THROTTLE BODY ACTUATOR ( CONNECTORS )

1. Disconnect the electrical connection from the phase transformer solenoid.

	Description	Connector
1	Variable valve timing actuator	See N76 TIMING VARIATOR ACTUATOR

2. Disconnect the electrical connection from the switching control actuator enablement solenoid valve.

	Description	Connector
2	Variable geometry solenoid valve	See L15 VARIABLE GEOMETRY CONTROL SOLENOID ( CONNECTORS )

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 from the engine coolant reservoir from the thermostat.

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

	Description	Connector
2	Fuel vapour recovery solenoid valve	See L10 FUEL VAPOUR RECOVERY SOLENOID

1. Disconnect the electrical connections from the injectors.

	Description	Connector
1	Injector	See N70 INJECTOR

2. Remove the electrical wiring (2a) after having released it from the securing band (2b).

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

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

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

The high pressure fuel pipe should be replaced each time it is refitted.

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

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

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

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

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

	Description	Code
1b	Spanner for rotating timing pullies	1.860.831.002

2. Remove the exhaust side timing driven pulley.

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

	Description	Code
1b	Counter-torque	1.860.856.001

2. Remove the inlet side timing driven pulley.

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

Check that the camshaft endfloat corresponds to the recommended values using a dial gauge on a magnetic base.

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

If the endfloat for the camshafts does not correspond to the recommended values, replace the worn components when reassembling the cylinder head.

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

The front cap has silicon sealant therefore a plastic hammer should be used for the removal.

2. Remove the inlet side camshaft front supper upper half-bearing.3. Remove the camshafts.4. Remove the camshaft front oil seals.5. Remove the inlet side camshaft front support lower half-bearing.6. Remove the hydraulic tappets.

1. Position the exhaust side camshaft in a vice fitted with protective jaws.2. Undo the pressure pump drive element and remove it.

1. Remove the calibrated jet for the lubrication of the high pressure fuel pump coupling.

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

	Description	Code
1b	Valve support	1.820.011.000

	Description	Code
1c	Special nut	1.820.049.000

	Description	Code
1d	Support	1.821.124.000

	Description	Code
1e	Chamber	1.821.205.000

	Description	Code
1f	Lever	1.821.058.000

2. Remove the valve upper shim.3. Remove the valve springs.Remove the tools for dismantling the valves.4. Remove the valve.Carry out the same operations for removing the remaining valves.

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

	Description	Code
1b	Extractor	1.860.989.000

2. Fit the lower valve shims.

Refitting ( Removing

) Clean any residues of sealant from the matching surfaces of the cylinder head and the front bearing cap.Check that the flatness of the lower cylinder head plane corresponds to the recommended values.

	Measurement		Value
-	Cylinder head lower surface flatness (mm)		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 combustion chamber permitted height.

	Measurement		Value
1	Minimum combustion chamber permitted height (mm)		12.8 ÷ 13.2

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

	Measurement		Value
-	Combustion chamber volume (cc)		38.2

Check that the valves do not show signs of scoring or seizing.Check that the diameter of the valve stems corresponds to the recommended figures; if not, replace the worn valves.

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

Check that the diameter of the valve head corresponds to the recommended figures; if not, replace the valves.

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

The taper of the valve contact band in relation to the valve seat is indicated below.

	Measurement		Value
-	Contact band taper in relation to valve seat (-)		45° 30''

Check that the outer diameter of the hydraulic tappets corresponds to the recommended figures; if not, replace the worn components.

	Measurement		Value
-	External hydraulic tappet diameter (mm)		32.959 ÷ 32.975

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

	Measurement		Value
-	Hydraulic tappet housing diameter (mm)		33.000 ÷ 33.025

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

	Measurement		Value
-	Valve spring free length (mm)	Outer	46.0
Inner	39.0

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

	Measurement		Value
-	External valve spring height (mm)		35.0
	Test load (daN)	25.0 ÷ 27.4

	Measurement		Value
-	External valve spring height (mm)		24.4
	Test load (daN)	49.4 ÷ 53.4

	Measurement		Value
-	Internal valve spring height (mm)		28.7
	Test load (daN)	11.6 ÷ 12.6

	Measurement		Value
-	Internal valve spring height (mm)		18.1
	Test load (daN)	23.6 ÷ 25.6

Check that the diameter of the camshaft bearings corresponds to the recommended figures; if not, replace the worn camshaft.

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

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

	Measurement		Value
-	Nominal camshaft cam lift (mm)	Inlet	10.6
Exhaust	10.2

1. Place the camshaft caps (1a) in their housings in the cylinder head and tighten 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 that the diameter of the camshaft supports corresponds to the recommended figures; if not, replace the cylinder head.

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

Regrind the valve seats to the recommended size, if necessary.

	Measurement		Value
-	Valve seat upper band angle "a" (-)		150°

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

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

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

Fit the support tool on the cylinder head.

	Description	Code
-	Support	1.860.470.001

Position the cylinder head in the vice using the support tool fitted previously.Place the lower valve shims in their housings.1. Temporarily position the valve (1a) in the seat and fit the tool (1b) for centering the valve guide oil seals on it.

	Description	Code
1b	Drift	1.860.814.001

2. Manually fit the valve guide oil seal, then remove the centering tool.3. Fit the valve guide oil seal using the tool.

	Description	Code
3	Fitting tool	1.860.812.000

Carry out the same operations to refit the remaining valve guide oil seals.

1. Fit the valve (1a) in its seat and support it using the tools (1b) and (1c).

	Description	Code
1b	Valve support	1.820.011.000

	Description	Code
1c	Special nut	1.820.049.000

2. Place the valve springs in their housings.3. Refit the upper valve shim4. Place the cotters (4a) in their housings using the tools (4b), (4c) and (4d).

	Description	Code
4b	Support	1.821.124.000

	Description	Code
4c	Chamber	1.821.205.000

	Description	Code
4d	Lever	1.821.058.000

Carry out the same operations to refit the remaining valves.Remove the tools for dismantling/reassembling the valves.

Place the calibrated jet for the lubrication of the high pressure fuel pump coupling in position.1. Position the exhaust side camshaft in a vice fitted with protective jaws.2. Place the the pressure pump drive element in its housing on the exhaust side camshaft and tighten it to the recommended torque.

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

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

Apply silicon 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 exhaust side camshaft front oil seal (1a) in place using the tool (1b).

	Description	Code
1b	Fitting tool	1.821.228.000

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

	Description	Code
1b	Fitting tool	1.821.252.000

Fit the cam angle sensor in place and secure it using the bolts.Refit the inlet side toothed driven pulley in its seat and secure with the bolts without tightening them.Refit the exhaust side toothed driven pulley in its seat and secure with the bolt without tightening.1. Position the water pump (1a) , complete with O-ring (1b), in its housing and secure 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. Position the high pressure fuel pump (1a) , complete with O-ring (1b), in its housing and secure it tightening the bolts (1c) to the recommended torque.

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

1. Place the thermostat (1a) in its housing with the O-ring (1b) and secure it 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. Place the injectors (1a) in their seats complete with brackets (1b) and fasten them tightening the nuts (1c) to the recommended torque.

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

2. Place the connectors complete with O rings in their seats on the injectors.

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

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

1. Place the fuel manifold (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

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

1. Position a new high pressure fuel pipe (1a) and secure it tightening the connectors (1b) and (1c) to the recommended torque.

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

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

Place the modular intake manifold assembly back in its housing and tighten the bands.Tighten the bolts fixing the modular intake manifold brackets.Place the electrical wiring in position and fasten it with the band.Connect the electrical connections to the injectors.Connect the electrical connection to the fuel vapour recovery solenoid valve.Secure the electrical wiring with the bands.Place the coolant return pipe to the engine coolant reservoir in position, connect it to the thermostat and tighten the band.Place the electrical wiring in position and fasten it to the modular intake manifold.Connect the electrical connection to the switching control actuator enablement solenoid valve.Connect the electrical connection to the phase transformer solenoid.Connect the electrical connection to the throttle casing with 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.

	Description	Code
-	Support	1.860.470.001

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