1016E22 R CYLINDER HEAD - OVERHAUL (AUTOMATIC TRANSMISSION) - Alfa - 166 - eLearn

3315371 - 1016E22 r cylinder head - overhaul (Automatic transmission)

) 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

	Name	Country
2b	-	1.860.952.000

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

1. Undo the nuts (1a) and remove the inlet manifold (1b) complete with gasket.

1. Undo the nut (1a) fixing the hub to the camshaft using the tools (1b) and (1c).

	Name	Country
1b	Counter-torque	1.822.146.000

	Name	Country
1c	Counter-torque	1.870.716.000

1. Undo the bolts fixing the driven pulley.2. Fit the tool on the driven pulley and fix it to the hub using the bolts

	Name	Country
2	Extractor	1.820.232.000

1. Tighten the tool (1a) nut using tools (1b) and (1c) for counter-torque until the driven pulley (1d) and the hub (1e) are removed.

	Name	Country
1b	Counter-torque	1.822.146.000

	Name	Country
1c	Counter-torque	1.870.716.000

1. Undo the bolts (1a) and remove the rear timing belt guard (1b).2. Undo the nuts (2a) and remove the bracket on the engine for the reaction rod (2b), complete with cam angle sensor.

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 nuts (1a) and remove the camshaft caps (1b).2. Remove the camshaft.3. Remove the camshaft front oil seal.4. Remove the inlet side tappet casings (4a) with the tappet adjustment shims (4b).5. Remove the exhaust side tappet casings (5a) with the rocker arm rods (5b).

1. Undo the cap (1a) and screw a suitable tool (1b) onto the threaded end of the rocker shaft.2. Remove the rocker shaft (2a) and remove the rocker arms (2b), complete with springs (2c) and washers (2d).3. Remove the spark plugs.

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	1.821.018.000

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

	Name	Country
1b	Extractor	1.821.005.000

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)		124.85 - 125.15

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)		8.972 - 8.987

	Measurement		Value
-	Stem diameter (mm)		8.940 - 8.955

1. Check that the outer diameter of the inlet side tappet casings is within the recommended values; if this is not the case, replace the worn tappet casings.

	Measurement		Value
1	Outer diameter (mm)	Inlet	34.974 - 34.989

1. Check that the diameter of the inlet side tappet casings is within the recommended values; if this is not the case, replace the cylinder head.

	Measurement		Value
1	Tappet casing housing diameter (mm)	Inlet	35.000 - 35.025

1. Check that the outer diameter of the exhaust side tappet casings is within the recommended values; if this is not the case, replace the worn tappet casings.

	Measurement		Value
1	Outer diameter (mm)	Exhaust	21.971 - 21.989

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

	Measurement		Value
1	Tappet casing housing diameter (mm)	Exhaust	22.000 - 22.021

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

	Measurement		Value
-	Free length (mm)	External	44.6
Internal	44.1

Using the dynamometer, check that the characteristics of the springs are within the recommended values; if this is not the case, replace the worn components.

	Measurement		Value
-	Length (mm)	External	32.5
	at load of (daN)	24.3 - 25.2

	Measurement		Value
-	Length (mm)	External	23.5
	at load of (daN)	47.0 - 48.8

	Measurement		Value
-	Length (mm)	Internal	30.5
	at load of (daN)	12.6 - 13.0

	Measurement		Value
-	Length (mm)	External	21.5
	at load of (daN)	22.2 - 23.1

Check that the diameter of the camshaft journals is within the recommended values; if this is not the case, replace the worn camshaft.

	Measurement		Value
-	Journal diameter (mm)		26.949 - 26.970

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
-	Nominal cam lift (mm)	Exhaust	34.011 - 34.050
Inlet	35.511 - 35.550

1. Fit the camshaft caps (1a) on the cylinder head and fix them tightening the nuts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	CAMSHAFT CAPS	M8	Cylinder head side 1.6 - 1.8

2. Check that the diameter of the camshaft bearings is within the recommended values; if this is not the case, replace the cylinder head.

	Measurement		Value
2	Camshaft bearing diameter (mm)		27.000 - 27.033

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

	Measurement		Value
-	Outer diameter (mm)	Exhaust	14.033 - 14.059 (*)
Inlet	14.033 - 14.044 (*)

Check that the outer diameter of the rocker shaft is within the recommended values; if this is not the caes, replace the rocker shaft.

	Measurement		Value
-	Outer diameter (mm)		15.988 - 16.000

Check that the inner diameter of the rocker arms is within the recommended values; if this is not the cae, replace the worn components.

	Measurement		Value
-	Inner diameter (mm)		16.016 - 16.034

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

	Name	Country
1b	Fitting tool	1.821.127.000

	Name	Country
1b	Fitting tool	1.821.128.000

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

	Measurement		Value
-	Inner diameter (bore) (mm)		9.000 - 9.015

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

	Measurement		Value
-	Outer diameter (mm)	Exhaust	36.610 - 32.626 (*)
Inlet	37.565 - 37.600 (*)

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

1. Regrind the valve seats to the recommended dimensions.

	Measurement		Value
1	Valve contact band taper (-)		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	1.821.016.000

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 shim.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.

Fit the spark plugs and tighten them to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	SPARK PLUGS	M14	Cylinder head side 2.1 - 2.6

Fit the rocker shaft in its seat and, at the same time, fit the rocker arms complete with springs and washers.Fit the access cap to the rocker shaft.Fit the exhaust side tappet casings with the rocker arms.Fit the inlet side tappet casings with the tappet adjustment shims.Fit the camshaft.Fit the camshaft caps and tighten the nuts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	CAMSHAFT CAPS	M8	Cylinder head side 1.6 - 1.8

Temporarily fit the hub and the driven pulley to allow the valve clearance to be checked.1. Place the valves in the closed position by working on the driven pulley using the tools.

	Name	Country
1	Counter-torque	1.822.146.000

	Name	Country
1	Counter-torque	1.870.716.000

2. Check that the inlet valve (2a) clearance is within the recommended limits using the tool (2b).

	Measurement		Value
2a	Valve clearance (mm)	Inlet	0.475 - 0.500

	Name	Country
2b	Feeler gauge	1.825.018.000

If the inlet valve clearance is not within the recommended limits, proceed with the adjustment as described below.Undo the nuts and remove the camshaft caps.Remove the camshaft.Remove an inlet side tappet casing complete with adjustment shim.1. Measure the thickness of the adjustment shim (1a) using the tool (1b).

	Name	Country
1b	Dial gauge mounting	1.824.034.000

Calculate the size of the adjustment shim required to restore the correct valve clearance and obtain it.

	Name	Country
-	Set of valve clearance adjustment shims	1.820.150.000

Fit the new adjustment shim and the cup.Work in the same way for the remaining pairs of tappet casings/adjustment shims.Fit the camshaft.Fit the camshaft caps and tighten the nuts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	CAMSHAFT CAPS	M8	Cylinder head side 1.6 - 1.8

1. Fit the bracket on the engine for the reaction rod (1a), complete with cam angle sensor, and fix it tightening the nuts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Nut	REACTION LINK BRACKET ON ENGINE	M10	Right cylinder head side 4.3 - 5.3

2. Fit the timing belt rear guard (2a) and fix it using the bolts (2b).

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

	Name	Country
1b	Fitting tool	1.870.725.000

Fit the hub and the driven pulley checking that the element is correctly positioned.1. Tighten the bolts fixing the driven pulley to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1	Bolt	TIMING GEAR DRIVEN PULLEYS	-	Hub side -

2. Tighten the nut (2a) fixing the hub to the camshaft to the recommended torque using the tools (2b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
2a	Nut	CAMSHAFT HUBS	M14	Camshaft side 9.5 - 11.7

	Name	Country
2b	Counter-torque	1.822.146.000

	Name	Country
2b	Counter-torque	1.870.716.000

1. Place the valves in the closed position by working on the driven pulley using the tools.

	Name	Country
1	Counter-torque	1.822.146.000

	Name	Country
1	Counter-torque	1.870.716.000

2. Check that the exhaust valve clearance is within the recommended limits.

	Measurement		Value
2	Valve clearance (mm)	Exhaust	0.275 - 0.300

If the exhaust valve clearance is not within the recommended limits, proceed with the adjustment as described below.1. Loosen the lock nut (1a) and adjust the bolt (1b) until the exhaust valve clearance is correct.Tighten the lock nut and check the exhaust valve clearance once again.

Fit the inlet manifold, complete with gasket, and fix it using the nuts.Remove the cylinder head from the supporting tools.Remove the cylinder head support tools from the vice and return them.