1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL - Alfa - 166 - eLearn

3315353 - 1016E10 single cylinder head, removed - overhaul

) 1. Position the tool in the vice.

	Name	Country
1	Mount	1.820.012.000

2. Fit the tool.

	Name	Country
2	Mount	1.820.258.000

3. Fit the tool.

	Name	Country
3	Spacer	1.820.267.000

4. Position the cylinder head (4a) on the supporting tools and fix it using the nuts (4b).

1. Loosen the manifold side connectors of the pipes leading from the fuel manifold to the injectors.2. Undo the injector side connectors of the pipes leading from the fuel manifold to the injectors.3. Undo the nuts (3a) and remove the fuel distributor manifold (3b), complete with pipes and fuel pressure sensor (3c).Fully undo the connectors previously loosened and detach the pipes from fuel manifold to fuel injectors from the fuel manifold.

Fit new pipes from fuel manifold to injectors upon reassembly.

4. Disconnect the pipe from the injectors to the fuel recovery manifold, injectors side.Undo the nuts and disconnect the supply wiring from the heater plugs.5. Undo the nuts (5a) and remove the complete air intake manifold (5b).

1. Undo the bolts (1a) and remove the water pump rigid inlet pipe (1b).2. Remove the seal.

1. Undo the bolts (1a) and remove the vacuum unit (1b) complete with O-ring.2. Undo the bolts (2a) and remove the thermostat (2b) complete with pipe and sensors.3. Remove the seal.

1. Undo the bolt (1a) for the driven pulley using the tools (1b).

	Name	Country
1b	Counter-torque	1.822.146.000

	Name	Country
1b	Counter-torque	1.822.156.000

2. Remove the driven pulley.3. Undo the bolts (3a) and remove the cam angle sensor (3b).

	Name	Connector
3b	Cam angle sensor	K47

4. Undo bolts (4a) and remove water pump (4b) complete with O-ring (4c).

1. Remove the clips (1a) and remove the fuel return pipe for lubricating the injectors (1b).2. Undo the nuts (2a) and remove the brackets (2b) for the injectors.3. Remove the injectors (3a) complete with seals (3b).

	Name	Connector
3a	Injector	N70

4. Remove the injector bracket support pads.5. Remove the heater plugs.

	Name	Connector
5	Heater plugs	A40

Check that the end float of the camshaft is within the recommended values using a dial gauge.

	Measurement		Value
-	End float (mm)		0.100 ÷ 0.230

If the end float of the camshaft is not within the recommended values, when reassembling the cylinder head, replace the worn components.1. Undo the camshaft cap bolts.2. Remove the camshaft support lubrication pipe.3. Remove the camshaft caps.4. Remove the camshaft.5. Remove the camshaft front oil seal.6. Remove the cups complete with valve clearance adjustment pads.

Remove the cylinder head from the support tools.Place a suitable wooden board between the support tools and the cylinder head to support the valves.Refit the cylinder head on the support tools and fix it using the nuts.1. Remove the split collars (1a) using the tools (1b), (1c) and (1d).

	Name	Country
1b	Mount	1.820.257.000

	Name	Country
1c	Lever	1.821.058.000

	Name	Country
1d	Chamber	1.821.205.000

2. Remove the upper valve shim.3. Remove the valve spring.

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

	Name	Country
1b	Extractor	1.821.208.000

2. Remove the lower shim.Work in the same way on the other valves.Remove the cylinder head from the support tools and recover the valves.

Position the cylinder head on a suitable workbench.1. Screw the special extraction tool (1b) in the valve seat (1a).

Turn the cylinder head upside down on the workbench.1. Remove the valve seat (1a) using the extraction tool (1b).Work in the same way on the other valves.

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

	Name	Country
1b	Extractor	1.821.053.000

Reassembling ( Dismantling

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

	Measurement		Value
-	Flatness of bottom surface (mm)		0.1

1. If the planarity of the lower cylinder head surface is not within the recommended values, regrind the lower cylinder head surface without exceeding the minimum permissible height.

	Measurement		Value
1	Permissible minimum height (mm)		141.00 ± 0.15

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)		7.974 - 7.992

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

	Measurement		Value
-	Outer diameter (mm)		36.975 - 36.995

Check that the diameter of the cup housings are within the recommended values; If this is not the case, replace the cylinder head.

	Measurement		Value
-	Cup seat diameter (mm)		37.000 - 37.025

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

	Measurement		Value
-	Free length (mm)		53.9

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)		36.7 - 39.6
	Length (mm)	36

	Measurement		Value
-	Laden (daN)		56 - 61
	Length (mm)	26.5

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

	Measurement		Value
-	Journal diameter (mm)		26.000 - 26.015

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)		8.5

1. Fit the camshaft caps (1a) on the cylinder head and tighten the bolts (1b) to torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CAMSHAFT CAPS	M7	1.3 - 1.6

2. Check the diameter of the camshaft mounts is within specified values; If this is not the case, replace the cylinder head.

	Measurement		Value
2	Diameter (mm)		26.045 - 26.070

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

	Measurement		Value
-	Outer diameter (mm)		14.010 - 14.030
	Oversizes (mm)	0.05, 0.10, 0.25

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

	Name	Country
1b	Fitting tool	1.821.254.000

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

	Measurement		Value
-	Inner diameter (mm)		8.022 - 8.040

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

	Measurement		Value
-	Inlet - outer diameter (mm)		36.135 - 36.150

	Measurement		Value
-	Exhaust - outer diameter (mm)		35.142 - 35.157

1. Fit the valve seats (1a) using a suitable tool (1b).

1. Regrind the valve seats to the recommended dimension.

	Measurement		Value
1	Contact band angle with valve (mm)		90° ± 20?

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

	Measurement		Value
1	Recess from cylinder head surface (mm)		0.1 - 0.5

	Name	Country
1	Dial gauge mounting	1.820.503.000

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

Place a suitable wooden board between the support tools and the cylinder head to support the valves.Fit the cylinder head, complete with valves, on the support tools and fix it using the nuts.Fit the lower shim.1. Fit the valve guide oil seals (1a) using the tools (1b) and (1c).

	Name	Country
1b	Drift	1.860.814.001

	Name	Country
1c	Fitting tool	1.821.178.000

Fit the valve spring.Fit the upper valve shim.1. Fit the split collars (1a) using the tools (1b), (1c) and (1d).

	Name	Country
1b	Mount	1.820.257.000

	Name	Country
1c	Lever	1.821.058.000

	Name	Country
1d	Chamber	1.821.205.000

Work in the same way on the other valves.

Remove the cylinder head from the support tools.Remove the wooden board supporting the valves from the support tools.Refit the cylinder head on the support tools.Fit the cups complete with valve clearance adjustment pads.Fit the camshaft.1. Fit the camshaft caps.Fit the camshaft journal lubrication pipe.2. Tighten the camshaft cap bolts to torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	CAMSHAFT CAPS	M7	1.3 - 1.6

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

	Name	Country
1b	Fitting tool	1.821.228.000

2. Fit the heater plugs and tighten them to torque.

	Name	Connector
2	Heater plugs	A40

	Fastening	Component	Ø	Value(daNm)
2	-	GLOW PLUGS	M12	1.3 - 1.6

1. Fit the injector bracket support pads.2. Fit the injectors (2a) complete with seals (2b).

	Name	Connector
2a	Injector	N70

3. Fit the brackets (3a) for the injectors and tighten the nuts (3b) to torque.

	Fastening	Component	Ø	Value(daNm)
3b	Nut	INJECTORS(DIESEL)	M8	2.6 - 3.2

4. Fit the fuel return pipe for lubricating the injectors (4a) and fix them using the clips (4b).

1. Fit the water pump (1a), complete with a new O-Ring (1b), and tighten the bolts (1c) to torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	COOLANT PUMP	M6	2.1 - 2.6

2. Fit the cam angle sensor (2a) and tighten the bolts (2b).

	Name	Connector
2a	Cam angle sensor	K47

3. Fit the driven pulley.4. Tighten the driven pulley bolt (4a) to torque, using the tools (4b).

	Fastening	Component	Ø	Value(daNm)
4a	Bolt	TIMING DUCT PULLEY	M12	10.2 - 12.6

	Name	Country
4b	Counter-torque	1.822.146.000

	Name	Country
4b	Counter-torque	1.822.156.000

Check that the valve clearance, with the valves in the closed position, is within the recommended values. if not replace the valve clearance adjustment shims as described below.

	Measurement		Value
-	Clearance with valve in closed - intake position (mm)		0.25 - 0.35

	Measurement		Value
-	Clearance with valve in closed - exhaust position (mm)		0.30 - 0.40

1. Lower the tappet in question using the tool.

	Name	Country
1	Lever	1.820.262.000

2. Fit the tool.

	Name	Country
2	Lever	1.860.724.001

Remove the tool.

	Name	Country
-	Lever	1.820.262.000

Extract the valve clearance adjustment pad and replace it with another of a suitable size.Remove the tool.

	Name	Country
-	Lever	1.860.724.001

1. Fit the gasket2. Fit the thermostat (2a), complete with pipes and sensors, and tighten the bolts (2b) to torque.

	Fastening	Component	Ø	Value(daNm)
2b	Bolt	COOLANT PUMP PULLEY	M6	2.1 - 2.6

3. Fit the vacuum unit (3a), complete with O-ring, and tighten the bolts (3b) to torque.

	Fastening	Component	Ø	Value(daNm)
3b	Bolt	BRAKE SERVO VACUUM PUMP	M6	2.1 - 2.6

1. Fit the gasket2. Fit the water pump rigid inlet pipe (2a) and tighten the bolts (2b).

1. Fit air intake manifold assembly (1a) and tighten nuts (1b).Position the heater plugs supply cable and fix it using the nuts.2. Connect the fuel return pipe for lubricating the injectors to the fuel manifold.Fit new pipes from fuel manifold to fuel injectors on the fuel manifold without tightening the relevant connectors.3. Fit the fuel distribution manifold (3a), complete with pipes and fuel pressure sensor, and tighten the nuts (3b).4. Tighten the injector side connectors to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
4	Connector	FUEL MANIFOLD LINE TO INJECTORS	M12	(Injector side) 2.2

5. Tighten the connectors for the pipes from the fuel manifold to the manifold side injectors to the recommended torque using the tool.

	Fastening	Component	Ø	Value(daNm)
5	Connector	FUEL MANIFOLD LINE TO INJECTORS	M14	(Fuel manifold side) 2.2

Remove the cylinder head from the support tools.Remove the cylinder head support tools from the vice and return them.