1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL - Alfa - 147 - eLearn

3025989 - 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. Undo the bolts (1a) and remove the water pump rigid inlet pipe (1b).2. Remove the gasket.

1. Undo the connectors (1a) and (1b) and remove the pipes from the fuel manifold to the injectors (1c).

When refitting, use new pipes from the fuel manifold to the injectors.

2. Undo the nuts (2a) and remove the fuel distribution manifold (2b) complete with fuel pressure sensor (2c).3. Manually push the springs (3a) and disconnect the pipe from the injectors to the fuel recovery manifold (3b), injectors side and remove it.Undo the nuts and disconnect the supply wiring from the heater plugs.Disconnect the coolant return pipe to the expansion tank and system vent pipe from the thermostat.4. Undo the nuts (4a) and remove the air chamber (4b), complete with E.G.R. valve (4c) and throttle casing (4d).

1. Undo the bolts (1a) and remove the vacuum unit (1b) complete with O-ring.2. Loosen the band (2a) and disconnect the pipe from the thermostat to the heat exchanger (2b), heat exchanger side.3. Undo the bolts (3a) and remove the thermostat (3b), complete with pipe and sensor.4. Remove the gasket.5. Undo the bolt (5a) and the nut (5b) and remove the water/exhaust gas heat exchanger for the E.G.R. system (5c).

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

1. Undo nuts (1a) and remove injector bracket (1b).2. Remove the injectors (2a) complete with seals (2b).3. Remove the injector bracket support pads.4. Remove the heater plugs.

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 vice.Place a wooden board on the cylinder head to support the valves and bolt in place.Refit the cylinder head in the vice.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	1.860.989.001

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

Position the cylinder head on the 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.

To replace the valve guides, see op. 1016E14.

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)		140.85 - 141.15

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 tappet casings 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 tappet casing seats is within the recommended values; If this is not the case, replace the cylinder head.

	Measurement		Value
-	Tappet casing housing diameter (mm)		37.000 - 37.025

Check that the length of the 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
-	Length (mm)		36
	at load of (daN)	36.7 - 39.6

	Measurement		Value
-	Length (mm)		26.5
	at load of (daN)	56.0 - 61.0

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	(Cylinder head side) 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	Support diameter (mm)		26.045 - 26.070

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

	Measurement		Value
-	Outer diameter (mm)	Exhaust	35.142 - 35.157
Inlet	36.135 - 36.150

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 (-)		89˚40' - 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 (1a) is within the recommended values, using a tool (1b) fitted with a dial gauge.

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

	Name	Country
1b	Dial gauge mounting	1.820.253.000

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

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 vice.Remove the wooden board supporting the valves.Refit the cylinder head in the vice.Fit the cups complete with valve clearance adjustment pads.Fit the camshaft.1. Fit the camshaft caps.

Spread LOCTITE 573 on the surfaces where camshaft caps 1 and 5 come into contact with the cylinder head.

Fit the camshaft journal lubrication pipe.2. Tighten the camshaft cap bolts to the specified torque.

	Fastening	Component	Ø	Value(daNm)
2	Bolt	CAMSHAFT CAPS	M7	(Cylinder head side) 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 the recommended torque.

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

1. Fit the injector bracket support pads.2. Fit injectors (2a) complete with seals (2b).3. Fit injector brackets (3a) and tighten nuts (3b) to torque.

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

4. Position the connectors for the pipe from the injectors to the fuel recovery manifold (4a) on the corresponding injector seats and fully insert them until the click of the spring (4b) is heard.

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	M8	(Cylinder head side) 2.1 ÷ 2.6

2. Fit the cam angle sensor (2a) and tighten the bolts (2b).3. Fit the driven pulley.4. Tighten the bolt for the driven pulley (4a) to the recommended torque usign 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 position (mm)	Exhaust	0.30 - 0.40
Inlet	0.25 - 0.35

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. Place the water/exhaust gas heat exchanger for the E.G.R. system (1a) back in its housing and secure it using the bolt (1b) and the nut (1c).2. Fit the thermostat (2a), complete with gasket (2b), pipes and sensor, then tighten the bolts (2c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2c	Bolt	THERMOSTAT	M8	(Cylinder head side) 2.1 ÷ 2.6

3. Connect the pipe from the thermostat to the heat exchanger (3a) and tighten the band (3b).4. Fit the vacuum unit (4a), complete with O-ring and tighten the bolts (4b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
4b	Bolt	BRAKE SERVO VACUUM PUMP	M8	(Cylinder head side) 2.1 ÷ 2.6

1. Fit the complete air chamber (1a) and tighten the nuts (1b).Connect the coolant return pipe to the expansion tank and the system vent pipe to the engine thermostat.Position the heater plugs supply cable and fix it using the nuts.2. Place the pipe from the injectors to the fuel recovery manifold (2a) back in its housing and connect it to the injectors pressing the connectors into position until the springs (2b) click into place. 3. Fit the fuel distribution manifold (3a), complete with fuel pressure sensor (3b) and tighten the nuts (3c).4. Place the new pipes from the fuel manifold to the injectors back in their housings.5. Tighten the connectors for the pipes from the fuel manifold to the injectors, injector side, to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
5	Connector	FUEL MANIFOLD LINE TO INJECTORS	M14	Injector side 1.9 - 2.3

6. 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)
6	Connector	FUEL MANIFOLD LINE TO INJECTORS	M14	(Mainifold side) 2.6 ÷ 3.2

Fit the water pump rigid inlet pipe, complete with gasket, and tighten the bolts.Remove the cylinder head from the support tools.Remove the cylinder head support tools from the vice and return them.