1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL - Alfa - 159 - eLearn

939010421 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

) CAMSHAFT HOUSING1. Position the camshaft housing (1a) in a vice using the tool (1b).

Tool	Description	Function	Validity
1860470000	Support	Overhaul cylinder head

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

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

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

1. Remove plugs (1a) and fit camshaft timing tools (1b) on the camshaft housing.

Check that the tools are correctly fitted in the housings in the camshafts.

Tool	Description	Function	Validity
1870896900	Template	Engine tuning	1.9 JTD 16V2.4 JTD 20V

1. Undo the bolts fixing the camshaft gears.

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

Remove the camshaft timing tools from the cylinder head extension.

Tool	Description	Function	Validity
1870896900	Template	Engine tuning	1.9 JTD 16V2.4 JTD 20V

1. Wtihdraw the camshafts (1a), as far as necessary and remove the camshaft gears (1b).

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

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

LOWER CYLINDER HEAD1. Position the cylinder head (1a) in a vice using the tool (1b).

Tool	Description	Function	Validity
1860470000	Support	Overhaul cylinder head

1. Loosen the band (1a), undo the bolts (1b), then remove the rigid fluid inlet pipe to the water pump assembly (1c).- Remove the gasket.

- Loosen the band and disconnect the degassing pipe from the thermostat.1. Loosen the collar and disconnect the E.G.r. exhaust gas pipe, heat exchanger side.2. Undo the nuts (2a) and remove the air chamber (2b) complete with E.G.R. valve (2c) and throttle body (2d).- Remove the gasket.

- Remove the hydraulic tappets.1. Loosen the band (1a), undo the bolts (1a) and remove the thermostat (1b) complete with O-ring.

1. Undo the bolts (1a) and remove the water/exhaust gas heat exchanger for the E.G.R. system (1b).

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

1. Fit a wooden stand on the cylinder head plane to support the valves and secure it using bolts.

Tool	Description	Function	Validity
1860804001	Stand	Removing/ refitting valves	1.81.9 JTD 16V2.4 JTD 20V

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

Tool	Description	Function	Validity
1860644001	Lever	Removing/ refitting valves	1.81.9 JTD 16V2.4 JTD 20V

Tool	Description	Function	Validity
1870890000	Chamber	Removing/ refitting valves	1.9 JTD 16V2.4 JTD 20V

2. Remove the valve upper shim.3. Remove the valve spring.4. Remove the shim (for exhaust valves only).5. Remove the valve guide oil seal with integrated lower valve shim.Carry out the same operations on the other valves.

Remove the wooden stand and recover the valves.

Tool	Description	Function	Validity
1860804001	Stand	Removing/ refitting valves	1.81.9 JTD 16V2.4 JTD 20V

Remove the lower cylinder head from the support tool.

Tool	Description	Function	Validity
1860470000	Support	Overhaul cylinder head

Replace the valve guide Op. 1016E14 VALVE GUIDES IN SINGLE CYLINDER HEAD - REPLACE DURING OP. 1016E10

Refitting ( Removing

) LOWER CYLINDER HEADClean any residues of the old gasket from the lower cylinder head plane.Check that the flatness of the lower cylinder head plane corresponds to the recommended values.

Measurement	Value		Validity
Cylinder head lower surface flatness	0.1 mm		1.9 JTD 8V2.4 JTD 20V

1. If the planarity of the lower cylinder head plane does not correspond to the recommended figures, regrind it without exceeding the minimum permitted height.

Measurement	Value		Validity
Cylinder head lower plane minimum permitted height	107.0 ± 0.05 mm		2.4 JTD 20V

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	Validity
Inlet valve stem diameter	5.982 - 6.000 mm	1.9 JTD 16V2.4 JTD 20V

Measurement	Value	Validity
Exhaust valve stem diameter	5.972 ÷ 5.990	1.9 JTD 16V2.4 JTD 20V

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

Measurement	Value	Validity
Valve spring free length	43.1 mm	1.9 JTD 16V2.4 JTD 20V

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

Measurement	Value	Validity
Length of valve springs under a load of 20.47 - 21.84 daN	34.0 mm	1.9 JTD 16V2.4 JTD 20V

Measurement	Value	Validity
Length of valve springs under a load of 44.81 - 47.59 daN	24.5 mm	1.9 JTD 16V2.4 JTD 20V

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

Measurement	Value	Validity
Diameter of inlet and exhaust shaft first bearing	43.800 - 43.815 mm	2.4 JTD 20V

Measurement	Value	Validity
Diameter of inlet and exhaust shaft second bearing	43.600 - 43.615 mm	2.4 JTD 20V

Measurement	Value	Validity
Diameter of inlet and exhaust shaft third bearing	43.400 - 43.415 mm	2.4 JTD 20V

Measurement	Value	Validity
Diameter of inlet and exhaust shaft fourth bearing	43.200 - 43.215 mm	2.4 JTD 20V

Measurement	Value	Validity
Diameter of inlet and exhaust shaft fifth bearing	43.000 - 43.015 mm	2.4 JTD 20V

Measurement	Value	Validity
Diameter of inlet and exhaust shaft sixth bearing	30.000 - 30.015 mm	2.4 JTD 20V

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

Measurement	Value	Validity
Nominal inlet/exhaust cam lift	8.0 mm	1.9 JTD 16V2.4 JTD 20V

1. Check that the diameter of the camshaft supports corresponds to the recommended figures; if not, replace the cylinder head.

Measurement	Value	Validity
Diameter of inlet and exhaust shaft first bearing	43.846 - 43.871 mm	2.4 JTD 20V

Measurement	Value	Validity
Diameter of inlet and exhaust shaft second support	43.646 - 43.671 mm	2.4 JTD 20V

Measurement	Value	Validity
Diameter of inlet and exhaust shaft third support	43.446 - 43.471 mm	2.4 JTD 20V

Measurement	Value	Validity
Diameter of inlet and exhaust shaft fourth support	43.246 - 43.271 mm	2.4 JTD 20V

Measurement	Value	Validity
Diameter of inlet and exhaust shaft fifth support	43.046 - 43.071 mm	2.4 JTD 20V

Measurement	Value	Validity
Diameter of inlet and exhaust shaft sixth support	30.045 - 30.070 mm	2.4 JTD 20V

The outer diameter of the valve seats is as follows.

Measurement	Value	Validity
Inlet valve seat outer diameter	29.600 - 29.611 mm	1.9 JTD 16V2.4 JTD 20V

Measurement	Value	Validity
Exhaust valve seat outer diameter	27.600 - 27.611 mm	1.9 JTD 16V2.4 JTD 20V

1. Grind the valve seats to the recommended size.

Measurement	Value	Validity
Valve seat band angle in contact with valve	45° +/- 1’	1.9 JTD 16V2.4 JTD 20V

Grind the valve seats using a suitable tool.Position the lower cylinder head in the vice using the tool.

Tool	Description	Function	Validity
1860470000	Support	Overhaul cylinder head

Fit the valves in the seats, then support them using the wooden stand and secure it using suitable bolts.

Tool	Description	Function	Validity
1860804001	Stand	Removing/ refitting valves	1.81.9 JTD 16V2.4 JTD 20V

1. Place the valve guide oil seal (1a) in position using the tool (1b).

Tool	Description	Function	Validity
1870897100	Extractor/ Fitting tool	Extracting/fitting valve guidesValve guide oil seal fitting	1.9 JTD 16V2.4 JTD 20V

1. Place the shim in position (for exhaust valves only).2. Fit the valve spring in its seat.3. Refit the upper valve shim.4. Place the cotters (4a) in their housings using the tools (4b) and (4c).

Tool	Description	Function	Validity
1860644001	Lever	Removing/ refitting valves	1.81.9 JTD 16V2.4 JTD 20V

Tool	Description	Function	Validity
1870890000	Chamber	Removing/ refitting valves	1.9 JTD 16V2.4 JTD 20V

Carry out the same operations on the other valves.

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

Tool	Description	Function	Validity
1860804001	Stand	Removing/ refitting valves	1.81.9 JTD 16V2.4 JTD 20V

- Refit the water pump, complete with gasket, in its housing and secure it tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Water pump	Bolt	M8	(cylinder head side) 2.3 - 2.8	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

- Place the engine oil heat exchanger for the E.G.R system in its housing and secure it to the cylinder head tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Exhaust gas/water heat exchanger for E.G.R. system	Bolt	M8	(cylinder head side) 2.3 - 2.8	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

- Place the thermostat in its housing with the new O-ring and secure it to the cylinder head by tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Thermostat	Bolt	M8	(cylinder head side) 2.5	1.9 JTD 16V2.4 JTD 20V

- Place the hydraulic tappets in their housings.- Connect the water return pipe from the E.G.R. heat exchanger and secure it using the band. - Place the intake manifold gasket in its housing.- Replace the air chamber complete with E.G.R. valve in its housing and secure it by tightening the nuts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Intake manifold	Nut	M8	(cylinder head side) 2.3 - 2.8	1.9 JTD 16V2.4 JTD 20V

- Connect the degassing pipe to the thermostat and secure with the band.- Place the water pump rigid return pipe, complete with gasket, in position and tighten the bolts.- Connect the the flexible water return pipe from the E.G.R. heat exchanger to the water pump rigid return pipe and secure it using the band. Remove the lower cylinder head from the support tool.

Tool	Description	Function	Validity
1860470000	Support	Overhaul cylinder head

CAMSHAFT HOUSING- Position the camshaft housing in the vice using the tool.

Tool	Description	Function	Validity
1860470000	Support	Overhaul cylinder head

Tighten the engine oil lubrication duct plugs.Place the camshafts in their housings.Place the camshaft gears in their housings and secure them without tightening the bolts.1. Fit the camshaft timing tools.

Check that the tools are correctly fitted in the housings in the camshafts.

Tool	Description	Function	Validity
1870896900	Template	Engine tuning	1.9 JTD 16V2.4 JTD 20V

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

Component	Fastening	dia	Value (daNm)	Validity
Camshaft gears	Bolt	M12	(camshaft side) 2.9 - 3.2 + 40°	1.9 JTD 16V2.4 JTD 20V

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

Tool	Description	Function	Validity
1870896800	Fitting tool	Fitting exhaust camshaft oil seal	1.9 JTD 16V2.4 JTD 20V

Fit the intake side camshaft plug.Refit the exhaust side camshaft toothed pulley and secure by screwing in the bolt without tightening.1. Position the cam angle sensor (1a) in its housing and secure it tightening the bolt (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Cam angle sensor	Bolt	M6	(cylinder head extension side) 0.8 - 1.0	1.9 JTD 16V2.4 JTD 20V

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

Component	Fastening	dia	Value (daNm)	Validity
Vacuum unit	Bolt (pretreated to be replaced)	M6	(cylinder head extension side) 0.5 + 50°	1.9 JTD 16V2.4 JTD 20V

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

Component	Fastening	dia	Value (daNm)	Validity
Engine oil filler	Bolt	M6	(cylinder head extension side) 0.8 - 1.0	1.9 JTD 16V2.4 JTD 20V

Remove the support tool complete with cylinder head extension from the vice and separate them.