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

939010421 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

) 1. Position the cylinder head in the vice using the support tool.

Tool	Description	Function	Validity
1860470000	Support	Overhaul cylinder head

1. Disconnect the pipes (1a) and remove the three-way connector (1b).

1. Undo the nuts (1a) and remove the lifting bracket (1b).2. Undo the fastenings (2a) and remove the pressure pump (2b).3. Undo the bolts (3a) and remove the two timing sensors (3b).4. Undo the fastenings and remove the camshaft rear cap cover.

- Mark the position of the camshafts.1. Undo the bolts (1a) and remove the camshaft caps (1b).

The rear inlet side camshaft cap has silicon sealant therefore a plastic hammer should be used for the removal.

2. Remove the camshafts.- Remove the camshaft front oil seals.

1. Remove the tappet rocker arms.2. Remove the hydraulic tappets.

1. Fit the valve support under the head.

Tool	Description	Function	Validity
2000003400	Support	Valve support	1.9 JTS2.2 JTS

1. Fit the cotters (1a) using the tools (1b) and (1c).2. Remove the valve upper shim.3. Remove the valve spring.

Tool	Description	Function	Validity
1821058000	Lever	Valve spring compression lever	1.9 JTS2.2 JTS1.9 JTD 8V

Tool	Description	Function	Validity
2000002700	Chamber	Valve spring compression	1.9 JTS2.2 JTS

1. Remove the valve guide oil seals (1a) with built in lower shim and the valve (1b).

Refitting ( Removing

) - Clean the contact surfaces between the cylinder head and the crankcase.COMBUSTION CHAMBER WITH THE POINT FOR MEASURING THE DEPTH SHOWN

- The lower cylinder head plane can be refaced if the flatness is not within the recommended values.

Measurement	Value		Validity
Cylinder head lower surface flatness	0.05 - 0.15 mm		1.9 JTS2.2 JTS

- The refacing does not have to be carried out for lower flatness values.- The refacing is not permitted for higher flatness values.- After refacing it is necessary to check that the minimum depth for each combustion chamber is 12.75 mm (at the point shown in the diagram above) in order to guarantee the minimum combustion chamber volume.- Check that the valves do not show signs of grooves 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	5.900 - 5.940 mm	1.9 JTS2.2 JTS

Measurement	Value	Validity
Exhaust valve stem diameter	5.900 - 5.940 mm	1.9 JTS2.2 JTS

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

Measurement	Value	Validity
Inlet valve head diameter	34.95 - 35.25 mm	1.9 JTS2.2 JTS

Measurement	Value	Validity
Exhaust valve head diameter	29.95 - 30.25 mm	1.9 JTS2.2 JTS

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

Measurement	Value	Validity
Nominal inlet cam lift	10.30 mm	1.9 JTS2.2 JTS

Measurement	Value	Validity
Nominal exhaust cam lift	10.30 mm	1.9 JTS2.2 JTS

1. Temporarily position the valve (1a) in the seat and fit the tool (1b) for centering the valve guide oil seal (1c) on it.2. Fit the valve guide oil seal using the tool.

Tool	Description	Function	Validity
1860814001	Shrink disk	Fit valve oil seals	1.9 JTS2.2 JTS1.9 JTD 8V

Tool	Description	Function	Validity
2000002600	Fitting tool	Valve oil seals	1.9 JTS2.2 JTS

- Position the spring and the upper shim on the valve.- Place the cotters back in their housings using the tools.

Tool	Description	Function	Validity
1821058000	Lever	Valve spring compression lever	1.9 JTS2.2 JTS1.9 JTD 8V

Tool	Description	Function	Validity
2000002700	Chamber	Valve spring compression	1.9 JTS2.2 JTS

- Carry out the same operations to refit the remaining bolts.- Place the camshafts in their housings.- Place the camshaft caps in their housings and secure them tightening the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Camshaft rear caps	Bolt	M6	(cylinder head side) 0.7 - 0.9	1.9 JTS2.2 JTS

Component	Fastening	dia	Value (daNm)	Validity
Camshaft front/ intermediate caps	Bolt	M8	(cylinder head side) 1.8 - 2.2	1.9 JTS2.2 JTS

- Place the two timing sensors in their housings and tighten the bolts to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Phase transformer solenoids	Bolt	M6	(cylinder head side) 1.0	1.9 JTS2.2 JTS3.2 JTS

- Place the pressure pump in position and tighten the fastenings to torque.

Component	Fastening	dia	Value (daNm)	Validity
Pressure pump	Bolt	M6	1.0	1.9 JTS2.2 JTS

- Connect the pipes and fit the three-way fuel connector.