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

939010421 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

) 1. Fit support tool (1a) on cylinder head (1b) and place it in the vice.

Tool	Description	Function	Validity
1860470000	Support	Overhaul cylinder head

1. Undo the protective plugs.2. Undo the bolts and remove the pullies.

1. Undo bolts (1a) and remove timing belt inner guard (1b).

1. Undo bolts (1a) and remove phase transformer solenoid valves (1b).

- Undo the bolts and remove the engine lifting brackets.1. Undo bolts (1a) and remove timing sensors (1b).2. Undo bolts (2a) and remove thermostat unit (2b).

1. Undo bolts (1a) and remove camshaft caps (1b).

The camshaft caps are numbered from 2 to 5, inlet side and from 6 to 9, exhaust side. The front cap, which is the same for both camshafts, is number 1.

The bolts securing the camshaft caps should be loosened in a spiral sequence, starting from the caps on the outside, in the following order: 5 - 2 - 4 - 3.

Mark the fitting position of the camshafts.

1. Remove camshafts (1a) and oil seals (1b).

1. Remove the tappet cups.

1. Unscrew the spark plugs and remove them.

1. Fit the tool in the lower part of the cylinder head.

Tool	Description	Function	Validity
1860804001	Stand	Removing/refitting valves	1.81.9 JTD 16V

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

Tool	Description	Function	Validity
1860644001	Lever	Removing/refitting valves	1.81.9 JTD 16V

Tool	Description	Function	Validity
1870881000	Chamber	Removing/refitting valves	1.8

2. Remove the shim.3. Remove the valve spring.- Carry out the same operations for removing the remaining valves.- Remove the valve support fitted previously.4. Remove the valves.

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

Tool	Description	Function	Validity
1870894000	Extractor	Valve guide oil seal extraction	1.81.9 JTD 8V

- Carry out the same operations for removing the remaining oil seals.

- Remove the cylinder head from the support tool. Op. 1016E14 VALVE GUIDES IN SINGLE CYLINDER HEAD - REPLACE DURING OP. 1016E10

Refitting ( Removing

) - Thoroughly clean the matching surfaces between the cylinder head and the engine block.- Check that the planarity of the lower cylinder head plane is within the recommended values. If this is not the case, replace the cylinder head (the cylinder head lower plane cannot be reground).

Measurement	Value		Validity
Cylinder head lower surface flatness	0.05 mm		1.8

- Fit the cylinder head support tool and place the assembly in a vice.- Check that the valves do not show signs of grooves or seizing.1. Check that the width of the valve bore in the cylinder head is within the recommended values.

Measurement	Value	Validity
Inlet valve seat width (mm)	1.0 ÷ 1.4	1.8

Measurement	Value	Validity
Exhaust valve seat width (mm)		1.8

2. Check that the angle of the valve bore in the cylinder head is within the recommended values.

Measurement	Value	Validity
Valve seat angle	90° 30’	1.8

- If the values are not within the recommended limits, replace the cylinder head.3. Check that the diameter of the valve head corresponds to the recommended figures.

Measurement	Value	Validity
Inlet valve head diameter (mm)	30.7 ÷ 30.8	1.8

Measurement	Value	Validity
Exhaust valve head diameter (mm)	27.1 ÷ 27.2	1.8

4. Check that the angle of the valve head is within the recommended values.

Measurement	Value	Validity
Valve head angle	90° 40’	1.8

5. Check that the diameter of the valve stem corresponds to the recommended figures.

Measurement	Value	Validity
Inlet valve stem diameter (mm)	4.955 ÷ 4.970	1.8

Measurement	Value	Validity
Exhaust valve stem diameter (mm)	4.935 ÷ 4.950	1.8

Measurement	Value	Validity
Valve stem diameter oversizes (mm)	0.075/0.150	1.8

- If the values are not within the recommended limits, replace the valves.

Op. 1016E14 VALVE GUIDES IN SINGLE CYLINDER HEAD - REPLACE DURING OP. 1016E10 - Place the valves in their seats and support them using the support tool.

Tool	Description	Function	Validity
1860804001	Stand	Removing/refitting valves	1.81.9 JTD 16V

- Fit the valve guide oil seal using the tool.

Tool	Description	Function	Validity
1870894000	Extractor	Valve guide oil seal extraction	1.81.9 JTD 8V

- Fit the springs and the shim.- Position the lever fitted with an adaptor, compress the valve spring and fit the cotters.

Tool	Description	Function	Validity
1860644001	Lever	Removing/refitting valves	1.81.9 JTD 16V

Tool	Description	Function	Validity
1870881000	Chamber	Removing/refitting valves	1.8

- Proceed in a similar way and fit the remaining oil seals, springs, shims and cotters.- Undo the bolts and remove the valve support tool.

Tool	Description	Function	Validity
1860804001	Stand	Removing/refitting valves	1.81.9 JTD 16V

- Fit the mechanical tappet cups.- Fit the inlet and exhaust side camshafts, following the position marked during the dismantling.- Fit two new oil seals on the camshafts, having lubricated them with engine oil.- Apply a bead of silicon sealant to the matching surfaces of the camshaft front cap.- Place the camshaft front cap in position using the two centering bushes.- Place the camshaft caps in position, following the progressive numbers indicated during the removal.- Tighten to the recommended torque the bolts fixing the camshaft caps, following the spiral sequence from the inside towards the outside.

Component	Fastening	dia	Value (daNm)	Validity
Camshaft caps	Bolt	-	0.8	1.8

1. Use a feeler gauge to check that the valve clearance is within the specified limits with the valves closed.

Measurement	Value	Validity
Inlet valve clearance in closed position (mm)	0.21 ÷ 0.29	1.8

Measurement	Value	Validity
Exhaust valve clearance in closed position (mm)	0.27 ÷ 0.35	1.8

- If the tappet clearance is not within the recommended tolerance, remove the camshaft involved and replace the cups, selecting the size according to the required clearance.

The tappet cups are graded according to size and therefore the Spare Parts list should be consulted for selecting the new cup to be fitted. The code is on the cup crown.

- After fitting the new cups, repeat the procedure for checking the tappet clearance.- Fit the timing belt inner guard and secure it using the bolts.1. Fit tool (1a) in special splining on camshafts (1b).

Tool	Description	Function	Validity
2000012000	Template	Camshaft timing	1.8

1. Place toothed driven pullies (1a) and (1b) in position.2. Fit the tool on the toothed driven pullies.

Tool	Description	Function	Validity
2000012100	Template	Camshaft timing	1.8

Fit the inlet side template first and then the exhaust side one.

When the templates are fitted, check that:- the reference (a) on the exhaust-side pulley is aligned with the reference (b) on the corresponding timing template;- the pin (c) on the intake-side pulley is in the position illustrated in the diagram in relation to the reference (d) on the corresponding timing template.

- Tighten the bolts fixing the pullies to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Variable valve timing actuator	Bolt (to be replaced)	-	6.5 + 120° + 15°	1.8

3. Tighten the sealing plugs with new O-rings.- Remove the templates used for timing.

- Place the thermostat unit in its housing complete with a new O-ring and tighten the fixing bolts.- Place the inlet and exhaust side timing sensors in position and secure them using the bolts.

Component	Fastening	dia	Value (daNm)	Validity
Timing sensor	Bolt	M6	0.6 ÷ 0.8	1.8

- Place the inlet and exhaust side phase transformer solenoid valves in position and secure them using the bolt.- Fit the spark plugs and tighten them to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Spark plugs	-	-	2.5	1.8

- Place the engine lifting brackets in their housings and secure them using the bolts.- Undo the fixing nuts and remove the cylinder head from the support tool.- Remove the support tool from the vice.