1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL - Alfa - 156 - eLearn

3239084 - 1016E10 single cylinder head, removed - overhaul

1. Undo the bolts (1a) and remove the complete thermostat (1b).2. Remove the seal.3. Remove the combined sender unit for coolant temperature gauge and overheating warning light

	Name	Connector
3	Coolant temperature sender unit	K35

1. Undo the bolt (1a) of the exhaust side camshaft pulley, using the tools (1b) for counter-torque.

	Name	Country
1b	Counter-torque	1.822.146.000

	Name	Country
1b	Counter-torque	1.822.156.000

2. Remove the exhaust side camshaft pulley.3. Undo the bolts (3a) of the inlet side camshaft pulley, using the tool (3b) for counter-torque.

	Name	Country
3b	Counter-torque	1.822.155.000

4. Remove the inlet side camshaft pulley.

1. Undo the bolts (1a) and remove timing sensor (1b).

	Name	Connector
1b	Timing sensor	K47

2. Undo the bolts (2a) and remove the water pump (2b) complete with O-ring (2c).

Check that the camshaft end float is within the recommended values using a dial gauge on a magnetic base.

	Measurement		Value
-	End float (mm)		0.10 - 0.23

If the camshaft endfloat is not within the recommended values, when reassembling the cylinder head, replace the worn components.

1. Undo the bolts (1a) and remove the camshaft caps (1b).2. Remove the upper bearing shell for the front camshaft support, inlet side.3. Remove the camshafts.4. Remove the front camshaft oil seals.5. Remove the lower bearing shell for the front camshaft support, inlet side.6. Remove the hydraulic tappets.

1. Remove the split collars (1a) using tools (1b), (1c), (1d), (1e) and (1f).

	Name	Country
1b	Valve supports	1.820.011.000

	Name	Country
1c	Special nut	1.820.049.000

	Name	Country
1d	Mount	1.821.124.000

	Name	Country
1e	Chamber	1.821.205.000

	Name	Country
1f	Lever	1.821.058.000

2. Remove the upper valve shim.3. Remove the valve springs.Remove the valve dismantling tools.4. Remove the valve.Work in the same way to remove the remaining valves.

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

	Name	Country
1b	Extractor	1.821.208.000

2. Remove the lower valve shim.

Remove the cylinder head from the supporting tools and position it on an appropriate workbench.1. Screw the special extraction tool (1b) in the valve seat (1a).Turn the cylinder head upside down on the workbench.Remove the valve seat using the extraction tool.

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

	Name	Country
1b	Extractor	1.821.176.000

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, reface the lower cylinder head surface without exceeding the minimum permissible combustion chamber depth.

	Measurement		Value
1	Minimum permissible combustion chamber depth (mm)		12.8 - 13.2

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
-	Inlet stem diameter (mm)		6.975 ÷ 6.990

	Measurement		Value
-	Exhaust stem diameter (mm)		6.960 ÷ 6.975

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

	Measurement		Value
-	Outer diameter (mm)		32.959 - 32.975

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

	Measurement		Value
-	Diameter of hydraulic tappet seats (mm)		33.000 - 33.025

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

	Measurement		Value
-	Outer springs free length (mm)		46

	Measurement		Value
-	Inner spring released length (mm)		39

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)		27.1 - 29.4
	Length (mm)	34

	Measurement		Value
-	Laden (daN)		48.5 - 52.4
	Length (mm)	24.5

	Measurement		Value
-	Laden (daN)		9.6 - 10.6
	Length (mm)	29.5

	Measurement		Value
-	Laden (daN)		20.1 - 22.1
	Length (mm)	20

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

	Measurement		Value
-	Outer diameter (mm)		13.010 - 13.030
	Oversize (mm)	0.20

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 diameter.

	Measurement		Value
-	Inner diameter (bore) (mm)		7.022 - 7.040

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

	Measurement		Value
-	Outer diameter (mm)	Exhaust	29.142 - 29.157
Inlet	35.135 - 35.150

1. Heat the cylinder to 80° C, then fit the valve seats (1a) using a suitable tool (1b).

Reface the valve seats to the recommended figure.

	Measurement		Value
-	Valve seat top band taper "a" (-)		150°

	Measurement		Value
-	Contact band with valve taper "b" (-)		90° ± 10?

	Measurement		Value
-	Valve seat lower band taper "c" (-)		30°

	Measurement		Value
-	Width "L" contact band with valves (mm)	Exhaust	1.0
Inlet	0.8

Grind the valve seats using a suitable tool.Fit the cylinder head on the supporting tools and fix it using the nuts.Fit the lower valve shim.Fit the valve guide oil seal (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.821.206.000

1. Fit the valve (1a) and support it using the tools (1b) and (1c).

	Name	Country
1b	Valve supports	1.820.011.000

	Name	Country
1c	Special nut	1.820.049.000

2. Fit the valve springs.3. Fit the upper valve shim.4. Fit the split collars (4a) using the tools (4b), (4c) and (4d).

	Name	Country
4b	Mount	1.821.124.000

	Name	Country
4c	Chamber	1.821.205.000

	Name	Country
4d	Lever	1.821.058.000

Work in the same way when fitting the remaining valves.Remove the valve dismantling/fitting tools.

Fit the hydraulic tappets.Fit the lower bearing shell for the front camshaft support, inlet side.Fit the camshafts.Fit the upper bearing shell for the front camshaft support, inlet side.1. Fit the camshaft caps (1a) and tighten the bolts (1b) to torque.

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

2. Fit the water pump (2a) complete with new O-ring and tighten the bolts (2c) to torque.

	Fastening	Component	Ø	Value(daNm)
2c	Bolt	ORDINARY PREPARATION	M6	1.7 - 2.1

Fit the timing sensor and fix it using the bolt.

	Name	Connector
-	Timing sensor	K47

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

	Name	Country
1b	Fitting tool	1.821.228.000

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

	Name	Country
1b	Fitting tool	1.821.252.000

1. Fit the inlet side camshaft pulley.2. Tighten the bolts (2a) of the inlet side camshaft pulley, using the tool (2b) for counter-torque.

	Name	Country
2b	Counter-torque	1.822.155.000

3. Fit the exhaust side camshaft pulley.4. Tighten to torque the bolt (4a) on the exhaust side camshaft pulley, using the tools (4b) for counter-torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	TIMING GEAR DRIVEN PULLEYS	M12	10.0 - 12.4

	Name	Country
4b	Counter-torque	1.822.146.000

	Name	Country
4b	Counter-torque	1.822.156.000

Combined sender unit for coolant temperature gauge and overheating warning light

	Name	Connector
-	Coolant temperature sender unit	K35

Fit the thermostat complete with gasket and tighten the bolts to torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	THERMOSTAT	M8	1.7 - 2.1

Fit the inlet manifold, complete with gasket, and fix it using the nuts.

	Fastening	Component	Ø	Value(daNm)
-	Nut	INLET MANIFOLD	M8	1.7 - 2.1

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