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

3239084 - 1016E10 single cylinder head, removed - overhaul

1. Position the upper cylinder head (1a) in the vice using the tool (1b).

	Name	Country
1b	Mount	1.860.470.001

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

Check that the end float of the camshaft is within the recommended values using a dial gauge.

	Measurement		Value
-	Camshaft end float (mm)		0.1 - 0.23

If the camshaft endfloat is not within the recommended values, when reassembling the cylinder head, replace the worn components.1. Remove the plugs (1a) and fit the camshaft timing tools (1b) in the camshaft housing.

Check that the tools, marked with the letter 'A', are correctly inserted in the housings in the camshafts.

	Name	Country
1b	Gauge	1.870.896.900

1. Undo the camshaft gear fixing bolts.

Remove the camshaft timing tools from the camshaft housing.

	Name	Country
-	Gauge	1.870.896.900

1. Release the camshafts (1a) as necessary and remove the camshaft gears (1b).

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

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

Remove the support tool, complete with camshaft housing, from the vice and separate them.

	Name	Country
-	Mount	1.860.470.001

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

	Name	Country
1b	Mount	1.860.470.001

Remove the gasket.

1. Place a wooden board on the cylinder head surface to support the valves and bolt in place.

	Name	Country
1	Stand	1.860.804.001

1. Using the tools (1a) and (1b), compress the valve spring and remove half-cones (1c).

	Name	Country
1a	Lever	1.860.644.001

	Name	Country
1b	Chamber	1.870.890.000

2. Remove washer (2a) and valve spring (2b).3. Use special pliers to remove the valve guide seat oil ring.

	Name	Country
-	Pliers	1.870.894.000

Work in the same way on the other valves.

Remove the wooden board and recover the valves.

	Name	Country
-	Stand	1.860.804.001

Remove the cylinder head from the support tool.

	Name	Country
-	Mount	1.860.470.001

Replace the valve guides as described in the specific procedure: Refer to op.. 1016E14 single cylinder head valve guides - replace during operation 1016e10Clean 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
-	Cylinder head lower plane planarity (mm)		<0.1

1. If the planarity of the lower cylinder head surface is not within the recommended values, regrind it starting from the nominal height of the head and, at the end of the operation, positioning a new gasket with the number of references indicated below. The head can be reground by 0.1 mm if starting with a gasket with 0 references and using a new gasket with 1 reference.The head can be reground by 0.2 mm if starting with a gasket with 0 references and using a new gasket with 2 references.The head can be reground by 0.1 mm if starting with a gasket with 1 reference and using a new gasket with 2 references.

If the limit condition is reached (head gasket with 2 references before regrinding), the cylinder head lower plane cannot be reground.

	Measurement		Value
-	Permissible minimum height (mm)		107.0 ± 0.05

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)		5,982 ÷ 6,000

	Measurement		Value
-	Stem diameter (mm)		5,92 ÷ 5,990

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

	Measurement		Value
-	Free length (mm)		43.1

Use a torque wrench to check that the valve spring specifications are within specified values; otherwise replace the springs.

	Measurement		Value
-	Length (mm)		34
	under load (daN)	21.2

	Measurement		Value
-	Length (mm)		24.5
	under load (daN)	45

Check that the cam journal diameters are within the recommended values; if this is not the case, replace the worn camshaft(s).

	Measurement		Value
-	Diameter (mm)	Fifth pin	43,000 ÷ 43,015
First pin	43,800 ÷ 43,815
Fourth pin	43,200 ÷ 43,215
Second pin	43,600 ÷ 43,615
Third pin	43,400 ÷ 43,415

Check that the nominal lift of the camshaft cams is within the recommended values; if this is not the case, replace the worn camshaft(s).

	Measurement		Value
-	Nominal cam lift (mm)	Exhaust	8
Inlet	8

1. Check the diameter of the camshaft mounts is within specified values; otherwise replace the single cylinder head extension.

	Measurement		Value
-	Diameter (mm)	Fifth support	43,046 ÷ 43,071
First support	43,846 ÷ 43,871
Fourth support	43,246 ÷ 43,271
Second support	43,646 ÷ 43,671
Third support	43,446 ÷ 43,471

Check the valve guide outer diameter is within specified values.

	Measurement		Value
-	Outer diameter (mm)	Exhaust	27,600 ÷ 27,611
Inlet	29,600 ÷ 29,611

1. If the values are not as specified, grind the valve seats to the required height.

	Measurement		Value
-	Contact band angle with valve (Gradi)	Exhaust	45° ± 0,1
Inlet	45°30' ± 1?

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	Cylinder head surface recess (mm)		-

	Name	Country
1b	Dial gauge mounting	1.870.404.001

If the value measured is not within the recommended limits, grind the valve seats again.

Position the cylinder head in the vice using the tool.

	Name	Country
-	Mount	1.860.470.001

Fit the valves in their seats, then support them using the wooden board and secure them using bolts.

	Name	Country
-	Stand	1.860.804.001

1. Fit fitting tool (1a) to the valve stem, then fit oil ring (1b) and press-fit the oil ring until it is fully home using a drift.

	Name	Country
1a	Drift	1.871.000.600

Work in the same way on the other valves.

1. Fit the valve spring in its seat.2. Place the upper valve shim back in its housing.3. Using tools (3a) and (3b), compress the valve spring and fit half-cones (3c) in their seat.

	Name	Country
3a	Lever	1.860.644.001

	Name	Country
3b	Chamber	1.870.890.000

Work in the same way on the other valves.

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

	Name	Country
-	Stand	1.860.804.001

Remove the cylinder head from the support tool.

	Name	Country
-	Mount	1.860.470.001

1. Position the upper cylinder head (1a) in the vice using the tool (1b).

	Name	Country
1b	Mount	1.860.470.001

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

Check that the tools, marked with the letter 'A', are correctly inserted in the housings in the camshafts.

	Name	Country
1	Gauge	1.870.896.900

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

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

	Name	Country
1b	Fitting tool	1.870.896.800

Fit the inlet side camshaft plug.1. Plact the cam angle sensor (1a) back in its housing and secure it tightening the bolt (1b) to the recommended torque.

1. Remove the tool for timing the camshafts (1a) and tighten plugs (1b).

	Name	Country
1b	Gauge	1.870.896.900

Remove the support tool, complete with camshaft housing, from the vice and separate them.

	Name	Country
-	Mount	1.860.470.001