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

125000908 - 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

) 1. Place the tool in the vice.

	Description	Code
1	Support	1.820.012.000

2. Fit the tool.

	Description	Code
2	Support	1.820.258.000

3. Fit the tool.

	Description	Code
3	Spacer	1.820.267.000

4. Position the cylinder head (4a) on the support tools and fasten it using the nuts (4b).

1. Disconnect the electrical connection from the engine coolant temperature sensor.

	Description	Connector
1	Engine temperature sending unit	K36

1. Undo the nuts (1a) and remove the modular intake manifold assembly (1b).2. Remove the seal.

1. Undo the bolts (1a) and remove the thermostat assembly (1b).2. Remove the seal.

1. Undo the exhaust side driven timing pulley bolt (1a) using the tools (1b) for counter-torque.

	Description	Code
1b	Counter-torque	1.822.146.000

	Description	Code
1b	Counter-torque	1.822.156.000

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

	Description	Code
3b	Counter-torque	1.822.155.000

4. Remove the inlet side camshaft drive pulley.

1. Undo the bolt (1a) and remove the cam angle sensor (1b).2. Undo the bolts (2a) and remove the water pump (2b) complete with O-ring (2c).

Check that the camshaft endfloat corresponds to the recommended values using a dial gauge on a magnetic base.

	Measurement		Value
-	Camshaft end float (mm)		0.10 ÷ 0.23

If the endfloat for the camshafts does not correspond to the recommended values, replace the worn components when reassembling the cylinder head.

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

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

	Description	Code
1b	Valve support	1.820.011.000

	Description	Code
1c	Special nut	1.820.049.000

	Description	Code
1d	Support	1.821.124.000

	Description	Code
1e	Chamber	1.821.205.000

	Description	Code
1f	Lever	1.821.058.000

2. Remove the valve upper shim.3. Remove the valve springs.Remove the tools for dismantling the valves.4. Remove the valve.Carry out the same operations for removing the remaining valves.

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

	Description	Code
1b	Extractor	1.821.208.000

2. Remove the lower valve shim.

Remove the cylinder head from the support tools and place it on a special workbench.1. Thread the special extraction tool (1b) in the valve seat (1a).Turn the cylinder head upsidedown on the workbench.Remove the valve seat using the extraction tool.

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

	Description	Code
1b	Extractor	1.821.176.000

Refitting ( Removing

) Clean 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
-	Cylinder head lower surface flatness (mm)		0.1

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

	Measurement		Value
1	Minimum combustion chamber permitted height (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 corresponds to the recommended figures; if not, 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 diameter of the valve head corresponds to the recommended figures; if not, replace the valves.

	Measurement		Value
-	Valve head diameter (mm)	Inlet	33.7
Exhaust	28.2

The taper of the valve contact band in relation to the valve seat is indicated below.

	Measurement		Value
-	Contact band taper in relation to valve seat (-)		-

Check that the outer diameter of the hydraulic tappets corresponds to the recommended figures; if not, replace the worn components.

	Measurement		Value
-	External hydraulic tappet diameter (mm)		32.959 ÷ 32.975

Check that the diameter of the hydraulic tappet housings corresponds to the recommended figures; if not, replace the cylinder head.

	Measurement		Value
-	Hydraulic tappet housing diameter (mm)		33.000 ÷ 33.025

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

	Measurement		Value
-	Valve spring free length (mm)	Outer	46.0
Inner	39.0

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

	Measurement		Value
-	External valve spring height (mm)
	Test load (daN)	27.1 ÷ 29.4

	Measurement		Value
-	External valve spring height (mm)		24.5
	Test load (daN)	48.5 ÷ 52.4

	Measurement		Value
-	Internal valve spring height (mm)		29.5
	Test load (daN)	9.6 ÷ 10.6

	Measurement		Value
-	Internal valve spring height (mm)		20.0
	Test load (daN)	20.1 ÷ 22.1

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

	Measurement		Value
-	Camshaft journal diameter (mm)		26.000 ÷ 26.015

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

	Measurement		Value
-	Nominal camshaft cam lift (mm)	Inlet	9.0
Exhaust	7.5

1. Fit the camshaft caps (1a) on the cylinder head and tighten the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	-	-	-	-

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

	Measurement		Value
-	Camshaft support diameter (mm)		26.045 ÷ 26.070

Check that the outer diameter of the valve guides to be fitted corresponds to the recommended figures.

	Measurement		Value
-	Valve guide outer diameter (mm)		13.010 ÷ 13.030

	Measurement		Value
-	Valve guide outer diameter oversize (mm)		0.20

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

	Description	Code
1b	Fitting tool	1.821.254.000

Ream the valve guide inner diameter to the recommended figure.

	Measurement		Value
-	Valve guide inner diameter (mm)		7.022 ÷ 7.040

Check that the outer diameter of the valve seats to be fitted corresponds to the recommended figures.

	Measurement		Value
-	Valve seat outer diameter (mm)	Inlet	35.135 ÷ 35.150
Exhaust	29.142 ÷ 29.157

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

Regrind the valve seats to the recommended size.

	Measurement		Value
-	Valve seat upper band angle "a" (-)		150°

	Measurement		Value
-	Angle "b" of contact band with valves (-)		90° ± 10?

	Measurement		Value
-	Angle "c" of valve seat lower band (-)		30°

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

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

	Description	Code
1b	Fitting tool	1.821.206.000

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

	Description	Code
1b	Valve support	1.820.011.000

	Description	Code
1c	Special nut	1.820.049.000

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

	Description	Code
4b	Support	1.821.124.000

	Description	Code
4c	Chamber	1.821.205.000

	Description	Code
4d	Lever	1.821.058.000

Carry out the same operations to refit the remaining valves.Remove the tools for dismantling/reassembling the valves.

Fit the hydraulic tappets.Fit the inlet side camshaft front support lower half-bearing.Fit the camshafts.Fit the inlet side camshaft front support upper half-bearing.1. Fit the camshaft caps (1a) and secure them tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	-	-	-	-

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

	Fastening	Component	Ø	Value(daNm)
2c	-	-	-	-

Fit the cam angle sensor and secure it using the bolt.1. Fit the exhaust side camshaft front oil seal (1a) using the tool (1b).

	Description	Code
1b	Fitting tool	1.821.228.000

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

	Description	Code
1b	Fitting tool	1.821.252.000

Fit the thermostat complete with gasket and fasten it tightening the fixing bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	-	-	-

Fit the modular intake manifold, complete with gasket and secure it tightening the nuts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	-	-	-	-

Connect the electrical connection to the engine coolant temperature sensor.Remove the cylinder head from the support tools.Remove the cylinder head support tools from the vice and put them down.