1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL - Alfa - 147 - eLearn

3025989 - 1016E10 single cylinder head, removed - overhaul

) UPPER CYLINDER HEAD1. 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 engine oil filler (1b). 2. Remove the gasket.

1. Undo bolts (1a) and remove vacuum unit (1b).2. Remove the gasket.

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. 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 upper cylinder head.

Check that the tools are correctly inserted in the housings in the camshafts.

	Name	Country
1b	Gauge	1.870.896.900

1. Undo the camshaft sprocket fixing bolts.

1. Undo the bolt (1a) and remove the exhaust side camshaft toothed drive pulley (1b).

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 sprockets (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 upper cylinder head from the vice and separate them. LOWER CYLINDER HEAD1. Position the lower cylinder head (1a) in the vice using the tool (1b).

	Name	Country
1b	Mount	1.860.470.001

2. Remove the hydraulic tappets.3. Undo the bolts (3a) and remove the thermostat (3b).Remove the gasket.

1. Undo the bolts (1a) and remove the water pump (1b).2. 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. Remove the cotters (1a) using tools (1b) and (1c).

	Name	Country
1b	Lever	1.860.644.001

	Name	Country
1c	Chamber	1.870.890.000

2. Remove the upper valve shim.3. Remove the valve spring.4. Remove the shim (for the exhaust valves only).5. Remove the valve guide oil seal with built-in lower valve shim. 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 lower cylinder head from the support tool.

	Name	Country
-	Mount	1.860.470.001

Replace the valve guides - 1016E14 single cylinder head valve guides - replace during operation 1016e10 .

Reassembling ( Dismantling

) Clean the residues of the old gasket from the lower surface of the lower 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 ± 0.05

1. If the planarity of the lower cylinder head surface is not within the recommended values, regrind it without exceeding the minimum permissible height.

	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)	Exhaust	5.972 ÷ 5.990
Inlet	5.982 ÷ 6.000

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; if this is not the case, replace parts that have yielded.

	Measurement		Value
-	Length (mm)		34.0
	Under load (daN)	20.17 ÷ 21.42

	Measurement		Value
-	Length (mm)		24.5
	Under load (daN)	42.82 ÷ 45.47

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

	Measurement		Value
-	Journal diameter (mm)	Fifth pin	30.000 ÷ 30.015
First pin	43.600 ÷ 43.615
Fourth pin	43.000 ÷ 43.015
Second pin	43.400 ÷ 43.415
Third pin	43.200 ÷ 43.215

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	8.0
Inlet	8.0

1. Check the diameter of the camshaft mounts is within specified values; If this is not the case, replace the cylinder head.

	Measurement		Value
-	Support diameter (mm)	Fifth support	30.045 ÷ 30.070
First support	43.646 ÷ 43.671
Fourth support	43.046 ÷ 43.071
Second support	43.446 ÷ 43.471
Third support	43.246 ÷ 43.271

The outer diameter of the valve seats should be as follows.

	Measurement		Value
-	Outer diameter (mm)	Exhaust	27.491 ÷ 27.512
Inlet	29.489 ÷ 29.514

1. Regrind the valve seats to the recommended dimension.

	Measurement		Value
-	Contact band angle with inlet valve ()		45˚ ± 20∍

Grind the valve seats using a suitable tool.LOWER CYLINDER HEADPosition the lower 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. Refit the valve guide oil seal (1a) in its housing using the tool (1b).

	Name	Country
1b	Fitting tool	1.870.897.100

1. Place the shim back in its housing (exhaust valves only).2. Place the valve spring back in its housing.3. Place the upper valve shim back in its housing.4. Place the split cotters (4a) back in their housings using the tools (4b) and (4c).

	Name	Country
4b	Lever	1.860.644.001

	Name	Country
4c	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

1. Place the water pump (1a), complete with gasket (1b), back in its housing and tighten the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	COOLANT PUMP	M8	(Cylinder head side) 2.3 ÷ 3.3

1. Place the thermostat (1a), complete with gasket, back in its housing and secure it tightening the bolts (1b) to the recommended torque.

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

2. Place the hydraulic tappets in their housings.

Remove the lower cylinder head from the support tool.

	Name	Country
-	Mount	1.860.470.001

UPPER CYLINDER HEAD1. 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 are correctly inserted in the housings in the camshafts.

	Name	Country
1	Gauge	1.870.896.900

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

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

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.Fit the exhaust side timing drive pulley and fix it with the bolt without tightening it. 1. Place the cam angle sensor (1a) back in its housing and secure it tightening the bolt (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CAM ANGLE SENSOR	M6	(Cylinder head side 08 10

1. Place the vacuum unit (1a), complete with gasket (1b), back in its housing and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	BRAKE SERVO VACUUM PUMP	M6	(Cylinder head side 05 06 50

1. Place the engine oil filler (1a), complete with gasket (1b), back in its housing and secure it tightening the bolts (1c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1c	Bolt	OIL FILTER FITTING	M6	(Cylinder head side 08 10

Remove the support tool, complete with upper cylinder head from the vice and separate them.