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

3025989 - 1016E10 single cylinder head, removed - overhaul

1. Position the tool in the vice.

	Name	Country
1	Mount	1.820.012.000

2. Fit the tool.

	Name	Country
2	Mount	1.820.258.000

3. Fit the tool.

	Name	Country
3	Spacer	1.820.267.000

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

Disconnect the electrical connection from the engine coolant temperature sensor.

	Name	Connector
-	Engine temperature sender unit	K36

1. Undo the nuts (1a) and remove the complete inlet manifold (1b).2. Remove the seal.

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

1. Undo the bolt (1a) for the exhaust side driven pulley using the tools (1b) and (1c) for anti-torque.

	Name	Country
1b	Counter-torque	1.822.156.000

	Name	Country
1c	Counter-torque	1.822.146.000

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

	Name	Country
3b	Counter-torque	1.822.155.000

4. Remove the inlet side driven pulley.

1. Undo the bolts (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 end float is within the recommended values using a dial gauge on a magnetic base.

	Measurement		Value
-	Camshaft 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.

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
-	Cylinder head lower plane planarity (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 height for the combustion chamber.

	Measurement		Value
1	Combustion chamber minimum permissible height (mm)		12.8 ÷ 13.2

The volume of the combustion chamber for each cylinder is given below.

	Measurement		Value
-	Combustion chamber volume (c.c.)		-

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
-	Valve stem diameter (mm)	Exhaust	6.960 ÷ 6.975
Inlet	6.975 ÷ 6.990

Check that the diameter of the valve stems is within the recommended values; if this is not the case, replace the valves.

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

The taper of the valve contact band in relation to the valve bore is given below.

	Measurement		Value
-	Valve contact band taper (-)		-

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
-	Hydraulic tappeter 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
-	Valve spring length released (mm)	External	46.0
Internal	39.0

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
-	Outer valve spring height (mm)
	Check load (daN)	27.1 ÷ 29.4

	Measurement		Value
-	Outer valve spring height (mm)		24.5
	Check load (daN)	48.5 ÷ 52.4

	Measurement		Value
-	Inner valve spring height (mm)		29.5
	Check load (daN)	9.6 ÷ 10.6

	Measurement		Value
-	Inner valve spring height (mm)		20.0
	Check load (daN)	20.1 ÷ 22.1

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

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

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

	Measurement		Value
-	Camshaft nominal cam lift (mm)	Exhaust	7.5
Intake	9.0

1. Place the camshaft cams back in their housings in the cylinder head and secure them tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CAMSHAFT CAPS	M7	(Cylinder head side) 1.4 ÷ 1.7

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

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

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

	Measurement		Value
-	Valve seat outer diameter (mm)	Exhaust	29.142 ÷ 29.157
Intake	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
-	Angle"a" valve seat upper band (-)		150˚

	Measurement		Value
-	Angle "b" contact band with valves (-)		90˚ ± 10∍

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

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

Position the cylinder head on the supporting tools and fix it using the nuts.Place the lower valve shim in its housing.1. Fit the valve guide oil seal (1a) using the tool (1b).

	Name	Country
1b	Fitting tool	1.821.206.000

1. Place the valve (1a) back in its housing 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. Place the valve springs in their housings.3. Place the upper valve shim in its housing.4. Place the cotters (4a) in their housings 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.

Place the hydraulic tappets in their housings.Place the inlet side camshaft front support lower half-bearing back in its housing.Place the camshafts back in their housings.Place the inlet side camshaft front support upper half-bearing back in its housing.1. Place the camshaft cams (1a) back in their housing and secure them tightening the bolts (1b) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	CAMSHAFT CAPS	M7	(Cylinder head side) 1.4 ÷ 1.7

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

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

2. Place the water pump (2a), complete with a new O-Ring (2b), back in its housing and secure it tightening the bolts (2c) to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
2c	Bolt	COOLANT PUMP	M8	(Cylinder head side) 2.3 ÷ 2.8

Place the cam angle sensor back in its housing and fix it using the bolt.1. Place the front camshaft oil seal, exhaust side (1a) back in its housing using the tool (1b).

	Name	Country
1b	Fitting tool	1.821.228.000

1. Place the front camshaft oil seal, inlet side (1a) back in its housing using the tool (1b).

	Name	Country
1b	Fitting tool	1.821.251.000

Fit the inlet side driven pulley and fix it using the bolts without tightening them.Fit the exhaust side driven pulley and fix it with the bolt without tightening it.Place the thermostat, complete with gasket, back in its housing and fix it tightening the bolts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Bolt	THERMOSTAT	M8	(Cylinder head side) 2.3 ÷ 2.8

Place the inlet manifold, complete with gasket, back in its housing and fix it tightening the nuts to the recommended torque.

	Fastening	Component	Ø	Value(daNm)
-	Nut	INLET MANIFOLD	M8	(Cylinder head side) 2.3 ÷ 2.8

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 return them.