Reinforced cylinder head gasket Alfa Romeo 2.0 Twin Spark 16V

The Alfa Romeo engines covered

The 2.0 litre (1,970 cc) Alfa Romeo petrol engines AR16201, AR32301, AR32310, AR34103, AR67204 and AR67299 are fitted to the 145, 146, 147, 155, 156, 156 Sportwagon, 166, GTV and Spider (916) models listed below.

These engines receive two original gaskets: part number 60 608 115 (AR16201, AR32301, AR34103, AR67204 and AR67299), with an 83.9 mm bore, and part number 60 664 642 (AR32310), with an 83.8 mm bore. Alfa Romeo publishes neither their construction nor their thickness. They are designed for standard combustion pressure: when that pressure rises, the clamping load weakens, the cylinder head lifts and coolant seeps into a cylinder.

Reinforced cylinder head gaskets

The gasket is not the only thing that seals: the fasteners, by clamping the cylinder head onto the block, contribute just as much. Beyond 100 N/mm² of admissible stress a composite gasket is crushed for good; the 301 stainless steel of MLS gaskets withstands 517 N/mm², 5 times more, and recovers its shape on every combustion.

This page presents the part number from Athena, an Italian maker of racing gaskets, for a single construction: the multi-layer steel MLS. The gasket has an 85.8 mm bore, against 83.9 and 83.8 mm for the original gaskets, and a thickness of 0.85 mm. As a rule, the gasket bore chosen is at least 0.5 mm larger than the actual cylinder bore. Each part number is sold individually, one gasket per engine.

Technical specifications

Gasket volume is that of the space the gasket leaves above each cylinder. It enlarges the combustion chamber and therefore lowers the compression ratio. The comparison only makes sense between gaskets of the same bore.

Preparation and fitting

First check with a straight edge that the cylinder head and block are flat, and have them machined if needed. The gasket is supplied coated by Athena: do not add sealing paste.

Technical guide

The construction offered

Athena MLS A stack of two to five layers of AISI 301 stainless steel, laser cut, stamped and then riveted. A layer folded back on itself surrounds each cylinder: this Gas Stopper carries the clamping force onto the combustion chamber, while beads seal the water and oil circuits. Each outer face carries two coats of finish: one holds up at high temperatures and takes up small flaws in the block and cylinder head, the other, silicone, stops the gasket from sticking when it is removed. Athena made it its all-steel choice, from a prepared naturally aspirated engine up to moderate forced induction.

Choosing bore and thickness

Gasket bore. The Athena MLS is offered in 85.8 mm (338408R), in that bore only.

Thickness. Alfa Romeo does not publish the thickness of the original gaskets. A thicker gasket enlarges the combustion chamber and lowers the compression ratio; a thinner one reduces it and raises the ratio.

Since the original thickness is not published, measure with a dial gauge how far the pistons stand above the block, especially if the removed gasket is thicker than 0.85 mm: that value gives the clearance left between piston and head.

The brand

Athena S.p.A. is an Italian maker of gaskets and engine components based in Alonte, in the Veneto, where its head office and main plant stand. It also operates sites in Spain, the United States, Brazil and India. Car makers fit its multi-layer gaskets as original equipment, and its competition range is entirely designed and produced in Italy.

Advantages over the original gasket

When a reinforced gasket becomes necessary

• Adding forced induction, or raising boost on an already turbocharged engine
• Cylinder rebored beyond what the bore of the original gaskets, 83.9 and 83.8 mm covers
• Looking for a compression ratio different from standard, higher or lower
• Engine that has already lost its gasket, or is consuming coolant
• Competition use, where the gasket goes through repeated temperature rises

Vehicle compatibility

OEM part number: 60 608 115 and 60 664 642.

Important: the part number on this page fits only the engines AR16201, AR32301, AR32310, AR34103, AR67204 and AR67299: check your vehicle's engine code before placing an order.

Why switch to a reinforced gasket?

When the original gasket reaches its limits, the reinforced gasket takes over: at higher combustion pressure it does not settle and keeps its geometry.

When a turbo or a supercharger is added, or the compression ratio is raised, the head gasket becomes the most heavily stressed part of the top end. A reinforced gasket is then the way to guard against the leak and the cylinder head removal that follows it.