R cylinder head - overhaul

Operation 1016E22 · Cylinder head/s - various operations

3.2 V6

Dismantling

1. Position the cylinder head (1a) in the vice, using tools (1b), 1 (c) and 1(d).

1. Undo the bolts (1a) and remove the fuel manifold (1b), complete with injectors (1c).

2. Undo the nuts (2a) and remove the bracket on the engine for the reaction rod (2b).

1. Undo the bolts (1a) and remove the inlet manifold (1b).

2. Remove the gasket.

1. Undo the bolts (1a) and remove the moving timing belt tensioner (1b).

2. Undo the bolt (2a) and remove the bracket (2b).

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

If the value of the camshaft end float is not within the recommended values, when reassembling, replace the worn components.

1. Undo the bolts (1a) and remove the camshaft caps (1b).

2. Remove the camshafts.

3. Remove the front camshaft oil seals.

4. Remove the hydraulic tappets.

1. Remove the spark plug housing gaskets.

2. Remove the spark plugs.

1. Remove the split collars (1a) for the cylinder in question using tools (1b), (1c), (1d), (1e) and (1f).

2. Remove the upper valve shims.

3. Remove the valve springs.

Remove the tools used for dismantling the valves.

4. Remove the valves.

Work in the same way to remove the remaining valves.

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

2. Remove the lower spring washers (2a) and the lower valve shims (2b).

Remove the cylinder head from the supporting tools and position it on an appropriate workbench.

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

Reassembling

Clean the residues of the old gasket from the lower surface of the cylinder head.

1. Check that the planarity of the lower cylinder head surface is within the recommended values.

If necessary, both cylinder heads should be refaced.

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.

The minimum permitted cylinder head height should never be exceeded, or else the actual cylinder head has to be replaced.

De-carbonize the valves and check that the stem does not show signs of grooves 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.

Check that the outer diameter of the hydraulic tappets is within the recommended values. if this is not the case, replace the worn hydraulic tappets.

Check that the diameter of the tappet casing housings are within the recommended values.

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

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.

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

The surfaces of the camshaft bearings should not show signs of wear, grooves or seizing or else the shafts have to be replaced.

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

The surfaces of the camshaft bearings should not show signs of wear, grooves or seizing or else the shafts have to be replaced.

Place the camshaft caps back in their housings in the right cylinder head following the sequence shown in the diagram.

1. Tighten the camshaft cap bolts to the specified torque.

2. Check the diameter of the camshaft mounts is within specified values.

Check that the outer diameter of the valve guides is within the recommended values.

Inlet valve guides are available from the Parts Dept. with an outer diameter of 12.053 12.064 mm.

Exhaust valve guides are available from the Parts Dept. with an outer diameter of 12.064 12.082 mm.

Check that the diameter of the valve guide seat is within the recommended values. if this is not the cse, ream the seats depending on the valve guide oversize.

1. Place the valve guides (1a) back in their seats using the fitting tool (1b).

Using the above mentioned tool guarantees the correct valve guide projection.

1. Ream the new valve guides using a suitable tool for calibrating the openings to the correct diameter.

1. Regrind the valve seats to the recommended dimensions.

Grind the valve seats using a suitable tool.

Use SIPAL Arexons abrasive or a similar product to grind the valve seats.

Positino the cylinder head in the vice using the tools.

Place the lower valve shims and the lower spring seals back in their housings.

1. Place the valve guide oil seals (1a) back in their housings using the tool (1b).

1. Place the valves (1a) for the cylinder in question back in their seats and support them using the tools (1b) and (1c).

2. Place the valve springs back in their seats.

3. Place the upper valve shims back in their housings.

4. Place the cotters (4a) for the valves for the cylinder in question bakc in their housings using the tools (4b), (4c) and (4d).

Remove the tools used for fitting valves.

Work in the same way when fitting the remaining valves.

1. Place the spark plugs back in their housings and tighten them to the recommended torque.

1. Carry out the valve leakage test using the tools (1a) and (1b).

1. Place the spark plug housing seals back in their housings.

2. Place the hydraulic tappets in their housings.

3. Place the camshafts back in their housings.

Place the camshaft caps back in their housings in the right cylinder head following the sequence shown in the diagram.

Tighten the camshaft cap bolts to the specified torque.

1. Fit the camshaft front oil seals (1a) using the tool (1b).

Place the bracket back in its housing and secure it using the bolt.

Fit the timing belt mobile tensioner and fix it using the bolts without tightening them.

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

1. Fit the bracket on the engine for the reaction rod (1a) and fix it tightening the nuts (1b) to the recommended torque.

Place the fuel manifold, complete with injectors, back in its housing and fix it using the bolts.

Remove the cylinder head from the supporting tools.