Right CYLINDER HEAD - Overhaul - Dismantling

Operation 1016E22 · CYLINDER HEAD/S - VARIOUS OPERATIONS

3.0 V6

Removing

1. Place the tool A in the vice.

2. Fit the tool (2a) A complete with the tool (2b) A.

3. Position the cylinder head (3a) on the support tools and fasten it using the nuts (3b).

1. Undo the bolts (1a) and remove the intake manifolds (1b).

2. Undo the bolts (2a) and remove the fuel distribution manifold (2b) with injectors (2c).

3. Remove the air intake manifold (3a) complete with gasket (3b).

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

2. Undo the bolt (2a) and remove the timing drive belt fixed belt tensioner (2b).

1. Loosen the bolts (1a) for the camshaft drive pullies using the tools (1b) A for counter-torque.

1. Remove the camshaft drive pullies (1a) using the tool (1b) A.

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

2. Undo the nuts (2a) and remove the reaction rod support (2b).

1. Undo the bolt (1a) and remove the coolant outlet connector (1b) from the right cylinder head.

2. Undo the bolt (2a) and remove the cam angle sensor (2b) complete with O-Ring (2c).

- Check that the camshaft endfloat M is within the recommended values using a dial gauge on a mangetic base.

- If the camshaft endfloat does not correspond to the recommended figures, replace the worn components when reassembling.

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

2. Remove the camshafts.

3. Remove the camshaft front oil seals.

4. Remove the hydraulic tappets.

5. Remove the spark plug seat seals.

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

2. Remove the valve upper shim.

3. Remove the valve springs.

- Remove the tools used 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) A.

2. Remove the spring lower seal (2a) and the valve lower shim (2b).

- Remove the cylinder head from the support tools and place it on a special workbench.

1. Thread the special extraction tool (b) into 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) A.

Refitting

- Clean any residues of the old gasket from the lower cylinder head plane.

1. Check that the planarity of the lower cylinder head plane M corresponds to the recommended values.

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

- Check that the valves do not show signs of grooves or seizing.

- Check that the diameter of the valve stems M corresponds to the recommended figures; if not, replace the worn valves.

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

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

- Check that the length of the valve springs M released corresponds to the recommended figures.

- Using a torque wrench, check that the spring M specifications correspond to the recommended figures; if not, replace the springs.

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

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

1. Fit the camshaft caps on the right cylinder head following the order illustrated in the diagram.

1. Tighten the camshaft cap bolts to torque C.

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

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

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

- Ream the valve guide inner diameter M to the recommended figure.

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

1. Heat the cylinder head to 100-120°C, then fit the valve seats (1a) using a suitable tool (1b).

1. Regrind the valve seats to the recommended size M.

- 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 and the lower valve seal.

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

1. Fit the valves (1a) for the cylinder in question and support them using the tools (1b) and (1c) A.

2. Fit the valve springs.

3. Fit the upper valve shims.

4. Fit the cotters (4a) using the tools (4b), (4c), and (4d) A.

- Carry out the same operations to refit the remaining valves.

- Remove the tools used for fitting the valves.

1. Fit the spark plug seat seals.

2. Fit the hydraulic tappets.

3. Fit the camshafts.

1. Fit the camshaft caps on the right cylinder head following the order illustrated in the diagram.

- Tighten the camshaft cap bolts to torque C.

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

- Fit the cam angle sensor complete with O-Ring and fasten it using the bolt.

- Fit the right cylinder head coolant outlet connector and fasten it using the bolt.

- Fit the reaction rod support and secure it using the nuts.

- Fit the timing belt guard and secure it using the bolts.

1. Fit the camshaft drive pullies.

2. Tighten the camshaft drive pulley bolts (2a) using the tools (2b) A to torque C.

- Fit the timing drive belt fixed belt tensioner and fasten it using the bolt.

- Fit the timing drive belt automatic belt tensioner and secure it without tightening the bolts.

- Fit the intake manifold complete with gasket.

- Fit the fuel distribution manifold complete with injectors and secure it using the fixing bolts.

- Fit the intake manifolds and secure them using the bolts.

- Remove the cylinder head from the support tools.

- Remove the cylinder head support tools from the vice and put them down.

3.2 V6

Removing

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

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

2. Undo the nuts (2a) and remove the reaction rod support (2b).

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

2. Remove the seal.

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

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

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

- If the camshaft endfloat does not correspond to the recommended figures, replace the worn components when reassembling.

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

2. Remove the camshafts.

3. Remove the camshaft front oil seals.

4. Remove the hydraulic tappets.

1. Remove the spark plug seat seals.

2. Remove the spark plugs.

1. Remove the cylinder half-cones (1a) using the tools (1b), (1c), (1d), (1e) and (1f).

2. Fit the upper valve shims.

3. Remove the valve springs.

- Remove the tools used for dismantling the valves.

4. Remove the valves.

- Carry out the same operations for removing the remaining valves.

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

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

- Remove the cylinder head from the support tools and place it on a special workbench.

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

Refitting

- Clean any residues of the old gasket from the lower cylinder head plane.

1. Check that the planarity of the lower cylinder head surface corresponds to the recommended values.

If grinding is necessary, adjust the flatness of both cylinder heads.

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

The minimum permitted cylinder head height must never be exceeded, otherwise the cylinder head must be replaced.

- Remove valve deposits, checking the rod for scoring or signs of binding.

- Check that the diameter of the valve stems corresponds to the recommended figures; if not, replace the worn valves.

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

- Check that the diameter of the main journal seats is within specified limits.

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

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

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

The camshaft journal surfaces must not show signs of wear, scoring or binding, otherwise replace the shafts.

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

The camshaft cam surfaces must not show signs of wear, scoring or binding, otherwise replace the shafts.

- Refit the camshaft caps on the right cylinder head following the order illustrated in the diagram.

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

2. Check that the diameter of the camshaft mounts is as specified.

- Check that the outer diameter of the valve guides is as specified.

Parts supplies intake valve guides with outer diameter of 12.053 ÷ 12.064 mm

Parts supplies exhaust valve guides with outer diameter of 12.064 ÷ 12.082 mm

- Check that the valve guide seat diamters is within specified values. If not, ream the seats according to the valve guide oversize.

1. Refit the valve guides (1a) in their seats using installing tool (1b).

The use of the above tool ensures correct valve guide protrusion.

1. Ream the new valve guides using an appropriate tool to calibrate the holes to the specified diameter.

1. Regrind the valve seats to the recommended size.

- Grind the valve seats using a suitable tool.

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

- Position the cylinder head in a vice using the tools.

- Refit the lower valve shims and the lower spring contact rings in their seats.

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

1. Fit the valves (1a) for the cylinder in question and support them using the tools (1b) and (1c).

2. Place the valve springs in their housings.

3. Refit the upper valve shims in their housings.

4. Place the cylinder valve half-cones (4a) in their housings using the tools (4b), (4c) and (4d).

- Remove the tools used for fitting the valves.

- Carry out the same operations to refit the remaining valves.

1. Fit the spark plugs and tighten them to the recommended torque.

1. Test the valve seal using tools (1a) and (1b).

1. Refit the spark plug socket seals.

2. Place the hydraulic tappets in their housings.

3. Place the camshafts in their housings.

- Refit the camshaft caps on the right cylinder head following the order illustrated in the diagram.

- Tighten the bolts fixing the camshaft caps to the recommended torque.

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

- Refit the bracket and secure with the bolt.

- Reposition the moving timing system tensioner in its housing and secure it without tightening the nut.

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

1. Refit the reaction rod bracket (1a) in its seat and secure it by tightening the nuts (1b) to the recommended torque.

- Place the fuel manifold pipe complete with injectors in its housing and secure it using the bolts.

- Remove the cylinder head from the support tools.

2.0 TB, 2.4 20V

- Operation not available