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I'd appreciate any advice on grinding the valves on a VVC engine, before we go ahead and seperate the upper and lower head.
Any insight into the causes of an apparent HGF would also be useful.

The gory details are as follows;

My 60,000 mile 200 vi has just started producing mayonnaise. The quantity of mayo was very small, probably just a few millilitres around the top of the expansion tank - very early stages of HGF? Coolant level was normal, and no mayo evident in the oil. There wasn't any mayo in the coolant two weeks ago.
A compression test showed about 160psi on cylinders 1-3, but only about 145 on cylinder 4.

The engine history is that the right hand exhaust camshaft pulley went awol (loose bolt) at about 35,000 miles, resulting in at least one of the right hand pistons (we think probably just piston 4) talking to the inlet valves. The previous owner had this repaired by a main dealer, and some valves were replaced - the cost of work to the head and valvetrain was about £200, but we are not sure exactly what this entailed.

The cylinder head is now off. The recovered coolant had just a trace film of oil on it. The head, block and liners appear to be in very good condition. There are no traces of leakage evident on the gasket or other surfaces. The liners have about 4 thou stand proud from the block, and we can't find any evidence of head warp. AFAIK it's never overheated either.

We assume the valves in cylinder four are a little leaky, and that the gasket is just starting to get iffy, so we intend to grind the valves in cylinder four and stick it all back together with new gaskets, through bolts, water pump and thermostat.

Any advice on seperating the cam carrier and grinding the valves would be gratefully received, as would any insights into the source of the mayo.

Thanks in advance.
 
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