B1BJ0JK1 - 406D9 ES9J4 ENGINE

DISMANTLING ENGINE (ES9J4)

1 - SPECIAL TOOLS

[-] Stand DESVIL (2509-T) .

[1] (-).0187-L (8012-T) adaptor .

[2] Cylinder head bolt socket (-).0185 (FACOM STX 14) .

[3] Camshaft hub immobilisation tool (-).0187-F .

[4] camshaft gear setting rod (-).0187-B .

[5] crankshaft setting rod (-).0187-A .

[6] flywheel stop FACOM D.86 (9044-T) type .

2 - DISMANTLING

Remove :

• the alternator
• the alternator bracket
• the pins

Place the engine on the stand [1] .

Remove :

• the exhaust intermediate manifold (1)
• the bracket (2)
• the roller/tensioner assembly (3)
• the bracket (4)
• the style cover (5)

Fit the oil filler plug .

Unclip the engine harness, then disconnect it from the various sensors .

Move aside : The ignition harness (6) .

Remove :

• the lifting plates (7)
• the inlet manifold connector and throttle housing assembly (8)
• the seal
• the vacuum capsule assembly (9) with its bracket and the pin
• the engine harness assembly

Remove the compact coil block assembly (10) by using the ends (A) and (B) .

Remove :

• the secondary coil assembly (11) (by using the ends (A) and (B))
• the spark plugs

Remove :

• the additional engine harness assembly (12), inlet manifold and injection rails
• the inlet manifold seals (13)

Remove :

• the 2 timing covers (14)
• the timing cover (15)

NOTE : the operation to peg the camshafts is made easier by first slackening the pinion bolts and turning the camshafts (using the tool [3], lightly oil the rods [4] before assembly) .

Peg in the order :

• the camshafts, using the rods [4]
• the crankshaft with the rod [5]

Remove the support (16) .

Position 1 bolt(s) (17) type M8 X 125 X 35 .

Start to tighten the bolt (17) until it touches at (C) .

Position 1 bolt(s) (18) type M8 X 125 X 75 .

Start to tighten the bolt (18) until it touches at (D) .

IMPERATIVE : the spacer bolt (19) must remain fully tightened .

Slacken the bolts (20) .

Unscrew the bolt (18) to the maximum .

IMPERATIVE : if the belt is to be re-used mark the direction of rotation .

Remove the timing belt .

Remove :

• camshaft setting rods [4]
• the rollers (21), (22), (23), (24)
• the plate (25)

1st fitting :

• the camshaft hub securing bolts and threads are right-handed

2nd fitting :

• the camshaft hub bolts and threads are left-handed

These bolts can be identified by the 2 arrows (E) stamped on the head .

Unscrew the camshaft hubs securing bolt by immobilising the camshafts using the tool [3] .

Lock the flywheel with the stop [6] .

Remove :

• the crankshaft setting rod [5]
• the camshaft pinions and hubs (26)
• the engine mounting (27)
• the water pump (28) and its gasket
• the timing covers (29)
• the crankshaft gear (30)

Remove :

• the pipe (31)
• the disptick and its guide
• the lifting plates
• knock sensor (32)
• the oil breather assembly (33)
• the coolant inlet and outlet manifold assembly (34)
• the thermostat

Remove :

• the flywheel (35)
• the tool [6]
• the oil filter (36)
• the starter (37) and its heat shield
• the heat shields (38)
• the exhaust manifold (39) and its gasket
• the drain screw (40)
• engine oil pressure sensor (41)
• engine oil level sensor (42)

Remove :

• the heat shield (43)
• the exhaust manifold (44) and its gasket
• the drain screw (45)

IMPERATIVE : progressively slacken in a spiral sequence the bolts of each cylinder head cover (46), starting from the outside .

Remove the cylinder head covers (46) .

IMPERATIVE : starting at the outside and working in a spiral sequence progressively slacken the cylinder head bolts .

Remove the cylinder head bolts .

Remove :

• the cylinder heads (47) and their gaskets

Remove the oil sump (48) .

WARNING : take care not to distort the mating surface .

Remove :

• tube (49)
• the seal (50)
• the filter gauze (51)
• the seal (52)
• the panel (53)
• oil filter nipple fastener (54)

Remove :

• the oil pump (55)

IMPERATIVE : starting at the outside and working in a spiral sequence progressively slacken the main bearing cap casting bolts .

Remove :

• the main bearing cap casting (56)

NOTE : mark the big end caps and shells before removing them (use an indelible pen) .

Remove :

• the big end caps
• the crankshaft (57) and its seal
• the shells
• the centralising pins (58)

Remove the pistons/connecting rods assemblies marking them in relation to the corresponding cylinder .

Remove the centralising dowels (59) .

Remove :

• the lock washers (60)
• the gudgeon pin (61)
• the piston (62)

Check the condition of the various parts .