B1BS00K1 - 406D9 DW10 ENGINE

DISMANTLING - DISMANTLING ENGINE

1 - DISMANTLING - DISMANTLING

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

Remove :

• the engine harness assembly
• the egr valve assembly

Remove :

• the exhaust manifold (1) and its gasket
• the inlet manifold assembly and its gasket (2)
• the securing clip 3

Disconnect the connectors (4) .

Remove :

• the bracket (5)
• the dipstick guide fasteners (6)
• the nuts (7)
• the pins (8) (use a lock nut)
• the bolts (9)

Secure the engine on a stand .

Remove : The thermostat (10) .

Place a draining tray under the engine .

Open the bleed screw (11) .

IMPERATIVE : WHEN WORKING ON THE DIESEL CIRCUIT, FOLLOW THE ADVICE ON CLEANLINESS .

Move aside the connections (12) .

IMPERATIVE : PLUG THE HOLES USING TOOL [1U] .

Remove :

• the assembly (13)
• the oil filter (14)
• the heat exchanger (15)

Remove :

• the nipple (16)
• the alternator
• the diesel filter support (17)
• the accessory bracket (18)
• the oil vapours breather tube (19)

LOCK THE FLYWHEEL WITH THE STOP [1I] .

Remove :

• the ancillary drive pulley (20) (USING THE TOOL [1R])
• the timing gear top covers (21)
• the bottom timing cover (22)
• the engine mounting (23)

REMOVE THE STOP [1I] .

Remove the starter .

1 - 1 - 1ST FITTING : WITH SINGLE ENGINE FLYWHEEL

PEG THE FLYWHEEL USING THE ROD [1G] .

1 - 2 - 2ND FITTING : WITH DOUBLE ENGINE FLYWHEEL

peg the flywheel using the rod [1y] .

Peg :

• the camshaft (USING THE TOOL [1P])

Slacken the bolt (24) .

Remove the timing belt .

Slacken the bolts (25) .

Remove :

• the camshaft pulley (26)
• the tensioning roller (27)
• the tensioner roller (28)
• the crankshaft gear (29) (retrieve the cotter)

Pin the pulley (31) USING THE TOOL [1W] .

Slacken the nut (30) .

Remove the high pressure pump drive pulley (31) (USING THE TOOL [1T]) .

IMPERATIVE : CLEAN THE FUEL UNIONS BEFORE SLACKENING .

IMPERATIVE : apply a counter-torque at (A) .

Remove :

• high pressure pipes (32)
• the bolts (33)

Disconnect the connectors (34), (35) .

Move aside : The hoses (36) and (37) .

PLUG THE HOLES USING TOOL [1U] .

Remove the fastenings (38) .

Remove the high pressure fuel pump .

NOTE : if necessary : entrust the checking of the high pressure injection pump to a dealer .

Remove :

• the bolts (39)
• the injection pump bracket (40)

IMPERATIVE : WHEN WORKING ON THE DIESEL CIRCUIT, FOLLOW THE ADVICE ON CLEANLINESS .

WARNING : if any work is carried out on the high pressure pipes they must always be replaced .

Apply a counter-torque at (b) .

Slacken the unions .

Apply a counter-torque at (c) .

Slacken the unions on the high pressure fuel direct injection rail .

Remove : The 4 high pressure pipes .

IMPERATIVE : plug the openings, USING THE TOOL [1U] .

Remove :

• the injector return rail (42)
• the supply rail (43)
• the glow plugs

Plug the openings, USING THE TOOL [1U] .

Remove :

• the lifting plates (45)
• the vacuum pump (46)

IMPERATIVE : do not turn the nut (d) .

Remove :

• the nuts (47)
• the cups (48)
• the injector clamps (49)
• the injectors (50)
• the sealing rings (51)
• the O-rings (52)
• the thrust buttons (53)

NOTE : if the injector cannot be removed, remove the stud (54) by using a lock-nut, then, using an open ended spanner, turn the injector at (e) .

IMPERATIVE : close the injector holes, plug the openings (USING THE TOOL [1U]) .

Remove :

• the cylinder head cover (55) (in the order shown)

ROD(S) [1P] IN POSITION .

SLACKEN THE CYLINDER HEAD BOLTS IN THE ORDER INDICATED, USING THE TOOL [4] .

Remove the cylinder head bolts .

ROCK AND FREE THE CYLINDER HEAD USING LEVERS [1N] .

Remove the cylinder head and gasket .

Clean the threads and taps .

REMOVE THE TOOL [1G] OR [1Y] .

INSERT THE FLYWHEEL STOP [1I] .

Remove :

• the clutch mechanism
• the flywheel (56)
• the sump (57)

WARNING : take care not to distort the mating surface .

Remove :

• the coolant pump (58)
• the seal carrier plate (59)
• the oil gallery plug (60)

Remove :

• the dipstick tube (61)
• the oil pump (62)
• the oil pump chain and drive pinion

IMPERATIVE : mark the location of the big end caps and main bearings .

Remove :

• the big end caps (63)
• the bearing caps (64)
• the oil seal (65)

Recover the end float adjusting shims on the main bearing (no. 2) .

IMPERATIVE : mark the location of the main bearing half shells .

Remove :

• the crankshaft (66)
• the bearing half-shells
• the end float adjustment shims (67)

Remove :

• the piston/connecting rod assemblies

Fit :

• the big end caps (68)

Remove :

• the lock washers (75)
• gudgeon pin (69)
• the piston (70)

NOTE : the gudgeon pins are paired with the pistons, do not mix the components .

Remove the piston head jets (71) .

Remove :

• the oil gallery plug (72)
• the oil level sensor (73)
• the oil pressure sensor (74)