B1DG09K1 - 406D9 XU5JP ENGINE

REMOVAL - REFITTING CYLINDER HEAD

1 - SPECIAL TOOLS

[1] liner retaining clamp (-).0132-A1Z .

[2] bolt M11x150x60 (-).0153-J .

[3] camshaft gear setting rod (-).0132-R .

[4] levers (-).0153-Q .

[5] Vacuum pump .

2 - REMOVAL

drain the cooling system .

Remove the hose (1) .

Slacken the bolts (2) .

Lift up the two clips (3) .

Disconnect, unclip and separate the harnesses, hoses and cables connected to the cylinder head .

Detach the exhaust pipe from the manifold .

Remove the air cleaner cover (4) .

Remove the filter element (5) .

Disconnect :

• the hoses connected to the cylinder head cover / air cleaner assembly
• the fuel pipes (6) after lowering the pressure in the circuit using the tool [5]

Remove the ten bolts securing the cylinder head cover / air cleaner assembly .

Remove the cylinder head cover / air cleaner assembly .

Remove the bolt (7) .

Remove the fixing nut from the top right-hand engine mounting .

Lift the engine using the lifting eye .

Remove the bolts (8) .

Return the engine to its flexible mounting .

Remove :

• the inlet manifold and its fixings
• the timing belt

Starting at the outside and working in a spiral sequence progressively slacken the cylinder head bolts .

Remove the cylinder head bolts .

Rock and free the cylinder head using levers [4] .

Remove the cylinder head and gasket .

Fit the liner retaining clamps [1] with the bolts [2] .

Clean the joint faces with an approved descaling product; Do not use sharp or abrasive tools; The joint faces must not have any trace of knocks or scores .

3 - CHECK

3 - 1 - CHECKING THE FLATNESS

Maximum permissible bow = 0,05 mm .

3 - 2 - CHECKING CYLINDER HEAD BOLTS BEFORE RE-USE

(X) must be less than 176,5 mm .

4 - REFITTING

Check that the camshaft turns freely in its bearings .

Remove the liner retaining clamps [1] .

Clean out the cylinder head bolt holes in the cylinder block with a tap .

Check that the two centralising dowels are fitted at (9) and (10) .

Position the new cylinder head gasket, tongue (11) at the clutch end .

Fit the cylinder head with the camshaft gear pinned .

Fill the cups (12) in the cylinder head with oil .

Coat the threads and the contact area under the bolt head with MOLYKOTE G RAPIDE PLUS grease .

4 - 1 - CYLINDER HEAD TIGHTENING

IMPERATIVE : tighten the cylinder head bolts in the order shown .

Pre-tighten : 6 da.Nm .

Bolt by bolt :

• slacken completely
• tighten to 2 da.Nm
• tighten a further 100 degrees using a FACOM D.360 type tool

Lift the engine using the lifting eye .

Tighten the bolts (8) to 4.5 daN.m .

Return the engine to its flexible mounting .

Tighten the engine mounting to 4.5 da.Nm .

Tighten the bolt (7) to 5 da.Nm .

refit the timing belt .

Apply SILICONE CATEGORIE 2 jointing paste at (A) .

Fit the cylinder head cover / air cleaner assembly using a new seal .

Tighten the ten bolts, in the order shown, to 1 da.Nm .

Replace the inlet manifolds fitted with new seals Tightening torque 2 da.Nm .

Continue the fitting operations in the reverse order to removal .

Couple up and clip the harnesses, hoses and cables connected to the cylinder head .

fill and bleed the cooling system .