B1DG0AK1 - 406D9 XU7JP4 ENGINE XU10J4R ENGINE

REMOVAL - REFITTING CYLINDER HEAD

1 - SPECIAL TOOLS

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

[2] Vacuum pump .

[3] Camshaft hub setting rods (-).0153-AB .

2 - REMOVAL

drain the cooling system .

Remove the pipe (1) and the air cleaner housing (1a) .

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

Lower the pressure in the injector supply pipe (2) by means of the pump [2] .

Unclip and disconnect the injector supply harness (3) .

Move aside the injector supply pipe (2) without disconnecting the fuel pipes (4) (Retrieving the thrust washers (4a)) .

IMPERATIVE : take all necessary precautions to protect the injector nozzles from damage or dirt .

Disconnect and move aside the coolant outlet click-on hose union .

Remove the 2 bolts (5) from the inlet manifold bracket .

Detach the exhaust pipe from the manifold .

Remove the compact coil unit (6) .

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

Remove the cylinder head covers (7) .

Remove :

• the bolt (8)
• the nuts (9)
• the bolts (10)
• the inlet manifold with the throttle housing
• the timing belt

Remove the right-hand engine mounting .

IMPERATIVE : 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 [1] .

Remove the cylinder head and gasket .

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 .

Clean the holes (A) between the bores .

3 - CHECKING THE FLATNESS

Maximum permissible bow = 0,05 mm .

4 - CHECKING CYLINDER HEAD BOLTS BEFORE RE-USE

XU10J4R ENGINE

(X) must be less than 112 mm .

XU7JP4 ENGINE

(X) must be less than 160 mm .

ALL MODELS

5 - REFITTING

Clean the threads of the cylinder head bolts in the cylinder block using a thread cutter .

Check that the pins (11) are present .

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

Fit the cylinder head, with the camshaft sprockets pegged [3] .

Correctly engage the end (C) of the timing cover .

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

6 - CYLINDER HEAD TIGHTENING

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

XU10J4R ENGINE

Pre-tightening 3.5 da.Nm .

Tighten to 7 da.Nm .

Tighten a further 160 degrees using a FACOM D.360 type tool .

XU7JP4 ENGINE

Pre-tightening to 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

Angular tightening to 100 ° .

Angular tightening to 100 ° .

ALL MODELS

7 - REFITTING (CONTINUED)

IMPERATIVE : fill with oil the cups above the hydraulic tappets .

Fit :

• the timing belt
• the right-hand engine mounting

XU10J4R ENGINE

Tighten :

• the nuts (12) : 8 da.Nm
• the bolts (13) : 8 da.Nm
• the nut (14) : 4.5 da.Nm
• the 3 securing bolts (15) : 5 da.Nm

XU7JP4 ENGINE

Tighten :

• the nuts (12) : 4.5 da.Nm
• the bolts (13) : 6 da.Nm
• the nut (14) : 4.5 da.Nm
• the 3 securing bolts (15) : 5 da.Nm

ALL MODELS

WARNING : strictly follow the fastening and routes of the various harnesses and pipes .

Refit the intake manifold, fitted with a new gasket .

Tighten :

• the bolts (10) to 2 da.Nm
• the nuts (9) to 2 da.Nm
• the bolt (8) to 1 da.Nm

Fit :

• the cylinder head covers (7), having cleaned the gaskets and the joint faces

NOTE : the cylinder head covers have composite gaskets which can be used several times ; if the gasket is damaged, it can be partially repaired with AUTO JOINT OR jointing paste .

Tighten the bolts to 1 da.Nm. in the order indicated : From (1) to (7) .

Fit :

• the compact coil unit (6) : tightening torque 1 da.Nm

Connect the pipes, cables and harnesses connected to the cylinder head .

WARNING : strictly follow the fastening and routes of the various harnesses and pipes .

Tighten the bolts (5) to 2 daN.m .

Fasten the exhaust pipe to the manifold .

Fit :

• the injector supply pipe (2) fitted with its injectors, having lightly lubricated the seals (with engine oil)
• the air inlet hose (1)

Refit the air cleaner housing (1a) .

Reconnect the vacuum pipe to the fuel pressure regulator .

fill and bleed the cooling system .