B1DG0EK1 - 406D9 ES9J4 ENGINE

REMOVAL - REFITTING CYLINDER HEAD

1 - SPECIAL TOOLS

[1] Cylinder head bolt socket (-).0185 .

2 - REMOVAL

remove the power train .

Cruise control :

• remove the vacuum capsule assembly (1) with its bracket and the pin

Remove :

• the engine harness assembly (2) and its bracket
• the lifting plates (3)
• the inlet manifold (4)

Disconnect the oil vapour recirculation pipes (5) .

Remove :

• the additional engine harness assembly (6), inlet manifold and injection rails

Recover the seals .

Plug the cylinder head openings .

remove the timing belt .

Remove :

• the coolant inlet and outlet manifold assembly (7)
• the oil vapour recirculation pipes (5)

Remove :

• the dipstick (8)
• the fastener (9)

Remove :

• the bolt (10)
• the power steering pump bracket (11)
• the M8 bolt (12)

Remove the cylinder head covers .

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 head (13) .

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 head (14) .

Recover the seals (15) .

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 (16) between the bores .

3 - CHECKING THE FLATNESS

Maximum permissible bow = 0.05 mm .

4 - CHECKING CYLINDER HEAD BOLTS BEFORE RE-USE

(X) must be less than 149.5 mm .

5 - REFITTING

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

Check that the pins (17) are present .

Position the new cylinder head gaskets .

WARNING : the holes (17a) must be free of obstructions .

Fit the cylinder heads, with the camshaft pinions with rods inserted .

refit the timing belt .

Brush the threads of the cylinder head bolts .

Fit the cylinder head bolts coated with MOLYKOTE G RAPID PLUS on the threads and under the bolt heads .

6 - TIGHTENING THE CYLINDER HEADS

IMPERATIVE : tighten the cylinder head bolts in the order shown (using the tool [1]) .

Pre-tighten : 2 ± 0.1 da.Nm .

Bolt by bolt .

Slacken completely .

Tighten to 1.5 ± 0.1 da.Nm .

Tighten a further 225 degrees using a FACOM D.360 type tool .

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 SILICONE CATEGORIE 2 jointing paste .

Refit the cylinder head covers .

On the right-hand side : .

On the left-hand side : .

IMPERATIVE : finger tighten then progressively tighten the securing bolts in the order shown (1 to 10) .

Pre-tightening 0.5 ± 0.03 da.Nm .

Tightening torque: 1 ± 0.1 da.Nm .

Check the tightening : 1 ± 0.1 da.Nm .

Fit :

• the M8 bolt (12)
• the power steering pump bracket (11)
• the bolt (10)

Tighten :

• the bolts (18) to 3.9 ± 0.2 da.Nm
• the bolt (10) to 6 ± 0.4 da.Nm

Tighten the fastener (9) to 2.5 ± 0.1 daN.m. .

Fit :

• the dipstick (8)

Fit :

• the oil vapour breather pipes (5)
• the coolant inlet and outlet manifold assembly (7)

Tighten :

• the bolts (19) to 0.8 ± 0.05 da.Nm
• the bolts (20) to 2.5 ± 0.1 da.Nm
• the bolt (21) to 0.8 ± 0.05 da.Nm

IMPERATIVE : always replace the inlet manifold seals .

Fit :

• the additional engine harness assembly (6), inlet manifold and injection rails

Reconnect the oil vapour breather pipes (5) .

IMPERATIVE : tighten the bolts in the order shown .

5 GEARBOX

Fastener M8 :

• pre-tightening 1 ± 0.1 da.Nm
• tightening torque: 2.5 ± 0.1 da.Nm
• check the tightening : 2.5 ± 0.1 da.Nm

5 GEARBOX 5 GEARBOX

Fastener M6 (Manual gearbox \ Automatic gearbox) :

• pre-tightening 0.4 ± 0.06 da.Nm
• tightening torque: 1 ± 0.1 da.Nm
• check the tightening : 1 ± 0.1 da.Nm

ALL MODELS

Continue the fitting operations in the reverse order to removal .