B1DG0ZK1 - 406D9 XU7JP 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 :
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 :
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 :
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 .