B1DG11K1 - 406D9 EW7J4 ENGINE

REMOVAL - REFITTING CYLINDER HEAD

1 - SPECIAL TOOLS

[1] Pipe with adapter for valve SHRADER (-).0141-T1 .

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

2 - REMOVAL

Remove the shield under the power train .

drain the cooling system .

Detach the exhaust pipe from the manifold .

Disconnect the battery .

Remove the style cover (1) .

Lower the fuel pressure by connecting the end of the tool [1] to the valve SHRADER; catch the fuel in a receptacle .

Remove :

• the fuel supply pipe (2)
• the timing belt
• the timing belt tensioner roller
• the air cleaner and air intake pipe (3)
• the dipstick guide tube (4) and the dipstick

Disconnect the crankcase breather hose (5) .

Remove the collar (6) .

Disconnect the connectors (7) - (8) - (9) .

Remove :

• the sensor (10)
• the compact coil unit (11)

Move aside :

• the inlet manifold (plug the cylinder head openings)
• the heater matrix pipes (12)

Remove the cylinder head covers (13) .

Remove and move aside the harness bracket (14) from the water outlet housing .

Disconnect the water outlet housing pipes (15) - (16) .

Remove the retaining fork and its fixing bolt (17) from the cooling pipes (18) and (19) on the rear of the water outlet housing .

Remove :

• the bolt (20)
• the cylinder head bolts ; using the tool [2]
• the cylinder head
• the cylinder head gasket
• the water outlet housing rigid pipe

WARNING : 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 .

2 - 1 - CHECKING THE FLATNESS

Maximum permissible bow = 0.05 mm .

3 - REFITTING

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

Check that the pins (21) are present .

Fit a new cylinder head gasket (TOP inscription upwards) .

Position the pipe (19) on the coolant pump .

Fit the cylinder head, with the camshaft pulley pegged .

Position the pipe (19) on the cylinder head, the gaskets having previously been coated with grease .

IMPERATIVE : always renew ; the cylinder head bolts .

coat the threads and the contact area under the bolt head with grease .

4 - CYLINDER HEAD TIGHTENING

IMPERATIVE : tighten the cylinder head bolts in the order shown (using the tool [2]) .

Stage 1 :

• proceed bolt by bolt in the order shown
• tightening torque of bolts : 4 da.Nm

Stage 2 :

• proceed bolt by bolt in the order shown
• tightening torque of bolts : 7,5 da.Nm

Stage 3 :

• proceed bolt by bolt in the order shown
• tighten a further 165 degrees using a FACOM D60 type tool

5 - REFITTING (NEXT)

Continue the fitting operations in the reverse order to removal .

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

Refit the bolt in the cylinder head intermediate bracket ; Tightening torque 4.5 da.Nm .

Refit the cylinder head covers fitted with new gaskets in the order indicated .

Proceed bolt by bolt in the order shown :

• pre-tightening ; tightening torque 0.5 da.Nm
• tightening ; tightening torque 1.1 da.Nm

Fit :

• the compact coil unit
• the inlet manifold ; tightening torque 2 da.Nm

Re-connect the connectors (7) - (8) - (9) .

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

Fit :

• the sensor (10)
• the dipstick guide fitted with a new seal

IMPERATIVE : replace the exhaust clamp .

fill and bleed the cooling system .