B1DG15K1 - 406D9 DW10ATED ENGINE

REMOVAL - REFITTING CYLINDER HEAD

IMPERATIVE : when carrying out an operation on the diesel circuit, respect safety instructions .

WARNING : if any work is carried out on the high pressure pipes they must always be replaced .

1 - SPECIAL TOOLS

[1] cross beam (-).0102-D .

[2] Lifting chain (-).0102-M .

[3] crankshaft turning tool (-).0117-EZ .

[4] cylinder head releasing levers (-).0188-L .

[5] dial gauge (-).1504 .

[6] dial gauge support (-).0110-H .

DW10ATED ENGINE

[8]Flywheel setting rod (-).0188-X .

ALL MODELS

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

[10] Pipe spanner (-).1603-G .

[11] Pipe spanner (-).1603-F .

[12] Set of plugs (-).0188-T .

[13] Tightening kit (-).1603-A/B/D/E .

2 - REMOVAL

DW10ATED ENGINE

drain the cooling system .

remove the turbocharger .

remove the timing belt .

ALL MODELS

Remove the bolts (1), (2) .

Refit the right-hand engine mounting .

Slightly tighten the bolts .

Disconnect the sensor (3) .

Move aside :

electrical harness (4)
the pipe (5)
the brake servo vacuum pipe (6)

IMPERATIVE : clean the fuel unions before slackening .

Remove :

the bracket (7)
the fuel return pipe (8)
the high pressure pipe (9) (using tools [10] and [13])

IMPERATIVE : plug the holes using tool [12] .

Remove :

the camshaft gear (10)
the cylinder head cover (11), in the order shown

Disconnect the cylinder head harnesses and pipes and move them aside .

DW10ATED ENGINE

Remove : The air cleaner assembly .

ALL MODELS

Disconnect the connectors (12) .

Remove :

the bracket (13)
the dipstick guide fasteners (14)

Slacken the nuts (15) .

Remove :

the pins (16) (use a lock nut)
the bolts (17)

Move aside the coolant outlet manifold (18) .

IMPERATIVE : starting at the outside and working in a spiral sequence progressively slacken the cylinder head bolts .

Remove the cylinder head bolts (Using the tool [9]) .

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

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 threads in the cylinder block with a M12 X 150 tap .

Check the condition :

of the mating surface
of the valves
of the valve springs and their cups
of the camshaft
of the camshaft bearings
of the various tapped holes
of the hydraulic tappets
of the valve rockers

3 - CHECKING THE FLATNESS

Maximum permissible bow = 0.05 mm .

4 - CHECKING VALVE PROTRUSION

DW10ATED ENGINE

ALL MODELS

Clean the checking surfaces .

Check the protrusion of the valves in relation to the cylinder head surface (4 Checking points (C)) :

calculate the average of the 4 values measured
(A) exhaust valve = 0.2 mm maximum
(B) inlet valve = 0.2 mm maximum

These values are obtained by grinding the valve seats .

Lap in the valves (if necessary) .

5 - CHECKING CYLINDER HEAD BOLTS BEFORE RE-USE

(X) must be less than 133.4 mm .

6 - CHOICE OF CYLINDER HEAD GASKET

DW10ATED ENGINE

Remove the crankshaft setting rod [8] .

ALL MODELS

(Y) = 10 mm .

Clean the checking surfaces .

Fit the dial gauge [5] on the bracket [6] .

Turn the crankshaft .

Place the needle of the dial gauge on one of the checking points (Checking point : D) .

Continue turning the crankshaft until the piston reaches TDC .

Read the value .

Turn a quarter turn backwards .

Move the piston to the Top Dead Centre value without ever exceeding it .

Zero the dial gauge .

Move the dial gauge/bracket assembly [5] and [6] over the cylinder block .

Read the value .

Place the needle of the dial gauge on one of the checking points (Checking point : E) .

Zero the dial gauge .

Move the dial gauge/bracket assembly [5] and [6] over the cylinder block .

Read the value .

Calculate the average of the 2 values measured .

Continue in the same way for the other three cylinders .

NOTE : maximum difference between 2 pistons = 0.07 mm .

WARNING : the highest average value determines the thickness of the gasket .

7 - CYLINDER HEAD GASKET IDENTIFICATION

(F) : thickness identification .

There are 5 categories of laminated metal cylinder gaskets .

piston protrusion measurements (mm)	thickness (mm)	notch(es) at (F)
0.47 to 0.604	1.30 ± 0.06	1
0.605 to 0.654	1.35 ± 0.06	2
0.655 to 0.704	1.40 ± 0.06	3
0.705 to 0.754	1.45 ± 0.06	4
0.755 to 0.83	1.50 ± 0.06	5

IMPERATIVE : if the value measured does not correspond to the values indicated, investigate the origin of the fault (measurement error, handling error etc.) .

8 - REFITTING

Clean the surfaces of the coolant housing outlet .

Turn the crankshaft with the tool [3] .

Peg the flywheel using the rod [8] .

Check that the pins (G) are present .

Fit a new cylinder head gasket (Following the direction of fitting) .

Ensure that the camshaft is pinned .

Refit the cylinder head .

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 .

9 - CYLINDER HEAD TIGHTENING

Tighten the cylinder head bolts in the order shown (Using the tool [9]) .

Stage 1 :

proceed bolt by bolt in the order shown
tightening torque of bolts : 2 da.Nm

Stage 2 :

proceed bolt by bolt in the order shown
tightening torque of bolts : 6 da.Nm

Stage 3 :

proceed bolt by bolt in the order shown
angular tightening to 220 °

NOTE : it is not necessary to retighten the cylinder head after bringing the engine up to operating temperature .

10 - REFITTING (CONTINUED)

Refit the coolant outlet manifold (18) fitted with a new seal .

Tighten :

the studs (16) to 2.5 m.daN + LOCTITE FREINFILET
the nuts (15) to 2 da.Nm
the bolts (17) to 2 da.Nm

Connect the connectors (12) .

Refit the support (13) .

Fit the cylinder head cover using a new gasket .

Run up the bolts .

Gradually tighten the cylinder head cover bolts in a spiral starting from the inside .

Tightening torque: 1 da.Nm .

IMPERATIVE : when carrying out an operation on the diesel circuit, respect safety instructions .

WARNING : if any work is carried out on the high pressure pipes (9) they must always be replaced .

Fit : The high pressure supply pipe, Finger tighten : The hoses .

Tighten the pipe (9) to 2 daN.m (Using the tools [10], [13]) .

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

Position the cross beam [1] fitted with its chains [2] and take the weight .

Remove the right-hand engine mounting .

Refit the bolts (1), (2) .

Tighten :

the bolt (2) to 4.5 da.Nm + LOCTITE FRENETANCH
the bolt (1) to 2 da.Nm

Fit the camshaft gear (10) .

refit the timing belt .

adjust the sensor air gap .

DW10ATED ENGINE

fit the turbocharger .

ALL MODELS

Continue the fitting operations in the reverse order to removal .

DW10ATED ENGINE

fill and bleed the cooling system .

ALL MODELS

Carry out the following road test :

engage 3rd gear, stabilise the engine speed at 1000 rpm
accelerate fully (to : 3500 rpm)

Check the sealing of the various unions .