B1DG17K1 - 406D9 DW10TD 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 .
[7] Flywheel setting rod (-).0188-Y .
[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
drain the cooling system .
remove the turbocharger .
remove the timing belt .
Remove the bolts (1), (2) .
Refit the right-hand engine mounting .
Slightly tighten the bolts .
Disconnect the sensor (3) .
Move aside :
IMPERATIVE : clean the fuel unions before slackening .
Remove :
IMPERATIVE : plug the holes using tool [12] .
Remove :
Disconnect the cylinder head harnesses and pipes and move them aside .
Remove : The air cleaner assembly .
Disconnect the connectors (12) .
Remove :
Slacken the nuts (15) .
Remove :
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 :
3 - CHECKING THE FLATNESS
Maximum permissible bow = 0.05 mm .
4 - CHECKING VALVE PROTRUSION
Clean the checking surfaces .
Check the protrusion of the valves in relation to the cylinder head surface (4 Checking points (C)) :
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
Remove the crankshaft setting rod [7] .
(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 [7] .
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 :
Stage 2 :
Stage 3 :
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 :
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 :
Fit the camshaft gear (10) .
fit the turbocharger .
Continue the fitting operations in the reverse order to removal .
fill and bleed the cooling system .
Carry out the following road test :
Check the sealing of the various unions .