B1DJ04K1 - 406D9 XU5JP ENGINE XU7JP ENGINE XU7JB ENGINE

DISMANTLING - ASSEMBLY 8 VALVE CYLINDER HEAD

1 - SPECIAL TOOLS

2 - DISMANTLING

Remove :

• the fuel pump (1) with its spacer and its seals (according to specification)
• the coolant outlet housing cover (2) and its gasket
• the thermostat (3)

NOTE : depending on the engine, the thermostat may be equipped with a fitted seal .

According to specification :

• mark the position of the ignition distributor in relation to the water outlet housing

Remove :

• the ignition distributor (4)
• the double ignition coil (5)
• the various sensors and thermistors (6)
• the thermostat (7)

A = No. 2 .

B = No. 4 .

Remove :

• the lubrication rail (8) and its seals (9)
• the retaining fork (10) (depending on engine type)
• the camshaft main bearing caps
• the camshaft (11)
• the oil seal (12)

The main bearing caps (no. 2 : A and no. 4 : B) are marked .

IMPERATIVE : mark the location of the tappets (13) .

Remove :

• the tappets (13)
• the adjustment shims (14)

Remove the filter (15) (Depending on engine type) .

Compress the spring a little Using the tool [1] .

Remove the half cones (16) .

Remove :

• the valve springs
• the valves
• the abutment washers

Remove :

• the valve stem oil seals using tool [2]

NOTE : for cleaning the joint faces, use DECAPJOINT scouring agent .

Checking the flatness :

• C : maximum permissible bow = 0,05 mm

Check the condition :

• valve seats and guides
• valve springs
• camshaft
• camshaft bearings
• internal and external threads

Make the necessary repairs .

3 - ASSEMBLY

Insert the new valve stem seals using the tool [3] .

Assembly .

Fit a new filter (15) (Depending on engine type) .

A = No. 2 .

B = No. 4 .

Fit a thrust button on each valve stem (Thickness 2,25 mm) .

IMPERATIVE : pay attention to the direction of fitting .

Refit the tappets (13) in their original positions .

IMPERATIVE : check that the tappets rotate freely in the cylinder head .

Lubricate the camshaft bearings and the cams with engine oil .

Fit :

• the camshaft

Depending on engine type :

• fit the retaining fork (10), tightening torque 1.5 da.Nm

Fit :

• the bearing caps

The main bearing caps (no. 2 : A and no. 4 : B) are marked .

Tighten the main bearing cap mounting bolts to the correct torque .

IMPERATIVE : Engine tightening torques .

NOTE : valve clearance adjustment .

Fit a new lip seal (17) using tool [4] .

Tighten the bolt (18) to its stop .

Coat the joint face of the water outlet housing with RECTIJOINT sealing product .

Fit :

• the thermostat (7)
• tightening torque : 1.4 da.Nm
• the various sensors and thermistors (6)
• tightening torque : 1.8 da.Nm
• the lubrication rail (8)

Fit :

• the thermostat (3) fitted with new seals
• the water outlet housing cover (2)
• tightening torque : 1.5 da.Nm