B1DJ05K1 - 406D9 XU7JP4 ENGINE XU10J4R ENGINE

DISMANTLING - ASSEMBLY 16 VALVE CYLINDER HEAD

1 - SPECIAL TOOLS

2 - DISMANTLING

Slacken the bolts (1), (2) Rod(s) [1] in position .

Remove :

• the pegs [1]
• the camshaft hubs (3) and (4)
• slacken the bolts (5)

Remove :

• the timing cover (6)
• the lubrication rails (7)

Remove the thermostat housing (8) .

Depending on engine type :

• move aside the vacuum pump (9)
• retrieve the lubrication tube (10)

Slacken by several turns the 12 securing bolts on each camshaft bearing housing (11) - (12) .

Progressively unscrew the bolts securing the bearing housings (11) - (12) .

Remove the camshaft bearing housings (11) - (12) .

To remove the camshafts (13) :

• tilt each camshaft by pressing on the end (clutch side) to release the centralising bearing (timing side)

Remove the lip seals (14) .

Removal of the tappets (15) :

• mark the positions of the tappets before removal
• use a valve grinding type suction cup tool

Using the tool [2] .

Remove :

• the thrust washer (16)
• the springs (17) - (18)
• the valves (making identification marks)

Remove :

• the valve stem oil seals using tool [3]
• the abutment washers (19)

3 - REMOVAL : ANTI-RETURN VALVE

Plug the pipe (20) .

Using bellows fitted with a 6.5 mm diameter end piece, blow into the pipe (21) .

WARNING : do not damage the camshaft seal contact surfaces .

(22) : Non-return valve housing (23) .

Remove the anti-return valve (23) .

Check the flatness :

• maximum permissible bow = 0.05 mm

NOTE : in order to clean the seal surfaces, use scouring product DECAPLOC 88 (or equivalent) .

Check the condition :

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

Make the necessary repairs .

IMPERATIVE : for the checking, grinding and replacement of the parts, refer to sections : data - identification .

4 - ASSEMBLY

Fit a new anti-return valve (23) in the pipe (22) .

WARNING : ensure that the direction of fitting of the anti-return valve is correct .

Fit :

• the thrust washer (19)

Insert the new valve stem seals using the tool [4] .

Using tool [2], refit :

• the spring (17)
• the spring (18) (depending on engine type)
• the thrust washer (16)
• the valves

Lubricate the tappets .

Refit the tappets in their original positions .

4 - 1 - HYDRAULIC TAPPETS

Check that the hydraulic tappets are not fully extended .

To check, compress the piston (24) in the tappet between the thumb and index finger to compress the spring .

If the piston appears blocked, the high pressure chamber (A) is full of oil and fully extended .

To drain the high pressure chamber, remove the piston (24) by tapping the tappet on a block of wood .

Remove the oil by pressing on the ball (26) and drain the low pressure chamber (B) .

When refitting, place a little oil in the low pressure chamber (B) .

5 - ASSEMBLY (CONTINUED)

Lubricate the cams and the bearings (MOLYDAL GB SP 370G) .

Fit the camshafts and turn them with the groove (27) at 12 o'clock and the groove (28) at 11 o'clock .

(The groove (27) is vertical and the groove (28) is aligned with the timing hole) .

Check that the pins (29) are present .

Apply a bead of SILICONE AUTOJOINT OR CATEGORIE 2 jointing paste at (C) round the perimeter of the joint faces and the tappings for the securing bolts .

Fit the camshaft bearing housings (11) and (12) .

IMPERATIVE : finger tighten then progressively tighten the securing bolts in the order shown (from (1) to (12)) .

Pre-tighten : 0.5 da.Nm .

Tightening torque: 1 da.Nm .

NOTE : the cylinder head covers have composite gaskets which can be used several times, if the gasket is damaged, it can be partially repaired with SILICONE AUTOJOINT OR CATEGORIE 2 jointing paste .

Fit new camshaft oil seals using tool [5] and the camshaft hub securing bolts (30) .

Fit (Depending on engine type) :

• the lubrication tube (10)
• the vacuum pump (9)

Fit :

• the thermostat (8)

Fit :

• the timing cover (6)
• the lubrication rails (7)

Tighten the bolts (5) .

Fit :

• the camshaft hubs (3) and (4)
• the pegs [1]

Tighten the bolts (1) and (2) to 7.5 daN.m. .