B1DJ0CK1 - 406D9 ES9J4 ENGINE

CYLINDER HEAD OVERHAUL

1 - SPECIAL TOOLS

2 - DISMANTLING

IMPERATIVE : slacken the camshaft bearing cap cover (1) securing bolts, progressively and in a spiral sequence starting from the outside, so as to separate the mating surfaces by a few millimetres .

Remove :

• the main bearing cap castings (1)

Remove :

• the camshafts (2)
• the camshaft oil seals (3)

Mark the positions of the tappets before removal (Use a valve grinding type suction cup tool) .

Remove :

• the hydraulic tappets (4)
• the oil pipe plugs (5) and their seals

Remove :

• the calibrated plug (6)
• anti-return valve (7)
• the coolant temperature sensor (8)
• the oil pipe plug (9) and its seal (10)

2 - 1 - CHECKING THE FLATNESS

Maximum permissible bow = 0,05 mm .

3 - DISMANTLING (CONTINUED)

Using the tool [1], remove :

• the spring retainers (11)
• the cup (12)
• the springs (13)
• the valves (14)

Remove :

• the valve stem oil seals (15) using tool [2] (press at (A))
• the abutment washers (16)

Check the condition :

• valve seats and guides
• of the valves
• of the valve springs and their cups
• of the camshafts
• of the camshaft bearings
• of the various tapped holes

IMPERATIVE : for checking, rectification or replacement of these parts, refer to the data sections .

4 - REASSEMBLY

Always renew :

• the seals
• the non-return valves (7)

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 .

Thoroughly clean the oil galleries .

Fit a new non-return valve (7) in the pipe (17) .

WARNING : ensure that the non-return valve is fitted the right way round (O-ring at the bottom) .

Fit :

• the calibrated plug (6)
• the abutment washers (16)

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

Fit (Using the tool [1]) :

• the valves (14)
• the springs (13)
• the cup (12)
• the spring retainers (11)

Refitting the tappets :

• lubricate the tappet bodies (MOLYDAL GB SP 370G)
• refit the tappets in their original positions
• check that the tappets rotate freely in the cylinder head

5 - CAMSHAFT IDENTIFICATION

It is possible to identify the camshafts by means of the marking (Zone(s) B - C - D - E) .

1st fitting :

• the camshaft hub securing bolts and threads are right-handed

2nd fitting :

• the camshaft hub bolts and threads are left-handed

These bolts can be identified by the 2 arrows (1) stamped on the head .

WARNING : the 2 assemblies are not interchangeable .

6 - REFITTING (CONTINUED)

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

Refit the camshaft(s) .

Check that the pins (18) are present .

Deposit a line of sealing compound (E10) at (F) around the edge of the mating surfaces .

Remove oil from the threads receiving the camshaft bearing housing securing bolts .

Refit the camshaft bearing cap covers .

On the right-hand side : .

On the left-hand side : .

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

Pre-tightening 0,2 da.Nm .

Tightening torque: 0,8 da.Nm .

Check the tightening : 0,8 da.Nm .

IMPERATIVE : before fitting the camshaft seals, ensure that the housing bases are free from jointing compound .

Apply grease to the space between the oil seal lips .

IMPERATIVE : the outer face of the lip seal must be free from all traces of oil .

Fit new camshaft oil seals using tool [4] and the camshaft hub securing bolts (19) .