B1DG05A1 - 206 DW8 ENGINE

REMOVAL - REFITTING CYLINDER HEAD

1 - SPECIAL TOOLS

[1] Cylinder head release levers (-).0188-L .

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

[3] dial gauge (-).1505 .

[4] FACOM D 360 angular tightening tool .

2 - REMOVAL

Disconnect the battery .

Remove :

- the style cover (1)
- the air filter and its connections (2)
- the inlet manifold (3)
- the EGR valve hose
- the vacuum pump

Drain :

- the cooling system
- the diesel filter chamber

Disconnect, unclip and separate the harnesses, hoses and cables connected to the cylinder head .

Remove :

- diesel filter assembly (4)
- the bolt (6)
- the 3 bolts (5)
- the thermostat (7)
- the pipe (8)
- the expansion chamber (9)
- the heater matrix connection to the cylinder head

Remove :

- the timing belt
- the camshaft pulley

Remove :

- the high pressure pipes (10)
- the bolt (11)
- the fuel return pipe (12)

Uncouple the front exhaust pipe (Manifold side) .

Starting at the outside and working in a spiral sequence progressively slacken the cylinder head bolts .

Remove the cylinder head bolts .

Rock and free the cylinder head using levers [1] .

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 tap M12 x 150 .

2 - 1 - CHECKING THE FLATNESS

Maximum permissible bow = 0,07 mm .

2 - 2 - CHECKING THE COMBUSTION CHAMBER PROTRUSION

Using tools [2] and [3] :

- combustion chamber protrusion : 0,015 ± 0,015 mm

2 - 3 - CHECKING VALVE POCKETING

Using tools [2] and [3] :

- inlet valve pocketing : 0,775 ± 0,275 mm
- exhaust valve pocketing : 1,175 ± 0,275 mm

2 - 4 - CHECKING CYLINDER HEAD BOLTS BEFORE RE-USE

Cylinder head bolt without end-piece :

- (X) must be less than 121,5 mm

Cylinder head bolt with end-piece :

- (X) must be less than 125,5 mm

2 - 5 - CHOICE OF CYLINDER HEAD GASKET

Remove the crankshaft setting rod .

Fit the dial gauge to the bracket and calibrate it to the markings (Tools [2]-[3]) .

Turn the crankshaft with the crankshaft drive tool .

Measure the protrusion of each piston at TDC .

Note the maximum protrusion (D) .

Select the appropriate cylinder head gasket thickness .

protrusion (D) | thickness identification
--- | ---
0,56 to 0,67 mm | 1 hole(s)
0,68 to 0,71 mm | 2 hole(s)
0,72 to 0,75 mm | 3 hole(s)
0,76 to 0,79 mm | 4 hole(s)
0,80 to 0,83 mm | 5 hole(s)

.

2 - 6 - CYLINDER HEAD GASKET IDENTIFICATION

(1A) :Engine identification .

(1B) : Nominal dimension .

(1C) : Repair size .

engine code | WJZ | WJZ
--- | --- | ---
engine type | DW8 | DW8
special features | CURTY | ELRING
engine identification group (1A) | E - F | E - F
1st nominal dimension group (1B) | N | N
2nd nominal dimension group (1B) | N - O | N - O
3rd nominal dimension group (1B) | N - O - P | N - O - P
4th nominal dimension group (1B) | N - O - P - Q | N - O - P - Q
5th nominal dimension group (1B) | N - O - P - Q - R | N - O - P - Q - R
1st repair dimension group (1C) | - | -
2nd repair dimension group (1C) | - | -

3 - REFITTING

Turn the crankshaft with the crankshaft drive tool .

Set the TDC sensor .

Check that pin is present (At A) .

Fit a new cylinder head gasket .

Check that the camshaft is in the setting position by offering up the timing gear (Bolt(s) M8 x 125) .

Refit the cylinder head .

Brush the threads of the cylinder head bolts .

Fit new washers .

Coat the threads and the contact area under the bolt head with MOLYKOTE G RAPIDE PLUS grease .

4 - CYLINDER HEAD TIGHTENING

IMPERATIVE : proceed bolt by bolt in the order shown .

Pre-tighten to 2 da.Nm .

Tightening torque 6 da.Nm .

Angular tightening to 180 ° (Using the tool [4]) .

5 - REFITTING (CONTINUED)

Fit :

- the camshaft pulley

Tightening torque : 2.3 da.Nm .

Fit :

- the timing belt

Fit the thermostat (7) with a new joint .

Tightening torque of bolts (5) : 1.4 da.Nm .

Refit the diesel filter assembly together with a new O-ring .

Tightening torque of bolt (13) : 1.8 da.Nm .

Continue the fitting operations in the reverse order to removal .

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

Bleed the fuel system .

Fill and bleed the cooling system .

Initialise the various ECUs .