B1DJ0AK1 - 206 TU5JP ENGINE TU1JP ENGINE TU3JP ENGINE

REASSEMBLY CYLINDER HEAD -ENGINE

1 - SPECIAL TOOLS

description | reference | reference
--- | --- | ---
[1] flywheel setting rod | (-).0132-QZ | -
[2] liner retaining clamp | (-).0132-A1Z
[3] camshaft setting rod | (-).0132-R
[4]angular locking cotter | FACOM D360 type | FACOM D360 type
[5] retaining wrench | (-).0132-AA | 6016-T

2 - CHECKING CYLINDER HEAD BOLTS BEFORE RE-USE

Measure the length (X) of the cylinder head bolts .

IMPERATIVE : the length x must be less than 176,5 mm .

Brush the threads of the cylinder head bolts .

Apply clean engine oil to the thread and under the head of the bolts .

3 - REASSEMBLY

Clean the cylinder head bolt threads in the cylinder block using a tap .

Check that the pins (1) are present .

Turn the crankshaft and set it using the tool [1] .

Aluminium cylinder block : Remove the liner retaining clamps [2] .

Fit the cylinder head gasket (2) with the inscriptions on the cylinder head side .

Position the camshaft pulley (3) without tightening it .

Position the camshaft rod [3] .

Fit :

- the cylinder head (4)
- the rocker arm assembly (6) ensuring that the dowels are present and correctly positioned

NOTE : slide rockers : lubricate the cams and the rocker arm pads .

WARNING : roller rockers : avoid direct contact between hands and rocker bearing tracks, apply a light film of clean engine oil to the bearing tracks and to the rocker shaft when the rail is fitted, check that there is no hard spot on the rocker bearings .

Fit :

- the cylinder head bolts

IMPERATIVE : tighten the cylinder head bolts in the order shown .

Refit the roller tensioner (7) .

Fit the nut (8) finger tight (tensioner in minimum position) .

Fit a new timing belt .

Fit the belt, the right way round, with run (A) taut, in the following order :

- crankshaft
- camshaft
- coolant pump
- roller tensioner

Turn the roller tensioner anti-clockwise to tension the belt (A) lightly .

Tighten the nut (8) .

Remove the timing tools [1], [3] .

Turn the crankshaft four revolutions in the normal direction of rotation .

Tighten the bolt (9) to 8 mdaN using the tool [5] .

| adjust the valve clearances
--- | ---
with valve fully open : exhaust | inlet : 0.20 mm | exhaust : 0.40 mm
1 | 3 | 4
3 | 4 | 2
4 | 2 | 1
2 | 1 | 3

rockers fitted with bolts (10) .