B1BJ0KK1 - 206 TU ENGINE

DISMANTLING ENGINE (NOT TU5J4 )

1 - SPECIAL TOOLS

half shell grades : original size
description | reference | reference
--- | --- | ---
stand | DESVIL | 2509-T
[1] adaptor | (-).0187-L | 8012-T

description | reference | reference
--- | --- | ---
[2] flywheel setting rod | (-).0132-QZ | 4507-T.A
[3] retaining wrench | (-).0132-AA | 6016-T
[4] camshaft setting rod | (-).0132-R | 4533-TA.C2
[5] levers | (-).0153-Q | 149-T
[6] flywheel stop | (-).0132-P | 4507-T.L
[7] liner retaining clamps | (-).0132-A1Z | 1132-T

2 - DISMANTLING

Place the engine on the stand [1] .

Remove :

- the cylinder head cover (1) and its gasket
- the two spacers (2)
- the deflector plate (3)
- the heat shield (4)

Remove :

- the exhaust manifold (7)
- the exhaust manifold gaskets
- the oil filter (8)
- the nipple (9) (according to specification)
- the heat exchanger (10) (according to specification)
- the dipstick (11)
- the dipstick tube (12)
- the electric gauge (13) (according to specification)
- the oil pressure switch (14)

Remove :

- the compact coil unit (15) (depending on engine type)
- the injection pipe (16)
- the inlet manifold (17)
- the thermostat (18)
- the coolant temperature sensor (19)
- the lifting plates (20)
- the knock sensor (21)

Remove :

- the timing cover components (22)

Fit the pins [2], [4] .

Slacken the bolt (23) .

Remove the timing belt (24) .

Remove the tensioner roller (25) .

Release the bolt (26), Using the tool [3] .

IMPERATIVE : starting at the outside and working in a spiral sequence progressively slacken the cylinder head bolts (27) .

Remove the cylinder head bolts .

Rock the cylinder head using the levers [5] to release it .

Remove :

- the cylinder head
- the cylinder head gasket

(A) Aluminium cylinder block :

- position the liner retaining clamps [7]

Remove the centralising dowels (28) .

Remove the rod [2] from the flywheel .

Insert the flywheel stop [6] .

(A) Aluminium cylinder block, Remove :

- the pins (30)
- the seal (31)

(B) Cast-iron cylinder block .

Remove :

- the coolant pump (29)
- the oil gallery plug (32)

Remove :

- the crankshaft gear (33)
- the spacer (34)

Remove :

- the clutch mechanism (35)
- the clutch plate (36)
- the flywheel (37)
- the oil gallery plug (38)

2 - 1 - ALUMINIUM CYLINDER BLOCK

Remove all of the securing bolts (39) and (40) from the main bearing cap casting .

Remove :

- the nuts (41)
- the bolts (42)
- the sump (43)

Remove :

- the oil pump (44)
- the oil pump centralising pin

Remove :

- the securing bolts (45)
- the main bearing cap casting (46)
- the crankshaft oil seal (timing gear end)
- the crankshaft oil seal (flywheel end)

Remove :

- the oil pump drive gear (47)
- the oil pump drive chain (48)
- the cotter (49)
- the big end caps (50)
- the crankshaft (51)
- the bearing half-shells
- the end float adjustment thrust washers (52)

NOTE : mark the shell bearings in relation to the big end caps before removal .

Remove :

- the liner retaining clamps [7]
- the liners/con rods/pistons assemblies (53), marking the liners in relation to the cylinder block if the liners are to be re-used

Carefully clean all the seal surfaces using scouring product D2 .

2 - 2 - CAST-IRON CYLINDER BLOCK

Remove :

- the sump (43)
- the oil seal carrier plate (54)

Extract the seal (55) .

Remove :

- the oil pump (44)
- the oil pump centralising pin (56)
- the oil pump chain and drive pinion
- the cotter (49)

Remove the oil seal carrier plate (57) .

Extract the seal .

NOTE : mark the big end caps and shells before removing them .

Remove :

- the big end caps (58)
- the crankshaft bearing caps (59)

NOTE : the main bearings are numbered from 1 to 5, with no. 1 at the flywheel end .

Remove :

- the two end float half washers in no. 2 main bearing, cylinder block side
- the crankshaft
- the shells

Remove the piston/connecting rod assemblies, marking them (if necessary) .

Remove the piston base cooling jets (60) .