B1DG0UK1 - 206 DW10TD ENGINE

REMOVAL - REFITTING CYLINDER HEAD

IMPERATIVE : when carrying out an operation on the diesel circuit, respect safety instructions .

WARNING : if any work is carried out on the high pressure pipes they must always be replaced .

1 - SPECIAL TOOLS

[1] cross beam (-).0102-D .

[2] Lifting chain (-).0102-M .

[3] crankshaft turning tool (-).0117-EZ .

[4] flywheel setting rod (-).0188-Y .

[5] cylinder head releasing levers (-).0188-L .

[6] dial gauge (-).1504 .

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

[8]Cylinder head bolt socket (-).0185 .

[9] Pipe spanner (-).1603-G .

[10] Pipe spanner (-).1603-F .

[11] Set of plugs (-).0188-T .

[12] Tightening kit (-).1603-A/B/D/E .

2 - REMOVAL

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drain the cooling system .

remove the turbocharger .

Remove the expansion chamber .

remove the timing belt .

Remove the bolts (1), (2) .

Refit the right-hand engine mounting .

Slightly tighten the bolts .

Disconnect the sensor (3) .

Move aside :

- electrical harness (4)
- the pipe (5)
- the brake servo vacuum pipe (6)

IMPERATIVE : clean the fuel unions before slackening .

Remove :

- the bracket (7)
- the fuel return pipe (8)
- the high pressure pipe (9) (using tools [9] and [12])

IMPERATIVE : plug the holes using tool [11] .

Remove :

- the camshaft gear (10)
- the cylinder head cover (11), in the order shown

Disconnect the cylinder head harnesses and pipes and move them aside .

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Remove : The air cleaner assembly .

ALL MODELS

Disconnect the connectors (12) .

Remove :

- the bracket (13)
- the dipstick guide fasteners (14)

Slacken the nuts (15) .

Remove :

- the pins (16) (use a lock nut)
- the bolts (17)

Move aside the coolant outlet manifold (18) .

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

Remove the cylinder head bolts (Using the tool [8]) .

Rock and free the cylinder head using levers [5] .

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 M12 X 150 tap .

Check the condition :

- of the mating surface
- of the valves
- of the valve springs and their cups
- of the camshaft
- of the camshaft bearings
- of the various tapped holes
- of the hydraulic tappets
- of the valve rockers

3 - REFITTING

3 - 1 - CHECKING THE FLATNESS

Maximum permissible bow = 0.05 mm .

3 - 2 - CHECKING VALVE PROTRUSION

Clean the checking surfaces .

Check the protrusion of the valves in relation to the cylinder head surface (4 Checking points (C)) :

- calculate the average of the 4 values measured
- (A) exhaust valve = 0.2 mm maximum
- (B) inlet valve = 0.2 mm maximum

These values are obtained by grinding the valve seats .

Lap in the valves (if necessary) .

3 - 3 - CHECKING CYLINDER HEAD BOLTS BEFORE RE-USE

(X) must be less than 133.4 mm .

3 - 4 - CHOICE OF CYLINDER HEAD GASKET

Remove the crankshaft setting rod [4] .

(Y) = 10 mm .

Clean the checking surfaces .

Fit the dial gauge [6] on the bracket [7] .

Turn the crankshaft .

Place the needle of the dial gauge on one of the checking points (Checking point : D) .

Continue turning the crankshaft until the piston reaches TDC .

Read the value .

Turn a quarter turn backwards .

Move the piston to the Top Dead Centre value without ever exceeding it .

Zero the dial gauge .

Move the dial gauge/bracket assembly [6] and [7] over the cylinder block .

Read the value .

Place the needle of the dial gauge on one of the checking points (Checking point : E) .

Zero the dial gauge .

Move the dial gauge/bracket assembly [6] and [7] over the cylinder block .

Read the value .

Calculate the average of the 2 values measured .

Continue in the same way for the other three cylinders .

NOTE : maximum difference between 2 pistons = 0.07 mm .

WARNING : the highest average value determines the thickness of the gasket .

3 - 5 - CYLINDER HEAD GASKET IDENTIFICATION

(F) : thickness identification .

There are 5 categories of laminated metal cylinder gaskets .

piston protrusion measurements (mm) | thickness (mm) | notch(es) at (F)
--- | --- | ---
0.47 to 0.604 | 1.30 ± 0.06 | 1
0.605 to 0.654 | 1.35 ± 0.06 | 2
0.655 to 0.704 | 1.40 ± 0.06 | 3
0.705 to 0.754 | 1.45 ± 0.06 | 4
0.755 to 0.83 | 1.50 ± 0.06 | 5

IMPERATIVE : if the value measured does not correspond to the values indicated, investigate the origin of the fault (measurement error, handling error etc.) .

Clean the surfaces of the coolant housing outlet .

Turn the crankshaft with the tool [3] .

Peg the flywheel using the rod [4] .

Check that the pins (G) are present .

Fit a new cylinder head gasket (Following the direction of fitting) .

Ensure that the camshaft is pinned .

Refit the cylinder head .

Brush the threads of the cylinder head bolts .

Fit the cylinder head bolts coated with MOLYKOTE G RAPID PLUS on the threads and under the bolt heads .

3 - 6 - CYLINDER HEAD TIGHTENING

Tighten the cylinder head bolts in the order shown (Using the tool [8]) .

Stage 1 :

- proceed bolt by bolt in the order shown
- tightening torque of bolts : 2 da.Nm

Stage 2 :

- proceed bolt by bolt in the order shown
- tightening torque of bolts : 6 da.Nm

Stage 3 :

- proceed bolt by bolt in the order shown
- angular tightening to 220 °

NOTE : it is not necessary to retighten the cylinder head after bringing the engine up to operating temperature .

Refit the coolant outlet manifold (18) fitted with a new seal .

Tighten :

- the studs (16) to 2.5 m.daN + LOCTITE FREINFILET
- the nuts (15) to 2 da.Nm
- the bolts (17) to 2 da.Nm

Connect the connectors (12) .

Refit the support (13) .

Fit the cylinder head cover using a new gasket .

Run up the bolts .

Gradually tighten the cylinder head cover bolts in a spiral starting from the inside .

Tightening torque: 1 da.Nm .

IMPERATIVE : when carrying out an operation on the diesel circuit, respect safety instructions .

WARNING : if any work is carried out on the high pressure pipes (9) they must always be replaced .

Fit : The high pressure supply pipe, Finger tighten : The hoses .

Tighten the pipe (9) to 2 daN.m (Using the tools [9], [12]) .

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

Position the cross beam [1] fitted with its chains [2] and take the weight .

Remove the right-hand engine mounting .

Refit the bolts (1), (2) .

Tighten :

- the bolt (2) to 4.5 da.Nm + LOCTITE FRENETANCH
- the bolt (1) to 2 da.Nm

Fit the camshaft gear (10) .

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refit the timing belt .

adjust the sensor air gap .

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fit the turbocharger .

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fill and bleed the cooling system .

Carry out the following road test :

- engage 3rd gear, stabilise the engine speed at 1000 rpm
- accelerate fully (to : 3500 rpm)

Check the sealing of the various unions .