B1DJ0DK1 - 206 DW10TD ENGINE

OVERHAUL CYLINDER HEAD

1 - DISMANTLING

Remove :

- the bolt (1)
- the setting rod [1p]
- the camshaft pulley hub (2)

Gradually loosen the securing bolts in sequence .

Remove :

- the main bearing cap casting (3)
- the camshaft (4)
- the camshaft lip seal

Marking their position, remove :

- the roller cam followers (5)/hydraulic tappets (6) assemblies

Remove :

- the valves (7) (use tool [12])
- the spring retainers (8)
- the abutment washers (9)
- the springs (10)

Remove :

- the valve stem oil seals (11) using tool [13]

Remove :

- anti-return valve (12)
- 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

2 - CHECKING THE FLATNESS

Maximum permissible bow = 0.05 mm .

Check the condition :

- of the valve seats and guides
- 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

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

3 - CHECK OF THE LONGITUDINAL CLEARANCE

IMPERATIVE : position the camshaft (4) in the main bearing caps casting (3) .

Fit the assembly (3), (4) .

Finger tighten then progressively tighten the securing bolts in the order shown .

Tighten the bolts to 1 daN.m .

To carry out this check :

- the camshaft must not be subject to any force (absence of the cam roller followers (5)/hydraulic tappets (6) assemblies)
- the camshaft main bearing cap casting (3) must be tightened to the correct torque

fit the dial gauge [7] using tools [5] - [8] .

This end float should be between 0,07 and 0,38 mm .

If incorrect :

- replace any defective parts

Remove the assembly (3), (4) .

4 - CHECKING VALVE PROTRUSION

Fit : The valves (7) .

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 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) .

5 - REASSEMBLY

Fit a new anti-return valve (12) in the pipe (13) .

WARNING : ensure that the direction of fitting of the anti-return valve is correct .

insert the new valve stem seals using the tool [18] .

Fit :

- the valves (7) (stems oiled)
- the abutment washers (9)
- the springs (10) using the tool [12]
- the spring retainers (8)

WARNING : avoid direct contact of the hands with the roller tracks; apply a light film of clean engine oil to the rollers; check that there are no points of resistance on the rollers .

Refitting the tappets :

- lubricate the tappet bodies
- the roller cam followers (5)/hydraulic tappets (6) assemblies
- check that the tappets rotate freely in the cylinder head

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

IMPERATIVE : position the camshaft (4) in the main bearing caps casting (3) .

Fit the assembly : (3), (4) .

Finger tighten then progressively tighten the securing bolts in the order shown .

Tighten the bolts to 1 daN.m .

Before fitting the camshaft seal, ensure that the bottom of the seat is free of sealing compound .

Apply grease to the space between the oil seal lips .

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

fit a new lip seal using tool [1q] .

Fit :

- the camshaft hub (2)
- the bolt (1)

Set the camshaft hub (2), using the tool [1p] .

Tighten the bolt (1) to 4,3 da.Nm .