B1DG0HK1 - 206 TU1JP ENGINE TU3JP ENGINE

REMOVAL - REFITTING CYLINDER HEAD

1 - SPECIAL TOOLS

[1] liner retaining clamp (-).0132-A1Z .

[2] Bolt(s) M10 x 150 (-).0132-A3Z .

[3] Camshaft gear setting rod (-).0132-RZ .

[4] Levers (-).0153-Q .

[5] Flywheel setting rod (-).0132-QY .

[6] Camshaft oil seal fitting drift (-).0132-T .

[7] Immobilisation key (-).0132-AA .

2 - REMOVAL

Disconnect the battery .

drain the cooling system .

remove the ancillary drive belt .

Remove :

- the air inlet neck (1)

POWER STEERING

Move aside the power steering pump (2) .

ALL MODELS

Disconnect the crankcase breather hose (3) .

Disconnect the pipes and harnesses attached to the cylinder head .

Remove the accelerator cable .

TU3JP ENGINE

Remove the engine suspension tie bars (4) .

TU1JP ENGINE

Without removing the securing bolt(s) on the cylinder head, pull the bar (4) towards the exhaust manifold .

ALL MODELS

Disconnect the front exhaust pipe from the manifold and from the clutch housing .

Peg the flywheel using the rod [5] .

Remove :

- the timing belt
- the cylinder head cover (6)
- the two spacers (7)
- the deflector plate (8)

Immobilise the camshaft gear with tool [7] .

Slacken the bolt (9) .

Remove ; The camshaft gear .

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

Remove :

- the cylinder head bolts
- the rocker shaft

WARNING : avoid knocks to the rocker bearings when the rail is handled .

Rock and free the cylinder head using levers [4] .

Remove the cylinder head and gasket .

TU1JP ENGINE

Fit the liner retaining clamps [1] with the bolts [2] .

ALL MODELS

Clean the joint faces with an approved descaling product .

The joint faces must not have any trace of knocks or scores .

3 - REFITTING

3 - 1 - CHECKING THE FLATNESS

Maximum permissible bow = 0,05 mm .

3 - 2 - CHECKING CYLINDER HEAD BOLTS BEFORE RE-USE

Y = Maximum length below head : 176,5 mm .

Replace the oil seal using tool [6] .

Fit the camshaft gear .

Tightening torque 8 da.Nm ; Using the tool [7] .

Check that the camshaft turns freely in its bearings .

Fit the cylinder head with the camshaft gear pinned [3] .

Position 1 and 4 pistons at TDC .

Remove the liner retaining clamps [1] .

Clean the threads of the cylinder head bolts in the cylinder block using a thread cutter M10 x 150 .

Check that the two centralising dowels are fitted at (4) and (5) .

Fit a new cylinder head gasket, with the maker's name to the top .

Fit : The rocker shaft .

WARNING : avoid touching the roller rocker 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 pre-coated with engine oil .

tighten the cylinder head bolts in the order shown .

refit the timing belt .

adjust the valve clearances .

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

fill and bleed the cooling system .