B1DG0YK1 - 206 EW10J4 ENGINE

REMOVAL - REFITTING CYLINDER HEAD

1 - SPECIAL TOOLS

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

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

[3] Camshaft hub setting rods (-).0189-A .

[4] Levers (-).0189-F .

[5] Pipe with adapter for valve SHRADER (-).0141-T1 .

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

2 - REMOVAL

DRAIN THE COOLING SYSTEM .

Detach the exhaust pipe from the manifold .

Lower the fuel pressure by connecting the end of the tool [5] to the valve SHRADER (1); catch the fuel in a receptacle .

Disconnect :

- the battery
- the connectors (on the throttle housing)
- the fuel breather unions
- the accelerator cable
- the EGR union

Remove :

- the bolt from the dipstick tube
- inlet manifold
- THE ANCILLARY DRIVE BELT
- THE TIMING BELT
- the timing belt tensioner roller
- the style cover

Remove the sensor (4) .

Remove the cylinder head covers (2) .

Remove :

- the compact coil unit (3)

Disconnect : The water housing outlet pipes .

Remove the retaining fork (5) for the coolant pipes (6) at the rear of the coolant outlet housing .

Remove the bolt (17) from the intermediate bracket on the cylinder head .

Remove the cylinder head bolts (Using the tool [6]) .

Position the tools [1]-[2] .

Tilt and detach the cylinder head using the tool [4] .

Raise the cylinder head and exhaust manifold assembly using the tools [1] and [2] .

Remove the cylinder head and gasket .

Remove the rigid pipe (7) from the coolant pump then from the coolant outlet housing .

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 .

3 - REFITTING

3 - 1 - CHECKING THE FLATNESS

Maximum permissible bow = 0.05 mm .

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

Check that the pins (9) are present .

Fit a new cylinder head gasket (TOP (11) inscription upwards) .

Position the pipe (10) on the coolant pump (After checking the presence of the seal) .

WARNING : replace the valve (A) .

Position the pipe (10) in the coolant outlet housing .

Fit the cylinder head with the camshaft gear pinned .

IMPERATIVE : do not re-use cylinder head bolts if they are longer than 147 mm .

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

3 - 2 - CYLINDER HEAD TIGHTENING

IMPERATIVE : tighten the cylinder head bolts in the order shown (using the tool [6]) .

cylinder head tightening
engine type | EW10J4
--- | ---
special features | without
pre-tightening (da.Nm) | 1.5
tightening (da.Nm) | 5
slackening | 360°
tightening (da.Nm) | 2
angular tightening (°) | 285°

IMPERATIVE : fill with oil the cups above the hydraulic tappets .

Refit the bolt (8) in the cylinder head intermediate bracket : Tightening torque 4,5 da.Nm .

IMPERATIVE : always replace the gaskets of the cylinder head cover .

Refit the cylinder head covers (In the order shown) .

Proceed bolt by bolt in the order shown .

Tightening torque of bolts : 0,9 da.Nm .

Fit :

- THE TIMING BELT
- THE ANCILLARY DRIVE BELT

Continue the fitting operations in the reverse order to removal .

WARNING : strictly follow the fastening and routes of the various harnesses and pipes .

FILL AND BLEED THE COOLING SYSTEM .