B1HG35K1 - 206 DV4TD ENGINE

REMOVAL - REFITTING INTEGRAL INTAKE SYSTEM

1 - SPECIAL TOOLS

[1] Protection kit (-).0194-S .

[2] Plugs kit (-).0194-T .

2 - REMOVAL

Disconnect the battery .

Remove :

- the style cover
- windscreen plastic crossmember
- the sound-proofing sheets

Disconnect the connector from the flow meter .

Remove the turbo outlet elbow .

Remove :

- the resonator (B) bolts
- the resonator (1) by tilting it

Remove :

- the air inlet neck
- the turbocharger air inlet hose
- the air filter cover bolts (3)
- the air filter cover and cartridge
- the air filter bowl mounting bolts (4)

Move aside the electrical harness (B) .

Remove the diesel filter protector bolts (5) (according to specification) .

Slacken the bolt (6) .

Remove the fuel filter .

Close the unions using the tool [2] .

Remove :

- the diesel filter support mounting bolts (7) - (8)
- the diesel filter support (9)

Remove :

- the integral intake system mounting bolts (10) - (11)
- the injectors connectors
- the fuel return circuit

IMPERATIVE : close the injectors using the tool [2] .

Remove the lower integral intake system .

Using the tools [1], close :

- the air ducts
- the camshaft housing

3 - REFITTING

Replace the seals (13) lubricating them lightly and ensuring that the rubber stops are present at (A) .

Refit the lower integral intake system (14) .

Partially tighten the mounting bolts (10) - (11) of the lower integral intake system (14) .

Tighten the bolts (11) to 1 da.Nm. in the order indicated .

Tighten the bolts (9) to 1 daN.m .

Remove the plugs on the fuel return circuit .

Fit :

- the fuel return circuit
- the injectors connectors
- the exhaust gas recirculation pipe

Tighten ; The diesel filter support (9) .

Tighten :

- the bolt (8) to 0.5 da.Nm
- the bolt (7) to 1 da.Nm

Refit the diesel filter on its support ; 0.5 da.Nm .

Refit the air cleaner housing ; Ensure that the centring pins are positioned correctly .

Refit the harness in the clamping point .

Tighten the bolts (4) to 0.5 daN.m .

Fit :

- the air inlet neck
- the resonator lubricating the o-ring
- the resonator bolt on the oil separator to 0.75 dan.m
- the resonator bolt on the turbo to 2.5 dan.m
- the turbocharger air inlet hose
- the air cleaner
- the air filter cover
- the style cover
- the sound-proofing sheets
- windscreen plastic crossmember

Connect the battery .