B1BJ0KK1 - 206 TU ENGINE

DISMANTLING ENGINE (NOT TU5J4 )

1 - SPECIAL TOOLS

2 - DISMANTLING

Place the engine on the stand [1] .

Remove :

• the cylinder head cover (1) and its gasket
• the two spacers (2)
• the deflector plate (3)
• the heat shield (4)

Remove :

• the exhaust manifold (7)
• the exhaust manifold gaskets
• the oil filter (8)
• the nipple (9) (according to specification)
• the heat exchanger (10) (according to specification)
• the dipstick (11)
• the dipstick tube (12)
• the electric gauge (13) (according to specification)
• the oil pressure switch (14)

Remove :

• the compact coil unit (15) (depending on engine type)
• the injection pipe (16)
• the inlet manifold (17)
• the thermostat (18)
• the coolant temperature sensor (19)
• the lifting plates (20)
• the knock sensor (21)

Remove :

• the timing cover components (22)

Fit the pins [2], [4] .

Slacken the bolt (23) .

Remove the timing belt (24) .

Remove the tensioner roller (25) .

Release the bolt (26), Using the tool [3] .

IMPERATIVE : starting at the outside and working in a spiral sequence progressively slacken the cylinder head bolts (27) .

Remove the cylinder head bolts .

Rock the cylinder head using the levers [5] to release it .

Remove :

• the cylinder head
• the cylinder head gasket

(A) Aluminium cylinder block :

• position the liner retaining clamps [7]

Remove the centralising dowels (28) .

Remove the rod [2] from the flywheel .

Insert the flywheel stop [6] .

(A) Aluminium cylinder block, Remove :

• the pins (30)
• the seal (31)

(B) Cast-iron cylinder block .

Remove :

• the coolant pump (29)
• the oil gallery plug (32)

Remove :

• the crankshaft gear (33)
• the spacer (34)

Remove :

• the clutch mechanism (35)
• the clutch plate (36)
• the flywheel (37)
• the oil gallery plug (38)

2 - 1 - ALUMINIUM CYLINDER BLOCK

Remove all of the securing bolts (39) and (40) from the main bearing cap casting .

Remove :

• the nuts (41)
• the bolts (42)
• the sump (43)

Remove :

• the oil pump (44)
• the oil pump centralising pin

Remove :

• the securing bolts (45)
• the main bearing cap casting (46)
• the crankshaft oil seal (timing gear end)
• the crankshaft oil seal (flywheel end)

Remove :

• the oil pump drive gear (47)
• the oil pump drive chain (48)
• the cotter (49)
• the big end caps (50)
• the crankshaft (51)
• the bearing half-shells
• the end float adjustment thrust washers (52)

NOTE : mark the shell bearings in relation to the big end caps before removal .

Remove :

• the liner retaining clamps [7]
• the liners/con rods/pistons assemblies (53), marking the liners in relation to the cylinder block if the liners are to be re-used

Carefully clean all the seal surfaces using scouring product D2 .

2 - 2 - CAST-IRON CYLINDER BLOCK

Remove :

• the sump (43)
• the oil seal carrier plate (54)

Extract the seal (55) .

Remove :

• the oil pump (44)
• the oil pump centralising pin (56)
• the oil pump chain and drive pinion
• the cotter (49)

Remove the oil seal carrier plate (57) .

Extract the seal .

NOTE : mark the big end caps and shells before removing them .

Remove :

• the big end caps (58)
• the crankshaft bearing caps (59)

NOTE : the main bearings are numbered from 1 to 5, with no. 1 at the flywheel end .

Remove :

• the two end float half washers in no. 2 main bearing, cylinder block side
• the crankshaft
• the shells

Remove the piston/connecting rod assemblies, marking them (if necessary) .

Remove the piston base cooling jets (60) .