B1CG01K1 - 206 TU ENGINE

REASSEMBLY ENGINE (ALUMINIUM CYLINDER BLOCK NOT TU5J4 )

1 - SPECIAL TOOLS

2 - REASSEMBLY

Place the cylinder block on the stand [1] .

Carefully clean the joint face and the cylinder block tappings .

Fit the rings using piston ring pliers :

• (2) compression ring
• (3) tapered sealing ring
• (4) scraper ring with its spring

Fit with the TOP mark upward .

Position the ring gaps at 120 degrees to the scraper ring gap .

Oil the pistons .

Fit the ring collar .

Moderately tighten .

Position the piston on the liner to obtain on fitting :

• the alignment of the liner/cylinder block marks
• the direction of the piston arrow on the timing side

Push the piston in the liner until the collar is freed .

Proceed in the same way for the other three assemblies .

Fit a new seal (6) to each liner taking care not to twist it .

Fit : CONNECTING ROD HALF SHELLS .

Fit the liners/con rods/pistons assemblies in the cylinder block following the positioning marks made during removal or during the liner protrusion check .

Position the liner retaining clamps [4] .

Fit; Cylinder block side :

• the bearing half-shells (7)

NOTE : MATCHING OF MAIN BEARING SHELLS .

IMPERATIVE : ensure the half shells are fitted correctly .

Bearings 1 - 3 - 5 = smooth shells (cylinder block and bearing caps) .

Bearings 2 - 4 = grooved shells (cylinder block and bearing caps) .

Oil the half shells and the journals .

Position :

• the crankshaft (8)
• the side stop thrust washers (9), grooved surface in contact with the crankshaft

Position a dial gauge on the end of the crankshaft using tools [2] - [3] .

Push the crankshaft in one direction until it reaches the limit of its travel .

Set the dial gauge to zero .

Push the crankcase in the opposite direction until it reaches the limit of its travel .

The end float should be 0.07 to 0.27 mm .

CORRECT THE END FLOAT BY CHANGING THE HALF THRUST WASHERS (9) .

Lubricate and fit the con rod half-shells .

WARNING : there is a correct way round for the big end caps to be fitted; the notches (A) of the big end caps half-shells must be opposite the notches of the big end half-shells .

Fit :

• the big end caps (11)

IMPERATIVE : always fit new connecting rod cap nuts .

Tighten the connecting rod cap nuts to the correct torque : 3.8 da.Nm .

Fit :

• the cotter (18)
• the oil pump chain (19) and gear (20) assembly

Fit the main bearing cap casting (21) with its half-shells (grooved on bearings 2 and 4) .

Oil the main bearing shells .

Check that the centralising dowels are present on the cylinder block .

NOTE : MATCHING OF MAIN BEARING SHELLS .

Coat the joint face with a thin, even layer of jointing compound (E10) .

Position the main bearing cap casting (21) .

Tighten the bolts (22) to 2 daN.m + 44° (Proceeding in a spiral direction starting at the centre) .

Tighten the bolts (23) to 0.8 daN.m .

Check that pin (12) is present .

Refit the oil pump .

Tighten the securing bolts to 0.9 da.Nm .

Coat the joint face with a thin, even layer of jointing compound (E10) .

Fit the sump .

Tighten the securing bolts to 0.8 da.Nm .

WARNING : remove the traces of sealing compound before refitting the crankshaft seal (flywheel end) .

Fit a new lip seal (24) using tool [5] (Flywheel end) .

Fit the oil gallery plug (25) and tighten it to 3 m.daN .

Refit the flywheel .

Coat the flywheel bolt threads with LOCTITE FRENBLOC .

Fit the stop [6] .

Tighten the bolts to 6.7 da.Nm .

Fit a new lip seal (26) using tool [7] (Timing gear end) .

Fit the oil seal against its shoulder by means of the bolt (27) .

Check that the cotter (28) is fitted .

Apply a thin coat of (E15) compound to the join between the spacer and the crankshaft and cotter .

Fit the spacer (29) .

Fit the timing gear (30) .

Fit the bolt (31) and its washer .

Tighten the bolt (31) to 10 da.Nm .

NOTE : ensure there are no traces of sealant on the timing gear .

Remove the stop [6] .

Fit the pump (32) using a new seal .

Tighten the bolts to 1.8 da.Nm .

Ensure that the seal (33) and the dowels (34) are present .

Fit the water pump assembly (32) .

Tighten the bolts :

• M10 : 6.5 da.Nm
• M8 : 3 da.Nm

Turn the crankshaft and set it using the tool [8] .

Fit the centralising pins (35) .