B1DG14K1 - 307 TU5JP4 ENGINE

REMOVAL - REFITTING CYLINDER HEAD

1 - SPECIAL TOOLS

[1] Camshaft setting rod(Inlet) (-). 0132 AJ2 .

[2] Camshaft setting rod(Exhaust) (-). 0132 AJ1 .

[3] flywheel setting rod (-).0132 QY .

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

[5] Levers (-). 0149 .

[6] Vacuum pump DA - 16 .

2 - REMOVAL

Remove :

• the style covers (1)
• the air filter assembly, air inlet neck and expansion chamber (2)

Disconnect the battery .

Drain the cooling system .

Remove :

• the ancillary drive belt
• the crankshaft pulley

Support the power train assembly by sliding a stand under the engine .

Remove :

• the complete left engine store (3)
• the top timing cover
• the lower timing cover
• the upper section of the dipstick guide tube
• the catalytic converter

Put the tools in place [1] - [2] - [3] .

Remove :

• the style cover (4)
• the compact coil unit (5)

Progressively slacken in a spiral sequence the bolts of each cylinder head cover starting from the outside .

Remove the cylinder head covers (6) .

Disconnect :

• the heater matrix hose (7)
• the connectors (8) (and disconnect them from their support)

Lower the pressure in the injector supply pipe by means of the pump [6] .

On the inlet rail, disconnect :

• the inlet pressure sensor
• the fuel supply and return pipes
• the accelerator cable

IMPERATIVE : slacken the bolts (9) progressively in a spiral sequence, starting from the outside .

Remove the cylinder head bolts .

Tilt and separate the cylinder head using the levers [5], taking care not to damage the timing cover .

Remove the cylinder head and gasket .

Clean the joint faces with an approved descaling product .

Do not use sharp or abrasive tools .

3 - REFITTING

3 - 1 - CHECKING THE FLATNESS

Maximum permissible bow = 0.05 mm .

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

(Y) must be less than 122.6 mm (TORX head) .

Clean the cylinder head bolt threads in the cylinder block using a tap .

Check that the pins (10) are present .

Fit a new cylinder head gasket inscription upwards) .

Fit the cylinder head, with the camshaft sprockets pegged .

Engage the end (A) of the timing cover correctly on the rib (B) of the seal carrier plate .

Lubricate the threads and contact surfaces under the head of the cylinder head bolts with engine oil .

IMPERATIVE : tighten the cylinder head bolts in the order shown .

Pre-tighten : 2 da.Nm .

Tightening using an angular torque wrench to 260° .

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

Refit the cylinder head covers (6) after cleaning the gaskets and joint surfaces .

NOTE : the cylinder head covers have composite gaskets which can be used several times ; if the gasket is damaged, it can be partially repaired with AUTOJOINT OR jointing paste .

Continue the fitting operations in the reverse order to removal .

WARNING : observe the tightening torque values .

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

Connect the battery .

Place in contact for 10 seconds .

Fill and bleed the cooling system .

Carry out the initialisation procedure for the injection ignition control unit .