B1DG18K1 - 307 TU3JP ENGINE

REMOVAL - REFITTING CYLINDER HEAD

1 - SPECIAL TOOLS

[1] Liner retaining clamp(-).0132-A1Z .

[2] Bolt(s) M10 X 150 (-).0132-A3Z .

[3] camshaft gear setting rod (5) (-).0132-RZ .

[4] Levers(-).0153-Q .

[5] flywheel setting rod (-).0153-QY .

[6] Vacuum pump FACOM DA-16 .

2 - REMOVAL

Disconnect the battery .

drain the cooling system .

Move aside the brake fluid reservoir (1) .

Remove :

• the windscreen wipers
• the plastic windscreen deflector (3)
• the plastic windscreen crossmember (2)
• the air filter and its duct (4)
• the ancillary drive belt

Protect the lower edge of the windscreen overhang using a piece of door seal .

Disconnect, unclip and separate the harnesses, hoses and cables connected to the cylinder head .

Remove the bolt (5) .

Disconnect the heater matrix pipe .

Bleed the injection rail using the tool [6] .

Disconnect the fuel supply pipes adjoining the cylinder head .

These hoses are of the click fit type .

Peg :

• the camshaft ; using the tool [3]
• the flywheel ; using the tool [5]

Remove :

• the front exhaust pipe
• the timing belt

Remove :

• the dipstick tube mounting bolt (6)
• the upper section of the dipstick guide tube

Remove :

• the cylinder head cover
• the spacers (7)
• the deflector plate (8)

Starting at the outside and working in a spiral sequence progressively slacken the cylinder head bolts .

Remove :

• the cylinder head bolts
• the rocker shaft

Rock and free the cylinder head using levers [4] .

Remove the cylinder head and gasket .

TU3JP ENGINE ALUMINIUM CYLINDER BLOCK

Fit the liner retaining clamps [1] with the bolts [2] .

ALL MODELS

3 - REFITTING

3 - 1 - CHECKING THE FLATNESS

Maximum permissible bow = 0.05 mm .

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

Length under head 176.5 mm .

Check that the camshaft turns freely in its bearings .

TU3JP ENGINE ALUMINIUM CYLINDER BLOCK

Remove the liner retaining clamps [1] .

ALL MODELS

Clean the threads of the cylinder head bolts in the cylinder block using a thread cutter M10 X M150 .

Check that the 2 centralising studs are present (9) .

Fit a new cylinder head gasket, with the maker's name to the top .

Fit the cylinder head with the camshaft gear pinned .

Fit :

• the rocker shaft
• the cylinder head bolts coated with MOLYKOTE G RAPID PLUS grease

3 - 3 - CYLINDER HEAD TIGHTENING

This operation is performed in (2) stages :

• pre-tighten to 2 da.Nm
• tighten a further 240 degrees using a FACOM D 360 type tool

refit the timing belt .

fit the ancillary drive belt .

Adjust the valve clearances .

fill and bleed the cooling system .

Proceed in the reverse order to removal .