B1DG19K1 - 307 DW10TD ENGINE

REMOVAL - REFITTING CYLINDER HEAD

1 - SPECIAL TOOLS

[1] Cross member (-).0911-AY .

[2] Brackets (-).0911-A2 .

[3] Crankshaft spanner(-).0117-EZ .

[4] flywheel setting rod (-).0188-Y .

[5] cylinder head releasing levers (-).0188-L .

[6] Dial gauge (-).1504 .

[7] dial gauge support (-).0110-H .

[8] flywheel stop (-).0188-F .

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

[10] Pipe spanner (-).1603-G .

[11] Pipe spanner (-).1603-F .

[12] Set of plugs (-).0188-T .

[13] Tightening kit (-).1603-A/B/D/E .

2 - REMOVAL

drain the cooling system .

Remove :

• the front wheels
• the front mud guards

Remove :

• the style covers (1)
• the air cleaner (3)
• the battery and its support (2)
• the scuttle crossmember (4)
• the soundproofing (6)

Move aside the brake fluid reservoir (5) .

Remove :

• the torque reaction link (8)
• the impacter and its bracket (7)
• the exhaust rear silencer

Remove the exhaust line .

IMPERATIVE : uncouple the exhaust line to avoid destroying the hose; this cannot withstand the torsion, traction or bending stresses caused by the removal of one of the power train supports .

Remove :

• the ancillary drive belt
• the timing belt

Remove the bolts (9) - (10) .

Refit the right-hand engine mounting .

Slightly tighten the bolts .

Remove :

• cross member [1]
• the supports [2]

Disconnect :

• the connector (11)
• the electrical harness (12)
• the hose (13)
• the brake servo vacuum pipe
• the priming bulb
• the pre/post-heat plugs supply

Disconnect and move aside :

• the crankcase breather hoses (14)
• the harnesses and pipes of the cylinder head
• the heater matrix hoses

Remove :

• the cylinder head cover (15)
• move aside the water outlet housing from the cylinder head
• the bolt of the dipstick bracket

IMPERATIVE : clean the fuel unions before slackening .

IMPERATIVE : cover the holes of the high pressure pump and the rail using caps [12] .

Remove :

• the high pressure diesel pipe between the high pressure pump and the rail
• the pre/post heat plugs

Remove the rail/injectors/pipes assembly .

Remove :

• the steering rack heat shield
• the air ducts (17) for the turbo intake

Disconnect the oil return pipe (18) from the cylinder cover .

Remove :

• the egr device (19)
• the turbo lower fixing bracket (20)
• the nuts (21) of the exhaust manifold

Move aside the exhaust manifold and turbocharger assembly (22) .

IMPERATIVE : starting at the outside and working in a spiral sequence progressively slacken the cylinder head bolts ; using the tool [9] .

Rock and free the cylinder head using levers [5] .

Remove the cylinder head and gasket .

NOTE : protect the bottom of the windscreen with a snapon type door seal ; the joint faces must not have any trace of knocks or scores ; clean the threads in the cylinder block with a M12 X 150 tap .

Check the condition :

• of the mating surface
• of the valves
• of the valve springs and their cups
• of the camshaft
• of the various tapped holes
• of the hydraulic tappets
• of the valve rockers

3 - REFITTING

3 - 1 - CHECKING THE FLATNESS

Maximum permissible bow = 0.05 mm .

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

(X) must be less than 133.4 mm .

Clean the surface of the water outlet housing joint .

Turn the crankshaft with the tool [3] .

Peg the flywheel using the rod [4] .

Check that the pins (G) are present .

Fit a new cylinder head gasket ; Following the direction of fitting .

Ensure that the camshaft is pinned .

Refit the cylinder head .

NOTE : protect the bottom of the windscreen with a snapon type door seal .

Brush the bolt threads .

fit the cylinder head bolts coated with MOLYKOTE G RAPID PLUS on the threads and under the bolt heads .

3 - 3 - CYLINDER HEAD TIGHTENING

Tighten the cylinder head bolts in the order shown .

NOTE : it is not necessary to retighten the cylinder head after bringing the engine up to operating temperature .

Fit :

• the injectors
• the fuel high pressure common injection rail
• glow plugs

Fit the cylinder head cover using a new gasket .

Run up the bolts .

Gradually tighten the cylinder head cover bolts in a spiral starting from the inside ; Tightening torque 1 da.Nm .

Fit :

• the exhaust manifold moving the bottom part of the engine towards the front
• the turbo fixing bracket
• the egr device

Reconnect the heat exchanger pipe .

Refit the coolant outlet manifold (28) fitted with a new seal .

Tighten :

• the studs (26) to 2.5 dan.m + LOCTITE FREIN FILET
• the nuts (25) to 2 da.Nm
• the bolts (27) to 2 da.Nm

Connect the connector (23) .

Refit the support (24) .

Position the cross beam [1] fitted with its chains [2] and take the weight .

Remove the right-hand engine mounting .

Refit the bolts (29) - (30) .

Tighten :

• the bolt (30) to 4.5 da.Nm LOCTITE FREINETANCH
• the bolt (29) to 2 da.Nm

Fit :

• timing belt
• ancillary drive belt

Continue the fitting operations in the reverse order to removal .

Re-prime the fuel circuit .

Initialise the various ECUs .

fill and bleed the cooling system .

Carry out the following road test :

• engage 3rd gear ; stabilise the engine speed at 1000 rpm
• accelerate fully up to 3500 rpm

Check the sealing of the various unions .