B1DG1AK1 - 307 EW10J4 ENGINE

REMOVAL - REFITTING CYLINDER HEAD

1 - SPECIAL TOOLS

[1] Cross beam (-).0102-D .

[2] Lifting chain (-).0102-M .

[3] Camshaft hub setting rods (-).0189-A .

[4] Levers (-).0189-F .

[5] Pipe with adapter for valve SHRADER (-).0141-T1 .

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

2 - REMOVAL

drain the cooling system .

Detach the exhaust pipe from the manifold .

Remove the style cover .

Lower the fuel pressure by connecting the end of the tool [5] to the valve SHRADER (1); catch the fuel in a receptacle .

Disconnect :

• the battery
• the connectors (on the throttle housing)
• the fuel breather unions
• the accelerator cable
• the EGR union

Remove :

• the bolt from the dipstick tube
• inlet manifold
• the ancillary drive belt
• the timing belt
• the timing belt tensioner roller

Fit ; The intermediate right engine mounting .

Remove :

• the sensor (4)
• the cylinder head covers (2)
• the compact coil unit (3)

Flywheel end :

• slacken the bolts (5)
• move aside the harness bracket (6)
• remove the rigid pipe (7) connecting the coolant pump to the water outlet housing
• move aside the water outlet housing (8) from the cylinder head

Unscrew the bolt (9) to the maximum .

Gradually slacken the cylinder head bolts spirally, using the tool [6] .

Remove the cylinder head bolts .

Position the tools [1] - [2] .

Tilt and detach the cylinder head using the tool [4] .

Raise the cylinder head and exhaust manifold assembly using the tools [1] and [2] .

Remove the cylinder head and gasket .

WARNING : clean the joint faces with an approved descaling product ; do not use sharp or abrasive tools ; the joint faces must not have any trace of knocks or scores .

3 - REFITTING

3 - 1 - CHECKING THE FLATNESS

Maximum permissible bow = 0.05 mm .

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

Nominal length (X) 144.5 mm .

Reuse length (X) ≤ 147 mm .

WARNING : do not use cylinder head bolts longer than 129 mm .

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

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

Check that the pins (10) are present .

Fit a new cylinder head gasket (TOP (A) inscription upwards) .

Check the condition of the joints in the rigid pipe (7) .

Position the pipe (7) on the coolant pump .

WARNING : replace the valve (11) .

Position the water outlet housing on the cylinder head .

Position the pipe (7) in the coolant outlet housing .

Fit the cylinder head with the camshaft gear pinned .

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

3 - 3 - CYLINDER HEAD TIGHTENING

IMPERATIVE : tighten the cylinder head bolts in the order shown (using the tool [6]) .

Continue the fitting operations in the reverse order to removal .

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

Tighten the bolt (9) to 4.5 da.Nm .

IMPERATIVE : always replace the gaskets of the cylinder head cover .

refit the cylinder head covers .

Fit :

• the compact coil unit (3)
• the sensor (4)

Install the tools [1] - [2] on the sling hooks of the cylinder head .

Remove the right side intermediate engine bracket .

refit the timing belt .

fit the ancillary drive belt .

Remove the tools [1] - [2] .

Continue the fitting operations in the reverse order to removal .

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

fill and bleed the cooling system .