B1DG0JK1 - 607 DW12TED4 ENGINE

REMOVAL - REFITTING CYLINDER HEAD (DW12TED4)

1 - SPECIAL TOOLS

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

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

[3] crankshaft turning tool (-).0117-EZ .

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

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

[6] dial gauge (-).1504 .

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

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

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

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

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

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

2 - REMOVAL

drain the cooling system .

remove the turbocharger .

remove the timing belt .

Remove the bolts (1), (2) .

Refit the right-hand engine mounting .

Slightly tighten the bolts .

Place a draining tray under the engine .

Open the bleed screw (3) .

Move aside the connections (4), (5), (6), (7), (8) .

IMPERATIVE : plug the holes using tool [11] .

Remove air ducts (9) .

Remove throttle housings and their supports (10) .

Unclip and remove filter element cup (11) .

Remove the bolts (12) .

Remove the filter element reservoir support (13) .

Remove heat exchanger duct (14) from egr valve .

Remove the collar (15) .

Disconnect duct (16) .

Disconnect pipe (17) .

Remove cooling hoses (18) .

Disconnect and separate harnesses from water inlet housing .

Remove the support (19) .

remove injectors .

IMPERATIVE : plug the holes using tool [11] .

remove the camshafts .

IMPERATIVE : clean the fuel unions before slackening .

Disconnect the cylinder head harnesses and pipes and move them aside .

Remove the high pressure pipe (20) .

Plug the holes using tool [11] .

Disconnect connectors (21) from rail .

Remove :

the pins (22) (use a lock nut)
the bolts (23)

Move aside the thermostat housing (24) a little .

IMPERATIVE : starting at the outside and working in a spiral sequence progressively slacken the cylinder head bolts .

Remove the cylinder head bolts (Using the tool [8]) .

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

Remove the cylinder head and gasket .

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 .

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 camshaft bearings
of the various tapped holes
of the hydraulic tappets
of the valve rockers

IMPERATIVE : for checking, rectification or replacement of these parts, refer to the data sections .

3 - CHECKING THE FLATNESS

Maximum permissible bow = 0.05 mm .

4 - CHECKING VALVE PROTRUSION

Clean the checking surfaces .

Check the pocketing of the valves in relation to the cylinder head face (Checking points (A)) .

Calculate the average of the 4 values measured .

(B) Inlet valve = 0.05 mm .

These values are obtained by grinding the valve seats .

Lap in the valves (if necessary) .

5 - CHECKING CYLINDER HEAD BOLTS BEFORE RE-USE

(X) must be less than 133.4 mm .

6 - CHOICE OF CYLINDER HEAD GASKET

Remove the crankshaft setting rod [4] .

Clean the checking surfaces .

Fit the dial gauge [6] on the bracket [7] .

Turn the crankshaft .

Place the needle of the dial gauge on one of the checking points (Checking point : D) .

Continue turning the crankshaft until the piston reaches TDC .

Read the value .

Turn a quarter turn backwards .

Move the piston to the Top Dead Centre value without ever exceeding it .

Zero the dial gauge .

Move the dial gauge/bracket assembly [6] and [7] over the cylinder block .

Read the value .

Place the needle of the dial gauge on one of the checking points (Checking point : E) .

Zero the dial gauge .

Move the dial gauge/bracket assembly [6] and [7] over the cylinder block .

Read the value .

Calculate the average of the 2 values measured .

Continue in the same way for the other three cylinders .

NOTE : maximum difference between 2 pistons = 0.07 mm .

WARNING : the highest average value determines the thickness of the gasket .

7 - CYLINDER HEAD GASKET IDENTIFICATION

Engine identification marking .

(F) : thickness identification .

There are 4 categories of laminated metal cylinder gaskets .

piston protrusion measurements	thickness	hole (F)	hole (G)
0.52 to 0.570	1.25 ± 0.04	1	1
0.571 to 0.610	1.30 ± 0.04	1	2
0.611 to 0.650	1.35 ± 0.04	1	3
0.651 to 0.690	1.40 ± 0.04	1	4

IMPERATIVE : if the value measured does not correspond to the values indicated, investigate the origin of the fault (measurement error, handling error etc.) .

8 - REFITTING

Clean the surfaces of the coolant housing outlet .

Turn the crankshaft with the tool [3] .

Peg the flywheel using the rod [4] .

Check that the pins (25) are present .

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

Ensure that the camshaft is pinned .

Refit the cylinder head .

Brush the threads of the cylinder head bolts .

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

9 - CYLINDER HEAD TIGHTENING

Tighten the cylinder head bolts in the order shown (Using the tool [8]) .

Stage 1 :

proceed bolt by bolt in the order shown
tightening torque of bolts : 2 da.Nm

Stage 2 :

proceed bolt by bolt in the order shown
tightening torque of bolts : 6 da.Nm

Stage 3 :

proceed bolt by bolt in the order shown
loosen by 2 turn(s)

Stage 4 :

proceed bolt by bolt in the order shown
tightening torque of bolts : 2 da.Nm

Stage 5 :

proceed bolt by bolt in the order shown
tightening torque of bolts : 6 da.Nm

Stage 6 :

proceed bolt by bolt in the order shown
angular tightening to 220 °

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

10 - REFITTING (CONTINUED)

IMPERATIVE : when carrying out an operation on the diesel circuit, respect safety instructions .

WARNING : if any work is carried out on the high pressure pipes they must always be replaced .

Fit :The high pressure supply pipe .

Finger tighten : The hoses .

Tighten the pipe (20) to 2.25 daN.m,Using the tools [10], [12] .

replace camshafts .

Fit the thermostat (24) with a new joint .

Tighten :

the studs (22) to 2.5 m.daN + LOCTITE FREINFILET
the bolts (23) to 2.5 da.Nm

Couple up and clip the harnesses, hoses and cables connected to the cylinder head .

Replace vacuum pump fitted with its new seals .

Tighten pump to 2 dan.m .

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

Remove the right-hand engine mounting .

Refit the bolts (1), (2) .

Tighten :

the bolt (1) to 4.5 da.Nm
the bolt (2) to 2.05 da.Nm + LOCTITE FRENETANCH

adjust air gap of sensor (26) .

refit the timing belt .

fit the turbocharger .

Continue the fitting operations in the reverse order to removal .

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 .