B1DG0PK1 - 607 EW12J4 ENGINE

REMOVAL - REFITTING CYLINDER HEAD

1 - SPECIAL TOOLS

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

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

2 - REMOVAL

Remove the shield under the power train .

drain the cooling system .

Detach the exhaust pipe from the manifold .

Remove the 2 bolts (1) .

Remove the style cover (2) .

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

Remove :

• the fuel supply pipe (3)
• the air cleaner and air intake pipe (4)
• the timing belt
• the timing belt tensioner roller

Remove the bolt (5) .

Disconnect the connectors (6), (7), (8), (9) .

Remove the sensor (10) .

Remove the compact coil unit (11) .

Remove the cylinder head covers (12) .

Disconnect the pipe (13) .

Disconnect the pipe (14) .

Move aside : The heater matrix pipes .

Move aside the harness support (15) on the water outlet housing .

Unclamp the vehicle speed sensor harness .

Disconnect : The water housing outlet pipes .

Move aside the intake manifold (Plug the cylinder head openings) .

Remove the retaining fork and its securing bolt (16) from the coolant pipes (17) and (18) at the rear of the water outlet housing .

Remove the cylinder head bolts, Using the tool [2] .

Remove the cylinder head and gasket .

Remove the rigid pipe from the water outlet housing .

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 - CHECKING THE FLATNESS

Maximum permissible bow = 0.05 mm .

4 - REFITTING

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

Check that the pins (21) are present .

Fit a new cylinder head gasket (TOP (22) inscription upwards) .

Position the pipe (23) on the coolant pump .

Fit the cylinder head, with the camshaft pulley pegged .

Position the pipe (23) on the cylinder head, the gaskets having previously been coated with grease .

IMPERATIVE : do not re-use cylinder head bolts if they are longer than 129 mm .

Coat the threads and the contact area under the bolt head with MOLYKOTE G RAPID PLUS grease .

5 - CYLINDER HEAD TIGHTENING

IMPERATIVE : tighten the cylinder head bolts in the order shown,using the tool [2] .

Stage 1 :

• proceed bolt by bolt in the order shown
• tightening torque of bolts : 1.5 da.Nm

Stage 2 :

• proceed bolt by bolt in the order shown
• tightening torque of bolts : 5 da.Nm

Stage 3 :

• proceed bolt by bolt in the order shown
• loosen by 1 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
• tighten a further 270 degrees using a FACOM D360 type tool

6 - REFITTING (CONTINUED)

Continue the fitting operations in the reverse order to removal .

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

Refit the bolt (5) in the cylinder head intermediate bracket, Tightening torque 4.5 da.Nm .

Refit the cylinder head covers fitted with new gaskets in the order indicated .

Stage 1 :

• proceed bolt by bolt in the order shown
• tightening torque of bolts : 0.5 da.Nm

Stage 2 :

• proceed bolt by bolt in the order shown
• tightening torque of bolts : 1.1 da.Nm

Fit : The compact coil unit .

Fit : The inlet manifold, Tightening torque 2 da.Nm .

Continue the fitting operations in the reverse order to removal .

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

IMPERATIVE : replace : the exhaust clip .

Initialise the various ECUs .

fill and bleed the cooling system .