B1DG0NK1 - 406D9 EW12J4 ENGINE EW10J4 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

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Remove the shield under the power train .

ALL MODELS

drain the cooling system .

Detach the exhaust pipe from the manifold .

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Remove the 2 bolts (1) .

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Disconnect the battery .

Remove the style cover (1) .

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 (2)
• the timing belt
• the timing belt tensioner roller
• the air cleaner and air intake pipe (3)
• the dipstick guide tube (4) and the dipstick

Disconnect the crankcase breather hose (5) .

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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

Disconnect the connectors (9), (10), (11), (12) .

Remove the sensor (13) .

Remove the compact coil unit (14) .

Remove the cylinder head covers (15) .

Disconnect the pipe (16) .

Disconnect the pipe (17) .

Move aside : The heater matrix pipes .

Move aside the harness support (18) 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 (19) from the coolant pipes (20) and at the rear of the water outlet housing .

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Remove the collar (6) .

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

Remove the sensor (10) .

Remove the compact coil unit (11) .

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

Move aside : The heater matrix pipes (12) .

Remove the cylinder head covers (13) .

Remove and move aside the harness bracket (14) from the water outlet housing .

Disconnect : The water housing outlet pipes (15), (16) .

Remove the retaining fork and its securing bolt (17) from the coolant pipes (18) and (19) at the rear of the water outlet housing .

Remove the bolt (20) .

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 .

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Check that the pins (21) are present .

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

Position the pipe (19) on the coolant pump .

Fit the cylinder head, with the camshaft pulley pegged .

Position the pipe (19) on the cylinder head, the gaskets having previously been coated with grease .

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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 : replace the valve (A) .

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IMPERATIVE : do not re-use cylinder head bolts if they are longer than 147 mm .

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

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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] .

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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

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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 285 degrees using a FACOM D360 type tool

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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 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 .

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Re-connect the connectors (7), (8), (9) .

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

Fit :

• the sensor (10)
• the dipstick guide fitted with a new seal

IMPERATIVE : replace : the exhaust clip .

fill and bleed the cooling system .

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

Fit :

• the sensor (13)

Continue the fitting operations in the reverse order to removal .

IMPERATIVE : replace : the exhaust clip .

Initialise the various ECUs .

fill and bleed the cooling system .

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