REMOVAL AND INSTALLATION


RECOMMENDED TOOLS



 [1] Cylinder head releasing levers (-).0188-L.

[2] Adapter for angular tightening 4069-T.

[3] Plugs kit (-).0194-T.

[4] Tool for removing-refitting exhaust clips (-).0193-A.

REMOVAL


Remove the engine cover.
Disconnect the battery.

caution Remove the tie bar (2); Wheels on the ground.
Remove:

  • The nuts (1), (4)
  • The tie bar (2)
caution Refit the nuts (1), (4).
Disconnect:

  • The connector (at "a")
  • The connector (at "b")
Remove:

  • The air filter (5) complete
  • The air duct (6)
  • The turbocharger inlet air duct (7)
Move aside the electrical harness (3).
Remove: The exhaust gas recycling exchanger.
Remove the recycling electrovalve for the exhaust gases.

Move aside the clip (8); Using tool [4].

Remove the 4 screws (9).
Pull away the heat shield (11).
Move aside the clip (10); Using tool [4].

From above the vehicle; Remove the 2 screws (12).

Remove the bolt (14).
Release: The precatalyser (13).

Remove:

  • The bolt (15)
  • The screws (16)
  • The bolt (17)

Remove:

  • The heat shield (19) (From above the vehicle)
  • The 3 fixing screws (18) (Turbocharger)

Remove:

  • The diesel injectors (25)
  • The fuel high pressure common injection rain (20)
  • Vacuum pump (22)
  • The high pressure fuel pump (21)
  • The accessories drive belt (24)
  • The pipe (23)
  • The timing belt
caution Plug the unions on the diesel injector and fuel high pressure common injection rail; Using the plugs [3].
Remove:

  • The camshafts
  • The coolant outlet elbow
  • The air inlet manifold

Remove:

  • The dynamic tensioner roller (29)
  • The screws (30)
  • The timing protector (26)
  • The upper bolts of the intermediate engine mounting (27) and (28)
  • The pre-heat plugs supply harness
  • The support bracket of the inlet distributor
Uncouple and move aside: The engine oil cooler pipe.

caution Mark the direction of fitting of the cylinder head gasket.
Remove:

  • The cylinder head bolts (in order 1 to 10)
  • The cylinder head
  • The cylinder head gasket
note If necessary, tilt and release the cylinder head; Using the levers [1].
caution Plug the turbocharger inlet and outlet openings.

CLEANING OPERATIONS TO BE PERFORMED JUST BEFORE REFITTING


caution Clean the gasket faces with an approved descaling product. Do not use a sharp or abrasive tool. The gasket faces must not have any traces of knocks or scores.
Clean out with a tap the threads in the crankcase which accommodate the cylinder head screws (M12 × 150 tap).
Brush the threads of the cylinder head bolts.

CHECKS


Check the flatness of the cylinder head.
note Maximum permissible bow = 0.03 mm

Check the length of the cylinder head screws.
Length of bolts under heads admissible: "A" = 128 mm.

INSTALLATION


caution On refitting, all removed seals must be replaced with new seals.

caution Check that the cylinder head to cylinder block centring pegs are in place (at "c").
Fit a new cylinder head gasket.
caution Position the reference holes "d" of the cylinder head gasket at the oil filter end.
Position the pistons at mid-stroke.
caution Remove: The plugs from the turbocharger air inlet and outlet pipes.
caution Check that the turbocharger air inlet and outlet pipes are free of foreign bodies.
Fit:

  • The cylinder head
  • The cylinder head bolts

CYLINDER HEAD TIGHTENING

caution Respect the tightening order (in order 1 to 10).
Tightening method:

  • Pre-tightening to 2 daN·m
  • Tighten to 6 daN·m ± 0.5 daN·m
  • Angular tighten to 220 ± 5°; Using the tool [2].

INSTALLATION (CONTINUED)
Remove the plugs [3].
Fit:

  • The support bracket of the inlet distributor
  • The pre-heat plugs supply harness
Reposition and reconnect: The engine oil cooler pipe.
Fit:

  • The intermediate engine mounting bolts (28); Tighten to 6 daN·m ± 0.5 daN·m
  • The intermediate engine mounting bolt (27); Tighten to 8 daN·m ± 0.5 daN·m
  • The timing protector (26)
  • The screws (30); Tighten to 0.5 daN·m ± 0.1 daN·m
  • The dynamic tensioner roller (29)
  • The coolant outlet elbow
  • The cams hafts
  • The timing belt
  • The accessories drive belt (24)
  • The air inlet manifold
  • The high pressure fuel pump (21)
  • Vacuum pump (22)
  • The high pressure common fuel rain (20)
  • The diesel injectors (25)
Reposition the turbocharger.
Fit:

  • The 3 bolts (18); Tighten to 2.5 daN·m ± 0.2 daN·m
  • The heat shield (19)
  • The screws (16), (15), (17)
Reposition:

  • The precatalyser (13)
  • Remove clips (8), (10); Using tool [4]
Tighten to 2.5 ± 0.2 daN·m; The clips(8), (10).
Fit:

  • The EGR electrovalve
  • The exhaust gas recycling exchanger
  • The screws (9)
  • The bolt (14)
  • The screws (12)
  • The pipe (23)
caution Check the absence of foreign bodies in the air ducts when refitting.
Fit:

  • The turbocharger inlet air duct (7)
  • The air duct (6)
Reposition the electrical harness (3).
Reconnect:

  • The connector (at "a")
  • The connector (at "b")
Fit: The air filter (5) complete
caution Fit: The tie bar (2); Wheels on the ground
Remove nuts (1), (4).
Fit:

  • The tie bar (2)
  • The nuts (1), (4); Tighten to 4.5 daN·m ± 0.7 daN·m
Connect the battery.
caution Perform the operations that are necessary after a battery reconnection (see the relevant operation).
Fill and bleed the cooling system.
Refit the engine cover.