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[1] Cylinder head releasing levers (-).0188-L.
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[2] Adapter for angular tightening 4069-T.
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[3] Plugs kit (-).0194-T.
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[4] Tool for removing-refitting exhaust clips (-).0193-A.
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caution |
Remove the tie bar (2); Wheels on the ground.
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Remove:
- The nuts (1), (4)
- The tie bar (2)
caution |
Refit the nuts (1), (4).
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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.
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Move aside the clip (8); Using tool [4].
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Remove the 4 screws (9). Pull away the heat shield (11). Move aside the clip (10); Using tool [4].
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From above the vehicle; Remove the 2 screws (12).
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Remove the bolt (14). Release: The precatalyser (13).
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Remove:
- The bolt (15)
- The screws (16)
- The bolt (17)
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Remove:
- The heat shield (19) (From above the vehicle)
- The 3 fixing screws (18) (Turbocharger)
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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].
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Remove:
- The camshafts
- The coolant outlet elbow
- The air inlet manifold
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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.
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caution |
Mark the direction of fitting of the cylinder head gasket.
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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].
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caution |
Plug the turbocharger inlet and outlet openings.
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Clean out with a tap the threads in the crankcase which accommodate the cylinder head
screws (M12 × 150 tap).
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Brush the threads of the cylinder head bolts.
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Check the flatness of the cylinder head.
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Check the length of the cylinder head screws. Length of bolts under heads admissible: "A" = 128 mm.
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caution |
Check that the cylinder head to cylinder block centring pegs
are in place (at "c").
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Fit a new cylinder head gasket.
caution |
Position the reference holes "d" of the cylinder head gasket
at the oil filter end.
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Position the pistons at mid-stroke.
caution |
Remove: The plugs from the turbocharger air inlet and outlet
pipes.
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caution |
Check that the turbocharger air inlet and outlet pipes are free
of foreign bodies.
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Fit:
- The cylinder head
- The cylinder head bolts
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caution |
Respect the tightening order (in order 1 to 10).
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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].
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- The support bracket of the inlet distributor
- The pre-heat plugs supply harness
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Reposition and reconnect: The engine oil cooler pipe.
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- 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)
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Reposition the turbocharger.
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- The 3 bolts (18); Tighten to 2.5 daN·m ± 0.2 daN·m
- The heat shield (19)
- The screws (16), (15), (17)
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- The precatalyser (13)
- Remove clips (8), (10); Using tool [4]
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Tighten to 2.5 ± 0.2 daN·m; The clips(8), (10).
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- The EGR electrovalve
- The exhaust gas recycling exchanger
- The screws (9)
- The bolt (14)
- The screws (12)
- The pipe (23)
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- The turbocharger inlet air duct (7)
- The air duct (6)
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Reposition the electrical harness (3).
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- The connector (at "a")
- The connector (at "b")
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Fit: The air filter (5) complete
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- The tie bar (2)
- The nuts (1), (4); Tighten to 4.5 daN·m ± 0.7 daN·m
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Fill and bleed the cooling system.
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