B1DG05A1 - 206 DW8 ENGINE

REMOVAL - REFITTING CYLINDER HEAD

1 - SPECIAL TOOLS

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

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

[3] dial gauge (-).1505 .

[4] FACOM D 360 angular tightening tool .

2 - REMOVAL

Disconnect the battery .

Remove :

the style cover (1)
the air filter and its connections (2)
the inlet manifold (3)
the EGR valve hose
the vacuum pump

Drain :

THE COOLING SYSTEM
the diesel filter chamber

Disconnect, unclip and separate the harnesses, hoses and cables connected to the cylinder head .

Remove :

diesel filter assembly (4)
the bolt (6)
the 3 bolts (5)
the thermostat (7)
the pipe (8)
the expansion chamber (9)
the heater matrix connection to the cylinder head

Remove :

THE TIMING BELT
the camshaft pulley

Remove :

the high pressure pipes (10)
the bolt (11)
the fuel return pipe (12)

Uncouple the front exhaust pipe (Manifold side) .

Starting at the outside and working in a spiral sequence progressively slacken the cylinder head bolts .

Remove the cylinder head bolts .

Rock and free the cylinder head using levers [1] .

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 tap M12 x 150 .

2 - 1 - CHECKING THE FLATNESS

Maximum permissible bow = 0,03 mm .

2 - 2 - CHECKING THE COMBUSTION CHAMBER PROTRUSION

Using tools [2] and [3] :

combustion chamber protrusion : 0,015 ± 0,015 mm

2 - 3 - CHECKING VALVE POCKETING

Using tools [2] and [3] :

inlet valve pocketing : 0,775 ± 0,275 mm
exhaust valve pocketing : 1,175 ± 0,275 mm

2 - 4 - CHECKING CYLINDER HEAD BOLTS BEFORE RE-USE

Cylinder head bolt without end-piece :

(X) must be less than 121,5 mm

Cylinder head bolt with end-piece :

(X) must be less than 125,5 mm

2 - 5 - CHOICE OF CYLINDER HEAD GASKET

Remove the crankshaft setting rod .

Fit the dial gauge to the bracket and calibrate it to the markings (Tools [2]-[3]) .

Turn the crankshaft with the crankshaft drive tool .

Measure the protrusion of each piston at TDC .

Note the maximum protrusion (D) .

Select the appropriate cylinder head gasket thickness .

protrusion (D)	thickness identification
0,51 to 0,549 mm	1 hole(s)
0,55 to 0,589 mm	2 hole(s)
0,59 to 0,629 mm	3 hole(s)
0,63 to 0,669 mm	4 hole(s)
0,67 to 0,71 mm	5 hole(s)

2 - 6 - CYLINDER HEAD GASKET IDENTIFICATION

(1A) :Engine identification .

(1B) : Nominal dimension .

(1C) : Repair size .

engine code	WJZ	WJZ
engine type	DW8	DW8
special features	CURTY	ELRING
engine identification group (1A)	E - F	E - F
1st nominal dimension group (1B)	N	N
2nd nominal dimension group (1B)	N - O	N - O
3rd nominal dimension group (1B)	N - O - P	N - O - P
4th nominal dimension group (1B)	N - O - P - Q	N - O - P - Q
5th nominal dimension group (1B)	N - O - P - Q - R	N - O - P - Q - R
1st repair dimension group (1C)	-	-
2nd repair dimension group (1C)	-	-

3 - REFITTING

Turn the crankshaft with the crankshaft drive tool .

Set the TDC sensor .

Check that pin is present (At A) .

Fit a new cylinder head gasket .

Check that the camshaft is in the setting position by offering up the timing gear (Bolt(s) M8 x 125) .

Refit the cylinder head .

Brush the threads of the cylinder head bolts .

Fit new washers .

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

4 - CYLINDER HEAD TIGHTENING

IMPERATIVE : proceed bolt by bolt in the order shown .

Pre-tighten to 2 da.Nm .

Tightening torque 6 da.Nm .

Angular tightening to 180 ° (Using the tool [4]) .

5 - REFITTING (CONTINUED)

Fit :

the camshaft pulley

Tightening torque : 2.3 da.Nm .

Fit :

the timing belt

Fit the thermostat (7) with a new joint .

Tightening torque of bolts (5) : 1.4 da.Nm .

Refit the diesel filter assembly together with a new O-ring .

Tightening torque of bolt (13) : 1.8 da.Nm .

Continue the fitting operations in the reverse order to removal .

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

Bleed the fuel system .

Fill and bleed the cooling system .

Initialise the various ECUs .