B1DG0EK1 - 406D9 ES9J4 ENGINE Removal - Refitting Cylinder Head 1 - Special Tools

02/10/2022 13:39 https://www.qclt.com/html/标致206_406/406D9/INFO/gb/b1dg0ek3.
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B1DG0EK1 - 406D9 ES9J4 ENGINE
REMOVAL - REFITTING CYLINDER HEAD
1 - SPECIAL TOOLS
[1] Cylinder head bolt socket (-).0185 .
2 - REMOVAL
remove the power train .
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Cruise control :
remove the vacuum capsule assembly (1) with its bracket and the pin
Remove :
the engine harness assembly (2) and its bracket

the lifting plates (3)
the inlet manifold (4)
Disconnect the oil vapour recirculation pipes (5) .
Remove :
the additional engine harness assembly (6), inlet manifold and injection rails
Recover the seals .
Plug the cylinder head openings .
remove the timing belt .
Remove :
the coolant inlet and outlet manifold assembly (7)

the oil vapour recirculation pipes (5)
Remove :
the dipstick (8)

the fastener (9)
Remove :
the bolt (10)

the power steering pump bracket (11)
the M8 bolt (12)
Remove the cylinder head covers .
IMPERATIVE : starting at the outside and working in a spiral sequence progressively slacken the cylinder
head bolts .
Remove the cylinder head bolts .

Remove the cylinder head (13) .
IMPERATIVE : starting at the outside and working in a spiral sequence progressively slacken the cylinder
head bolts .
Remove the cylinder head bolts .
Remove the cylinder head (14) .
Recover the seals (15) .
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 holes (16) between the bores .
3 - CHECKING THE FLATNESS
Maximum permissible bow = 0.05 mm .
4 - CHECKING CYLINDER HEAD BOLTS BEFORE RE-USE
(X) must be less than 149.5 mm .
5 - REFITTING
Clean the threads of the cylinder head bolts in the cylinder block using a thread cutter .
Check that the pins (17) are present .
Position the new cylinder head gaskets .
WARNING : the holes (17a) must be free of obstructions .
Fit the cylinder heads, with the camshaft pinions with rods inserted .
refit the timing belt .
Brush the threads of the cylinder head bolts .
Fit the cylinder head bolts coated with MOLYKOTE G RAPID PLUS on the threads and under the bolt
heads .
6 - TIGHTENING THE CYLINDER HEADS
IMPERATIVE : tighten the cylinder head bolts in the order shown (using the tool [1]) .
Pre-tighten : 2 ± 0.1 da.Nm .
Bolt by bolt .
Slacken completely .
Tighten to 1.5 ± 0.1 da.Nm .
Tighten a further 225 degrees using a FACOM D.360 type tool .
NOTE : the cylinder head covers have composite gaskets which can be used several times; if the gasket is
damaged, it can be partially repaired with SILICONE CATEGORIE 2 jointing paste .
Refit the cylinder head covers .
On the right-hand side : .
On the left-hand side : .
IMPERATIVE : finger tighten then progressively tighten the securing bolts in the order shown (1 to 10) .
Pre-tightening 0.5 ± 0.03 da.Nm .
Tightening torque: 1 ± 0.1 da.Nm .
Check the tightening : 1 ± 0.1 da.Nm .
Fit :
the M8 bolt (12)

the power steering pump bracket (11)
the bolt (10)
Tighten :
the bolts (18) to 3.9 ± 0.2 da.Nm

the bolt (10) to 6 ± 0.4 da.Nm
Tighten the fastener (9) to 2.5 ± 0.1 daN.m. .
Fit :
the dipstick (8)
Fit :
the oil vapour breather pipes (5)

the coolant inlet and outlet manifold assembly (7)
Tighten :

the bolt (21) to 0.8 ± 0.05 da.Nm
IMPERATIVE : always replace the inlet manifold seals .
Fit :
the additional engine harness assembly (6), inlet manifold and injection rails
Reconnect the oil vapour breather pipes (5) .
IMPERATIVE : tighten the bolts in the order shown .
5 GEARBOX
Fastener M8 :
pre-tightening 1 ± 0.1 da.Nm

tightening torque: 2.5 ± 0.1 da.Nm
check the tightening : 2.5 ± 0.1 da.Nm
5 GEARBOX 5 GEARBOX
Fastener M6 (Manual gearbox \ Automatic gearbox) :
pre-tightening 0.4 ± 0.06 da.Nm

tightening torque: 1 ± 0.1 da.Nm
check the tightening : 1 ± 0.1 da.Nm
ALL MODELS
Continue the fitting operations in the reverse order to removal .

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02/10/2022 13:39 https://www.qclt.com/html/标致206_406/406D9/INFO/gb/b1dg0ek3.

B1DG0EK1 - 406D9 ES9J4 ENGINE

REMOVAL - REFITTING CYLINDER HEAD

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

remove the power train .

the engine harness assembly (2) and its bracket

Disconnect the oil vapour recirculation pipes (5) .

Recover the seals .

Plug the cylinder head openings .

remove the timing belt .

the coolant inlet and outlet manifold assembly (7)

the dipstick (8)

the bolt (10)

Remove the cylinder head covers .

Remove the cylinder head bolts .

Remove the cylinder head (13) .

Remove the cylinder head bolts .

Remove the cylinder head (14) .

Recover the seals (15) .

Clean the joint faces with an approved descaling product .

Do not use sharp or abrasive tools .

Clean the holes (16) between the bores .

3 - CHECKING THE FLATNESS

Maximum permissible bow = 0.05 mm .

4 - CHECKING CYLINDER HEAD BOLTS BEFORE RE-USE

(X) must be less than 149.5 mm .

Check that the pins (17) are present .

Position the new cylinder head gaskets .

WARNING : the holes (17a) must be free of obstructions .

refit the timing belt .

Brush the threads of the cylinder head bolts .

6 - TIGHTENING THE CYLINDER HEADS

Pre-tighten : 2 ± 0.1 da.Nm .

Tighten to 1.5 ± 0.1 da.Nm .

Tighten a further 225 degrees using a FACOM D.360 type tool .

Refit the cylinder head covers .

On the right-hand side : .

On the left-hand side : .

Pre-tightening 0.5 ± 0.03 da.Nm .

Tightening torque: 1 ± 0.1 da.Nm .

Check the tightening : 1 ± 0.1 da.Nm .

the M8 bolt (12)

the bolts (18) to 3.9 ± 0.2 da.Nm

Tighten the fastener (9) to 2.5 ± 0.1 daN.m. .

the dipstick (8)

the oil vapour breather pipes (5)

the bolts (19) to 0.8 ± 0.05 da.Nm

IMPERATIVE : always replace the inlet manifold seals .

Reconnect the oil vapour breather pipes (5) .

IMPERATIVE : tighten the bolts in the order shown .

pre-tightening 1 ± 0.1 da.Nm

Fastener M6 (Manual gearbox \ Automatic gearbox) :

pre-tightening 0.4 ± 0.06 da.Nm

Continue the fitting operations in the reverse order to removal .

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