Page 58 of 208
TOP AND FRONT OF ENGINE
Cylinder head gasket
11
SPECIAL TOOLING REQUIRED
REMOVAL
Place the vehicle on a two post lift .
Disconnect the battery.
Remove :
- the bonnet,
- the timing belt (see method described in
section 11 "Timing belt").
Drain the cooling circuit via the lower radiator
hose.
EQUIPMENT REQUIRED
Engine support tool
55mm torx socket
Mot. 251-01 Dial gauge support tool
Mot. 252-01 Plate for measuring piston
protrusion
Mot. 591-02 Index
Mot. 591-04 Angular tightening wrench
Mot. 1054
TDC pin
Mot. 1159 Tool for mounting engine on
subframe
Mot. 1202 Hose clip pliers
Mot. 1273 Tool for checking belt tension
Mot. 1311-06 Tool for removing fuel pipe
Tension wheel nut 5
Crankshaft pulley bolt 2 + 115° ± 15°
Bolt for suspended engine mounting cover 6.2
Nut for suspended engine mounting cover 4.4
Wheel bolts 9
TIGHTENING TORQUES (in daN.m or/and°)
99024R2
Fit tool Mot. 1159 between the subframe and
the cylinder block. F8Q Engine
11-23
Page 59 of 208
TOP AND FRONT OF ENGINE
Cylinder head gasket
11
Remove :
- the exhaust downpipe,
- the hoses and connectors of the cylinder head
coolant pipe housing outlet,
- the connection at (1) using tool Mot. 1311-06,
13097R
99461R
- the air filter assembly by disconnecting the
EGR solenoid valve and the air temperature
sensor (unclip the fuel supply pipes from the
air filter housing),
- the air inlet pipe
- the accelerator cable
- the feeds for the heater plugs ,
- the connector of the injector with sensor,
along with the fast idle solenoid valve connec-
tor (5),
- the fuel supply and return unions at (A) and
(B).
Disconnect connector (6) from the diesel fuel fil-
ter, remove it from its support and move the die-
sel fuel filter pipe assembly to one side. Place bracket Mot. 1159 at the mounting of the
coolant pipe on the cylinder block, then remove
the engine support tool.
99310R
F8Q Engine
11-24
Page 60 of 208
TOP AND FRONT OF ENGINE
Cylinder head gasket
11
13083-1R1
To release the quick release unions, refer to the
following diagrams.
11734R
F8Q Engine
11-25
Page 61 of 208
TOP AND FRONT OF ENGINE
Cylinder head gasket
11
11733R
Remove the fuel pipe support (7).
Slacken the mounting bolts for the lower timing
cover, without removing them.
99173-1R
13093R
Remove :
- the accessories belt tensioning system,
- the cylinder head bolts.
Release the cylinder head by setting aside the
lower part of the lower camshaft housing,
without causing the cylinder head to pivot, since
this is centred by the two dowels at ( C ).
Using a syringe, extract any oil which may have
entered the cylinder head mounting holes .
This is necessary in order to obtain the correct
tightening of the bolts.
Protect the oil outlet duct in order to prevent any
foreign bodies from entering the oilways in the
cylinder head.
Failure to take this advice could lead to the
blocking of the oilways, resulting in a rapid dete-
rioration of the camshaft. F8Q Engine
11-26
Page 62 of 208
TOP AND FRONT OF ENGINE
Cylinder head gasket
11
Wear gloves whilst carrying out this operation.
99180S
CHECKING THE GASKET FACE
Check for gasket face bow, using a straight edge
and a set of shims.
Maximum deformation: 0.05 mm.
No regrinding of the cylinder head is permitted.
Check the cylinder head for cracks.
F8Q Engine
CLEANING
It is very important not to scratch the gasket faces
of the aluminium components.
Use the Décapjoint product to dissolve any part of
the gasket which remains attached.
Apply the product to the parts to be cleaned; wait
about ten minutes, then remove it using a
wooden spatula.
11-27
Page 63 of 208
TOP AND FRONT OF ENGINE
Cylinder head gasket
11
REFITTING (special notes)
Refit the cylinder head gasket selected previous-
ly. This is centred by two dowels at (C).
99173-1R
Bring the pistons to mid-stroke position to
prevent them from coming into contact with the
valves during the tightening of the cylinder head .
Centre the cylinder head on the dowels.
Lubricate the threads and under the heads of the
mounting bolts.
Tighten the cylinder head (see section 07
"Tightening the cylinder head").
Refitting is the reverse of removal.
Refit the timing belt, (see method described in
section 11 "Timing belt").
Fill and bleed the cooling circuit , (see section 9
"Filling -bleeding").
MEASURING THE THICKNESS OF THE CYLINDER
HEAD GASKET
Checking piston protrusion
Clean the piston heads in order to eliminate any
traces of deposits.
Turn the crankshaft in its operating direction
once, to bring piston n° 1 close to
TDC .
Fit tool Mot. 252-01 on the piston.
Fit tool Mot. 251-01, complete with dial gauge
Mot. 252-01. on the plate Ensure that the dial
gauge measuring pin is in contact with the cylin-
der block; then locate the piston
TDC.
NOTE
: All measurements are to be carried out in
the longitudinal axis of the engine, in order to eli-
minate any errors due to tilting of the piston.
99173R
Measure the piston protrusion.
ONLY TAKE INTO CONSIDERATION THE
DIMENSIONS OF THE PISTON WITH THE
GREATEST PROTRUSION.
For a maximum piston protrusion:
- lower than 0.868 mm, use a gasket marked by
a tab with two holes ,
- included between 0.868 mm and 1mm, use a
gasket marked by a tab with one hole,
- greater than 1mm, use a gasket marked by a
tab with three holes. F8Q Engine
11-28
Page 64 of 208
TOP AND FRONT OF ENGINE
Replacement of valve adjusters
11
SPECIAL TOOLING REQUIRED
Mot. 1366-01 Tool for removing valve adjusters
(additional item to Mot. 1366)
TIGHTENING TORQUES (in daN.m)
Studs for mounting manifolds on
cylinder head 1
Nut for mounting manifolds on
cylinder head 2.7
Mounting bolt for strut on inlet manifold 2.5
Mounting bolt for strut on cylinder block 2.5
Place the vehicle on a two-post lift
Disconnect the battery.
CHECKING THE VALVE CLEARANCE
Remove the air filter housing along with the cy-
linder head cover.
Place the valves of the cylinder concerned at the
"end of exhaust - beginning of inlet" position and
check the clearance .
86911-1S
1
3
4
24
2
1
3
Compare the two dimensions noted to the re-
commended dimensions, and replace the adjus-
ters if necessary .
Clearance ( in mm ), when the engine is cold :
- Inlet: 0.10
- Exhaust :0.25 F8Q Engine
11-29
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TOP AND FRONT OF ENGINE
Replacement of valve adjusters
11
REPLACEMENT OF VALVE ADJUSTERS
In order to carry out this operation it is necessary
to remove the inlet and exhaust manifolds (see
section 12 Inlet/Exhaust Manifolds) .
Fully open the valve concerned (by turning the
engine in its operating direction).
Insert tool Mot. 1366-01 into the duct concerned .
11231R
For inlet valves
Turn the engine in the operating direction,in
order to bring the valve into contact with tool
Mot. 1366-01 (rotate the camshaft by 90° in
relation to the fully open position).
For the exhaust valves
It is vital to turn the engine in the opposite direc-
tion to normal operation (in order to avoid the
locking of the engine), until the valve comes into
contact with tool Mot. 1366-01 (rotate camshaft
by 90° in the relation to the fully open position).
Extract the valve adjuster using a screwdriver and
a magnetic tool.
11232-1R
NOTE : during the refitting of the valve adjuster,
extract any oil which may be in the bottom of the
pushrod bore ( C ) .
98895R1
REFITTING
Refitting is the reverse of removal. F8Q Engine
11-30
