Page 244 of 652

11A-127
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D7F – D4F, and 772
11A
1 - Cleaning the cylinder head
aApply SUPER CLEANER FOR JOINT FACES (see
Vehicle: Parts and consumables for the repair)
(04B, Consumables - Products) to the areas to be
cleaned.
aWait for approximately ten minutes.
aRemove the residue using a wooden spatula.
aComplete the cleaning operation using a grey abra-
sive pad.
2 - Checking the gasket face
aCheck the flatness of the cylinder head gasket face
(see Cylinder head: Check) .3 - Optional additional operations
aWhen replacing the cylinder head, strip the cylinder
head (see Cylinder head: Stripping - Rebuilding) .
aIf necessary, carry out a complete check of the cylin-
der head (see Cylinder head: Check) .
II - REFITTING OPERATION FOR PART
CONCERNED
aBring the pistons to mid-stroke position to prevent
them from coming into contact with the valves during
the tightening of the cylinder head.
aCheck for the cylinder head centring dowels on the
cylinder block.
aRefit:
-a new cylinder head gasket,
-the cylinder head.
Cylinder head tightening procedure
aRefit the new cylinder head bolts.
aFit the cylinder head bolts, without tightening them. WARNING
Do not scrape the joint faces of the aluminium,
any damage caused to the joint face will result in
a risk of leaks.
WARNING
Do not allow this product to drip onto the paint-
work.
Clean the cylinder head carefully to avoid any
foreign bodies entering the oil return and supply
pipes.
Failure to follow this advice could lead to the
blocking of the various oil inlet galleries, which
would quickly result in engine damage.
WARNING
Protect the oilway so that foreign bodies do not
enter the oil pipes in the cylinder head.
Failure to follow this instruction could lead to the
blocking of the oilways, resulting in a rapid deteri-
oration of the camshaft.
Note:
The cylinder head bolts must not be lubricated
before being fitted.
WARNING
No regrinding of the cylinder head is permitted.
WARNING
In order to ensure that the bolts are correctly
tightened, use a syringe to remove any oil which
may be in the cylinder head mounting holes.
Page 250 of 652

11A-133
TOP AND FRONT OF ENGINE
Cylinder head: Removal - Refitting
D4F, and 780 or 782
11A
2 - Checking the gasket face
aCheck the flatness of the cylinder head gasket face
(see Cylinder head: Check) .
3 - Optional additional operations
aWhen replacing the cylinder head, strip the cylinder
head (see Cylinder head: Stripping - Rebuilding) .
aIf necessary, carry out a complete check of the cylin-
der head (see Cylinder head: Check) .
II - REFITTING OPERATION FOR PART
CONCERNED
aBring the pistons to mid-stroke position to prevent
them from coming into contact with the valves during
the tightening of the cylinder head.
aCheck for the cylinder head centring dowels on the
cylinder block.
aFit a new cylinder head gasket onto the cylinder
block, positioning the marking (8) on the oil filter
side.
aRefit the cylinder head.
Cylinder head tightening procedure
aRefit the cylinder head bolts.
aFit the cylinder head bolts, without tightening them.aTighten to torque and in order the cylinder head
bolts (initial torque) (20 N.m).
aCheck that the cylinder head bolts are tightened to
20 N.m.
aAngle tighten in order the cylinder head bolts (230˚
±± ± ±
6˚).
III - FINAL OPERATION
aConnect the cooling hoses.
aRefit:
-the cooling hose clips using the (Mot. 1448),
-the engine wiring.
aRemove the blanking plugs.
aConnect:
-the petrol inlet union on the injector rail - injectors.
-the coolant temperature sensor connector,
-the throttle body connector ,
-the fuel vapour rebreather solenoid valve connec-
tor,
-the injector rail - injector wiring connector,
-the air inlet pressure connector.
-the upstream oxygen sensor connector.
aClip the injection wiring onto the inlet manifold.
aConnect:
-the compressor discharge valve air pipe to the air
filter unit outlet air pipe, WARNING
No regrinding of the cylinder head is permitted.
19598
WARNING
In order to ensure that the bolts are correctly
tightened, use a syringe to remove any oil which
may be in the cylinder head mounting holes.
18641
Page 352 of 652
13A-9
FUEL SUPPLY
Fuel pressure: Check
D4F or D7F
13A
CHECK
aI - PREPARATION OPERATION FOR CHECK
aEnsure you have a checking tool (Mot. 1311-01) and
a “T” union (Mot. 1311-08).
aRemove the oil filler neck.
II - TEST OPERATION
aDisconnect the petrol inlet pipe from the injector rail. Special tooling required
Mot. 1311-01Pressure gauges and petrol
pressure measur ing unions.
Mot. 1311-08Union for taking fuel pres-
sure measurements .
IMPORTANT
During this operation, be sure to:
-refrain from smoking or bringing red hot objects
close to the working area,
-be careful of fuel splashes when disconnecting
the union.
IMPORTANT
Wear goggles with side protectors for this opera-
tion.
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
116887
D4F
Page 353 of 652
13A-10
FUEL SUPPLY
Fuel pressure: Check
D4F or D7F
13A
aConnect:
-the pipe fitted with a pressure checking gauge with
the “T” union of the tool (Mot. 1311-08),
-the “T” union to the rail,
-the petrol inlet duct to the “T” union.
aRefit the oil filler neck.aConnect:
-the pipe fitted with a pressure checking gauge with
the “T” union of the tool (Mot. 1311-08),
-the “T” union to the rail,
-the petrol inlet duct to the “T” union.
aRefit the oil filler neck. D4F, and 772
121821
D4F, and 780 or 782
121728
Page 354 of 652
13A-11
FUEL SUPPLY
Fuel pressure: Check
D4F or D7F
13A
aConnect:
-the pipe fitted with a pressure checking gauge with
the “T” union of the tool (Mot. 1311-08),
-the “T” union to the rail,
-the petrol inlet duct to the “T” union.
aStart the engine.
aDetermine the pressure:
-the pressure must be a constant 3.5 bar,
-It may take a few seconds to obtain a correct injec-
tor rail pressure reading.
aSwitch off the engine.
III - FINAL OPERATION
aRemove the “T” union (Mot. 1311-08).
aRemove:
-the oil filler neck,-the “T” union (Mot. 1311-08).
aConnect the fuel supply union.
aRefit the oil filler neck. D7F
121822
D7F
D4F
D4F