The removal/refitting of these new units does not present any particular difficulty
The cylinder head cover sealing function has changed and must be carried out with care
Driving the ancillaries
The ancillaries pulley (1) is made of stamped metal with integrated vibration damper
This pulley differs in the shape of the exterior crown wheel
There is complete interchangeability between a part of the previous design and a new part
Sealing of bearing no. 1
The appearance of the seal has not changed, only the material is different
There is complete interchangeability between a part of the previous design and a new part
Cylinder head
Cylinder head gasket
Addition of a cylinder head gasket to accommodate better the range of piston protrusion
WarningSelect the cylinder head gasket in relation to the protrusion of the pistons
(A) engine identification
(B) thickness identification
| piston protrusion (*) | gasket thickness compressed | number of holes at A | number of holes at B |
|---|---|---|---|
| 0.51 to 0.55 mm | 1.26 ± 0.04 mm | 2 | 1 |
| 0.55 to 0.59 mm | 1.30 ± 0.04 mm | 2 | 2 |
| 0.59 to 0.63 mm | 1.34 ± 0.04 mm | 2 | 3 |
| 0.63 to 0.67 mm | 1.38 ± 0.04 mm | 2 | 4 |
| 0.67 to 0.71 mm | 1.42 ± 0.04 mm | 2 | 5 |
| 0.71 to 0.79 mm | 1.46 ± 0.04 mm | 2 | 3 |
| (*): use the highest piston as a reference | |||
Sealing of the cylinder head cover
The cylinder head assembly consists of 3 components
- (1) plastic cylinder head cover (2)
- (1) cylinder head cover (3)
- The cylinder head (4)
These 3 components are now sealed by type E7 sealing compound
The cylinder head covers (2) and (3) no longer have a recess for a pre-formed gasket
Removing
Remove the cylinder head assembly
Remove the cylinder head assembly
Remove the cylinder head assembly
Remove the cylinder head assembly
NoteThe use of sealing compound may make separation of the components difficult
WarningClean the gasket faces with an approved descaling product; do not use abrasives or sharp tools on the joint faces; the seal faces should not show any traces of impacts or scratches
The dry sealing compound can be removed easily from the flat surfaces of the casings
However, for precise cleaning, use a wooden or plastic spatula
Refitting
Refit the cylinder head
Refit the cylinder head
Refit the cylinder head
Refit the cylinder head
Apply sealing compound (a) in an even bead of approximately E7 mm diameter round the edge of the cylinder head cover 3.5
Refit the lower cylinder head cover on the cylinder head
Once the components are in contact, engage the mounting bolts and tighten them to a torque of 0.5 ± 0.1 dan.m starting with the centre bolt
Apply sealing compound (a) in an even bead of approximately E7 mm diameter round the edge of the cylinder head cover 3.5
Refit the plastic cylinder head cover
Engage the mounting bolts
Pre-tighten the bolts to 0.8 ± 0.1 dan.m; angular tightening 50° (+0°; +5°)
WarningProceed bolt by bolt in the order shown
WarningTo prevent damage to the sealing compound on refitting, avoid any movement of the components while bolting the assembly
NoteThe plastic cylinder head cover mounting bolts are self-cutting. refitting them in the holes already cut does not present any difficulties but it is recommended that the bolts are engaged as straight and as deeply as possible; clean the bolts before refitting
Cylinder head bolts
The cylinder head bolts are male torx recess bolts with captive washer
WarningBefore reusing the cylinder head bolts, check their length
X = maximum length below head
Length of reusable bolts X = 125.5 mm
WarningDo not re-use cylinder head bolts if they are longer than 125.5 mm
NotePass a tap M12 X 150 into the internal screw threads of the cylinder block receiving the cylinder head bolts
Fit the cylinder head bolts coated with MOLYKOTE G RAPID PLUS on the threads and under the bolt heads
WarningDo not lubricate the new bolts
Tighten the cylinder head
Tighten the cylinder head
Tighten the cylinder head
Tighten the cylinder head
Tightening procedure
- Pre-tighten: 2 ± 0.2 da.Nm
- Tightening: 6 ± 0.6 m.daN
- Angular tightening 180°
There is complete interchangeability between a part of the previous design and a new part
Combining the bolts is permitted
Valve stem seals
Valve stem seals: brown in colour
There is complete interchangeability between a part of the previous design and a new part
Valve springs
The valve springs are painted yellow to enable them to be identified
There is complete interchangeability between a part of the previous design and a new part
Timing belt tensioner roller
Roller tensioner with steel pulley
There is complete interchangeability between a part of the previous design and a new part
Lubrication
The moulded body of the piston head coolers has changed to a mechanical welded tube body
There is complete interchangeability between a part of the previous design and a new part
Cooling system
The coolant pump turbine is made of brown plastic
Right and left side