Cylinder Head Assembly: Service and Repair

Fig. 2 Cylinder block drain plug.:

Removal

1. Disconnect battery ground cable and drain cooling system, then remove cylinder block drain plug (A), Fig. 2.
2. Remove radiator grille and grille upper crossmember, heat shields, water pump belt, air intake hose, and diagnostic socket.
3. Mark installation position, then disconnect vacuum hoses, electrical connectors and control cables.
4. Disconnect heater hoses at water pump.
5. Disconnect and plug fuel lines.
6. Remove distributor cap and wires, mark position of rotor and distributor body, then remove distributor. Do not rotate crankshaft with distributor removed.
7. Disconnect exhaust pipe and remove catalytic converter.
8. On turbo engine, remove connecting hose between turbo and air cooler, and disconnect oil lines and EGR hose.
9. Remove rocker cover, loosen rocker arm adjusting screws and remove pushrods, arranging them in correct sequence.
10. Loosen cylinder head bolts and remove six inner bolts.
11. Remove rubber washers and cups in spark plug recesses.
12. Install rubber band or string around four remaining cylinder head bolts to secure rocker arm assemblies, then remove rocker arm assemblies and cylinder head bolts together. Do not lift cylinder head from cylinder block. The cylinder head gaskets will stick to the cylinder head, block and liners and destroy the water tight seal at the bottom of the liners.

Fig. 3 Typical cylinder head removal.:

13. To remove cylinder head, rotate cylinder head around centering dowel A, Fig. 3, by tapping each side of cylinder head with a plastic mallet.
14. Raise cylinder head slightly and remove lifters.
15. Remove cylinder head and lifter chamber seal. Install liner clamp MOT 521-01 or equivalent onto cylinder block. Do not rotate engine until cylinder liners are clamped. If liners are moved, liner seals may break and cause water leaks after assembly.
16. Clean head gasket and block surfaces with suitable gasket remover. Do not use any sharp edged tools for cleaning.

Fig. 6 Cylinder head positioning tools.:

Installation

Note: Cylinder head positioning is very important. The alignment of the distributor driveshaft gear depends on this operation. Renault positioning tools Mot. 446 (1) and Mot. 451 (2), Fig. 6, or suitable equivalents must be used.

1. Ensure all foreign material is removed from oil passages and remove oil or water from cylinder head bolt holes to allow bolts to be properly tightened.
2. Ensure that centering dowel of cylinder head and distributor drive pinion are properly positioned in cylinder block.
3. Remove liner clamp and position cylinder head gasket on block. Once gasket is installed it should not be moved. If gasket is moved, do not reuse it.

Fig. 7 Cylinder head positioning tool installation.:

4. Install Mot. 451 studs, Fig. 7, tightening studs until ball contacts cylinder head gasket and holds gasket in place on cylinder block.
5. Install rubber lifter chamber gasket. Ensure gasket fits into the slots of the head gasket and into the positioning holes in the block.
6. Install positioning tool Mot. 446 in the hole in front of the cylinder block, Fig. 7.
7. Install the lifters into their correct order in the cylinder head. Tap them lightly to secure into cylinder head.
8. Assemble rocker shaft assemblies to cylinder head. Check to ensure that rocker arm support holes align with centering dowels.
9. Check to ensure distributor drive gear is properly positioned, then install cylinder head onto block and hand tighten 4 end head bolts securing rocker arm assemblies.

Fig. 6 Cylinder head positioning tools.:

10. Remove locating studs with stud remover (3), Fig. 6.

Fig. 5 Cylinder head tightening sequence:

11. Lubricate cylinder head bolts and washers with engine oil, then torque bolts in sequence shown in Fig. 5 to 57-61 ft.lbs.
12. Remove tool Mot. 446, then install pushrods.
13. Tap lightly on each rocker arm adjusting screw to ensure that lifter is completely up against cam lobe, then adjust rocker arm clearance.
14. Ensure that positioning tabs on valve cover are all inside cylinder head and that gasket is resting properly on cylinder head, then tighten valve cover bolts.
15. Reverse remaining steps to complete installation, then fill and bleed cooling system as outlined.
16. Run engine until cooling fan goes on, shut engine off and allow it to cool for at least 2-1/2 hours, then retighten cylinder head as follows:
a. Unscrew bolt No. 1 one half turn and torque to 57-61 ft.lbs.
b. Repeat above step for each bolt in sequence.
c. Adjust rocker arms.