Note: When installing, use a new head gasket and new cylinder head bolts, and a new valve cover gasket may also be required - see text.
Removal
1. The following procedure describes the removal and installation of the cylinder head together with the intake manifold and exhaust manifold and the high pressure fuel pump.
2. Disconnect the ground cable from the battery (refer to Chapter Engine electrical equipment). On models with F9Q engine, unscrew the mounting nuts and remove the engine soundproof cover.
Warning: If the car radio in your car is coded, make sure you know the code before disconnecting the battery.
3. Drain the fluid from the cooling system, including the cylinder block.
4. To improve access, unscrew the reinforcement rod (where is available) between the domes of the front suspension struts.
5. Remove the accessory drive belt. On models with F9Q engines and air conditioning, loosen the accessory belt tensioner mounting plate, then loosen the fuel pump/generator mounting bolt.
6. Disconnect the ground cable from the rear of the engine.
7. On models with the F8Q engine, disconnect the accelerator pedal cable from the high-pressure fuel pump, and move the cable away from the engine, making a note of its route (refer to Chapter Power and exhaust systems if necessary).
8. Loosen the banjo connection and disconnect the fuel supply line from the fuel pump (refer to the accompanying illustration). Remove the sealing washers. Plug the open end of the tube and the hole in the pump to prevent dirt from entering.
9. Remove the retaining clip and disconnect the main fuel return hose at the high pressure fuel pump. Route the hose through the rear mounting eye on the cylinder head and move the hose away from the engine. Plug the open ends of the tube and hose to prevent dirt from entering.
10. Disconnect and remove the air duct connecting the air filter to the intake manifold or turbocharger (please note that you will also need to disconnect the breather hoses that are connected to the air duct).
11. On turbocharged engines, disconnect and remove the air duct connecting the air cooler (intercooler) with turbocharger.
12. Remove the toothed drive belt as described in Section Removal, inspection and installation of the toothed drive belt, and the tensioning mechanism as described in Section Removal and installation of drive belt gears and tensioner mechanism. To support the engine/transmission, Renault vehicles use a special holder installed under the right front side of the cylinder block and subframe and an additional bracket secured below the water pump.
13. Unbolt the hose retainer from the front of the fuel pump bracket and move the hoses and retainer away from the pump.
14. Disconnect the breather hoses from the oil separator, and on turbocharged engines, also disconnect the hose from the boost pressure corrector on the fuel pump. Also disconnect the ends of these hoses from the manifold.
15. Unscrew one hose retainer from the front mounting eye and one from the vacuum pump and remove the hose assembly from the engine.
16. On engines without a turbocharger, disconnect the coolant hose from the thermostat housing.
17. On turbocharged engines, unscrew the thermostat housing from the cylinder head and move it to the side without disconnecting the hoses and sensor wiring (refer to the accompanying illustration).
18. Disconnect the coolant hose from the left rear corner of the cylinder head and move it away from the head.
19. Disconnect the hose from the vacuum pump (refer to the accompanying illustration).
20. Disconnect all electrical wiring from the fuel pump. Mark all connections to avoid confusion during installation.
21. Disconnect the electrical supply wires from the glow plugs.
22. On non-turbocharged engines, disconnect the wiring connector from the coolant temperature gauge/warning lamp sensor assembly located in the thermostat housing below the vacuum pump.
23. Disconnect all pipes and hoses from the manifold and turbocharger, following the relevant Sections of the Chapter Power and exhaust systems. Mark all tubes and hoses to avoid confusion during installation.
24. Where applicable, unscrew the hose holders from the manifolds and around the head and move the hoses to the side.
25. On turbocharged engines, remove the two bolts securing the turbocharger inlet elbow to the bracket on the transmission. Remove the nut and bolt securing the mounting bracket to the turbocharger and inlet elbow, and remove the elbow.
26. Remove the bolts securing the inner upper timing belt cover to the cylinder block.
27. Remove the bolt securing the intermediate pulley of the toothed drive belt, which passes through the inner cover.
28. Remove the front part of the exhaust system as described in Chapter Power and exhaust systems.
29. On engines with a turbocharger, unscrew the union nut securing the turbocharger oil feed pipe to the cylinder block and remove the pipe.
30. On turbocharged engines, remove the bolts securing the turbocharger bracket to the turbocharger and engine and remove the bracket.
31. If not already done, remove the dowel pin from the cylinder block and rotate the crankshaft counterclockwise a quarter turn to position all four pistons in the middle of the cylinders.
32. Working in the reverse order to that shown in the illustration, gradually loosen the cylinder head mounting bolts one half turn at a time until they can be removed by hand (refer to the accompanying illustration). Throw away the bolts.
33. The cylinder head together with the parts attached to it is very heavy, therefore it is recommended to use a winch when removing it from the cylinder block.
34. Raise your head (together with manifolds, fuel pump and inner upper timing belt cover) up from the cylinder block (refer to the accompanying illustration). If the dowel pins are loose, remove them and fold them together with the head.
35. If required, manifolds, turbocharger (where it is applied) and the fuel pump can be removed from the head, following the relevant Sections of the Chapter Power and exhaust systems.
Inspection
1. The mating surfaces of the cylinder head and block must be completely clean. Use a scraper to remove all traces of gasket and carbon deposits, and clean the tops of the pistons. Work especially carefully with the aluminum cylinder head, as the soft metal can be easily damaged. Also, make sure that no dirt gets into the oil and water passages - this is especially important for the lubrication circuit, as carbon deposits can block the oil supply to the camshaft and crankshaft bearings or rocker arms. Use masking tape and paper to isolate the water, oil passages and bolt holes in the cylinder block. Clean the piston crowns in the same way.
2. Check the block and head for nicks, deep scratches and other damage. If there are small scratches, they can be carefully removed with a file. More serious damage can be eliminated by resharpening, but this work should be entrusted to a specialist.
3. Using a straightedge placed on its edge, check the cylinder head for warpage. On the E7J engine, also check the cylinder liner protrusion.
4. Clean all bolt holes in the block. Make sure there is no oil left in them, otherwise there is a risk that the block may crack under hydraulic pressure when tightening the bolts.
5. Inspect the bolt threads and the threads in the cylinder block for damage. If necessary, use a tap of the appropriate size to renew the threads in the block and use a die to clean the threads on the bolts. It is recommended to replace the bolts after each removal.
Selecting a Gasket
1. Turn the crankshaft so that pistons #1 and #4 are in a position just below TDC (below the cylinder block surface). Place the dial micrometer on the cylinder block, set it to zero on the block surface. Move the probe of the device to the center of piston No.1, then slowly rotate the crankshaft back and forth so that the piston passes the TDC position, noting the highest reading of the micrometer. Record the result.
2. Repeat this procedure on piston #4, then turn the crankshaft half a turn (180°) and repeat the procedure on pistons #2 and #3 (refer to the accompanying illustration). All measurements must be taken on the longitudinal axis of the crankshaft (to eliminate errors due to piston tilt).
3. If a micrometer is not available, piston protrusion can be measured using a ruler and feeler gauge or a caliper. However, these methods are less accurate and therefore cannot be recommended.
4a. Use the largest measured piston protrusion value to determine the appropriate shim.
4b. Thickness marking holes are located in the front corner of the gasket, on the flywheel side (refer to the illustrations).
Note: The gasket thickness designation holes are located 25mm from the edge of the gasket. Ignore other holes outside this area.
Cylinder head mounting bolts
The manufacturer recommends replacing the cylinder head bolts after each removal.
Installation
1. Install manifolds, turbocharger (where it is applied) and the high-pressure fuel pump to the cylinder head, following the relevant Sections of Chapter Power and exhaust systems.
2. Remove the dowel pin from the cylinder block and turn the crankshaft clockwise until pistons #1 and #4 pass the bottom dead center position and begin to rise, then position them in the middle of the cylinders (this is necessary to prevent the possibility of the piston hitting the valves. Do not turn the crankshaft any further until you install the timing belt.
3. Make sure the dowel pins are in place in the cylinder block, then position the gasket with the correct orientation (refer to the accompanying illustration).
4. Lower the head onto the cylinder block. The inner upper timing belt cover must be correctly connected to the lower inner cover on the cylinder block. Disconnect the lifting device and winch. On F8Q engines, ensure that the swirl chambers do not fall out of their sockets in the cylinder head.
5. Lightly lubricate the new cylinder head bolts. Allow the excess oil to drain, then insert the bolts with washers and tighten them finger tight.
6. Tighten the cylinder head mounting bolts in the sequence shown to the specified Specifications by effort (refer to the accompanying illustration). Please note that on F8Q engines without a turbocharger or on F9Q engines, there is no need to re-tighten the bolts. However, on F8Q engines with a turbocharger, at the end of assembly after the first engine start, it is necessary to tighten the bolts additionally, having previously warmed up the engine to normal operating temperature and waited until it has cooled down completely.
7. On turbocharged engines, install the turbocharger bracket and tighten the mounting bolts.
8. On turbocharged engines, install the turbocharger oil feed pipe/hose and tighten the union nut onto the cylinder block.
9. Install the front part of the exhaust system as described in Chapter Power and exhaust systems.
10. Install the timing belt idler pulley bolt to the cylinder block, then install the timing belt tensioner as described in Section Removal and installation of drive belt gears and tensioner mechanism.
11. Install the new timing belt as described in Section Removal, inspection and installation of the toothed drive belt.
12. On turbocharged engines, inspect the O-ring in the turbocharger inlet elbow and replace if necessary. Install the elbow and bracket.
13. Install the hose mounts to the manifolds as noted prior to removal.
14. Connect all pipes and hoses to the manifolds and turbocharger as noted before removal.
15. On non-turbocharged engines, connect the wiring harness to the coolant temperature gauge/warning lamp sensor assembly.
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16. Connect the power wires to the glow plugs.
17. Connect all electrical wiring to the high pressure fuel pump.
18. Connect the engine ground cable to the rear mounting eye.
19. Connect the coolant hose to the cylinder head and the hose to the brake system vacuum pump.
20. Connect the air ducts to the air filter, intake manifold, turbocharger and air cooler (intercooler), where available. Make sure all hoses are connected correctly.
21. On turbocharged engines, inspect the sealing ring between the thermostat housing and the cylinder head and replace it if necessary. Install the thermostat housing to the cylinder head.
22. On engines without a turbocharger, connect the coolant hose to the thermostat housing.
23. Connect the crankcase breather hoses and, on turbocharged engines, also connect the boost pressure correction hose. Install the brackets to the engine mounting eye and vacuum pump.
24. Install the hose bracket to the high pressure fuel pump bracket.
25. Route the main fuel return hose through the engine mounting eye and connect it to the pipe on the high pressure fuel pump.
26. Connect the fuel supply hose to the fuel pump.
27. Connect the gas pedal cable as described in Chapter Power and exhaust systems.
28. Where applicable, install the reinforcement rod to the front suspension strut domes.
29. Make sure that the drain plug in the cylinder block (where is available) securely fastened, then fill and bleed the cooling system.
30. Install the auxiliary drive belt tensioner and bracket, then install the drive belt.
31. Connect the ground cable to the battery.
32. Bleed the fuel system as described in Chapter Power and exhaust systems.
33. On turbocharged engines, before starting the engine, perform the procedure described in Chapter Power and exhaust systems (filling the turbocharger lubrication circuit). On models with F9Q engine, install the soundproofing engine cover.
34. On F8Q engines with turbocharger, tighten the cylinder head bolts to final torque (refer to Specifications), after warming up the engine to normal operating temperature and waiting until it has cooled completely. It may be necessary to remove the upper right engine mount bracket (refer to Section Engine/Transmission Mount Replacement) to gain access to one of the bolts.