Recommended tools
| reference | description | reference | reference |
|---|---|---|---|
| [1] | flywheel locking tool | (-).0132.QY | 4507-T.A |
| reference | description | reference | reference |
|---|---|---|---|
| [2] | dial gauge support and rod | (-).0118-FZ (5602-T) + (-).0117-AH | 4060-T |
| reference | description | reference | reference |
|---|---|---|---|
| [3] | angular tightening wrench | FACOM D.360 | 4069-T |
| reference | description | reference | reference |
|---|---|---|---|
| [4a] | exhaust camshaft setting rod | (-).0132-AJ1 | 4533-T.AC1 |
| reference | description | reference | reference |
|---|---|---|---|
| [4b] | inlet camshaft setting rod | (-).0132-AJ2 | 4533-T.AC2 |
| reference | description | reference | reference |
|---|---|---|---|
| [5] | pin for the dynamic roller tensioner | (-).0188-Z | 4200-T.H |
Refitting
Crankshaft
(1) cylinder block
(3) cylinder block shells
NoteTo select the lower half bearing shells and the end float shims, refer to the specification
WarningEnsure that the half bearing shells are positioned correctly
Fit the class "B" (colour black) half bearing shells to the bearings on the cylinder block side
- Bearings 1;3;5 = plain half bearing shells (cylinder block and bearing cap casing)
- Bearings 2;4 = grooved half bearing shells (cylinder block and bearing cap casing)
Oil the bearing shells and the journals
Position
- The crankshaft (2)
- The side stop thrust washers (4), grooved face in contact with the crankshaft
Fit the crankshaft bearing caps
Oil the crankshaft bearing cap screws (on threads and under heads)
Do up the crankshaft bearing caps by hand, then pre-tighten to 1 m.daN
Crankshaft end float
Fit the tools [2] on the cylinder block (3)
Fix a dial gauge on the supports [2]
Push the crankshaft in one direction, to the stop
Set the dial gauge to zero
Push the crankshaft in the opposite direction, to the stop
NoteThere should be an endfloat of 0,07 to 0,27 mm
Adjust the endfloat by changing the thrust washers (4) (see the relevant operation)
WarningSelect half-brackets of the same thickness
Connecting rod/piston assemblies
Refit the connecting rod/piston assemblies (see the relevant operation)
Position the rings with the ring pliers
The face of sealing ring (6) marked TOP should be uppermost
Direct ring gap (6) 180° with respect to ring gap (5)
Note(7) scraper ring (no direction of fitting)
Oil the cylinders
Observe the marks made during the dismantling operation
Point the arrow on the piston towards the timing
Engage the piston, properly positioning the scraper ring
Proceed likewise for the other three bearing sets
Turn the cylinder block over
WarningFit the conrod caps with the bearing shells chosen according to the specifications
Oil
- The sleeves
- The lower bearing shells
Refit the conrod caps
WarningObserve pairing of the conrods/big end caps
Oil and fit the conrod cap screws
Tighten the conrod caps 3,8 ± 0,3 m.daN
Crankshaft main bearing caps
- Tighten the bolts to 2 m.daN
- Angular tighten to 49 ± 2 °; using tool [3]
WarningMake sure that the crankshaft rotates freely and without tight spot
Oil pump
Refit
- The oil pump centralising pin (8)
- The key to the crankshaft
- The oil pump pinion and pump/chain assembly
Tighten the oil pump fixing screws to 0,8 ± 0,1 m.daN
Coat the seal face "a" with a thin layer of silicone paste AUTO JOINT OR (E10)
Fit the seal carrier plate (9); tighten the bolts to 1 ± 0,1 daN.m
Proceed in the same way for the other side
WarningMethod and tools for fitting the different seals according to their type (see removing-refitting: dynamic seals)
Fit the seals
Sump
Refit the sump
Tighten the 19 bolts (10) to 0,8 ± 0,1 daN.m
Engine flywheel
WarningThe screw holes (11) must be cleaned before refitting the screws (11)
WarningClean the contact surfaces between the crankshaft and the engine flywheel
Refit
- The flywheel
- The bolts (11)
WarningTighten one screw at a time in a star sequence
Tighten the bolts (11) to 7 ± 0,7 daN.m
Check the presence of the keyway on the crankshaft output
Refit the crankshaft gear (14)
Refit the screw (13) equipped with a washer
Pre-tighten the bolt (13) to 4 m.daN; angular tightening 45 ± 3°
Refit the coolant pump (12) using a new seal (tighten to 2 ± 0,2 m.daN)
Turn the crankshaft in the normal direction of rotation so that it can be pegged
Position the flywheel peg [1]
Cylinder head
Clean out with a tap the threads in the crankcase which accommodate the cylinder head screws (M10 x 150 tap)
Check the presence of the 2 centring pins (15)
Fit a new cylinder head gasket (inscriptions on top)
WarningCheck the length of the cylinder head bolts (see data)
WarningFit the cylinder head bolts coated with MOLYROTE G RAPID PLUS E3 on the threads and under the bolt heads
Refit
- The cylinder head (16)
- The 10 bolts (17)
Cylinder head tightening
WarningProceed bolt by bolt in the order shown
Tightening procedure
- Pre-tightening to 2 ± 0,2 daN.m
- Angular tighten to 260 ± 5 °; using tool [12]
WarningRetightening of the cylinder head after a repair is prohibited
Fill with oil the cylinder head cups located above the hydraulic push-rods
NoteClean the parts and the joint faces before refitting any of them
Refit the cylinder head covers (18)
Tighten the cylinder head cover bolts to 1 ± 0,2 m.daN; (in the order indicated)
NoteThe cylinder head covers have composite gaskets which can be used several times; if the seal is damaged, it can be partially repaired with sealing product AUTOJOINT (OR)
Refit
- The timing cover
- The camshaft pulleys; tighten the bolts to 4,5 ± 0,5 daN.m
Timing belt
Refit
- The roller tensioner (22)
- The nut (19)
- The tensioning roller (21)
- The (20) bolt
Tighten the bolts to 2 ± 0,2 daN.m
WarningFrom engine no. 1806405: there are 2 fittings of the roller tensioner, guide roller and camshaft pulley assemblies. mixing is forbidden
Peg the camshafts; using tools [4a] and [4b]
Fit the timing belt, strictly in the following order
- Intake camshaft pulley
- Exhaust camshaft pulley
- Roller tensioner
- Crankshaft pulley
- Water pump pulley
- Dynamic roller tensioner
Remove tools [1], [4a]and [4b]
Timing belt overtension
Rotate the roller tensioner (22) using an Allen key (at "b")
Position the index "d" in position "c"; tension the belt to the maximum of the space indicated
Hold the roller tensioner (22); using tool [5]
Tighten the nut (19) to 1 ± 0,2 daN.m
Turn the crankshaft 4 turns in the normal direction of rotation
WarningNever turn the crankshaft backwards
Check the setting of the valve timing by refitting the pegs [1], [4a] and [4b]
Remove setting rods [1], [4a]and [4b]
Fitting and tensioning the timing belt
Slacken the roller tensioner fixing nut, maintaining the position of the roller tensioner with the aid of a hexagonal spanner (at "b")
Bring the index "f" to its adjustment position "e"
WarningThe index "d" must not go past the slot "e". if it does, repeat the timing belt tensioning operation
Hold the roller tensioner (22) in this position, using an Allen key
Tighten the nut (19) to 2,2 ± 0,2 daN.m
WarningThe tensioning roller must not turn while its mounting is tightened. if it does, repeat the timing belt tensioning operation
Refit
- The timing housings
- The crankshaft pulley; tighten the bolts to 2 ± 0,2 daN.m
- The thermostat; tighten the bolts to 1 ± 0,2 daN.m
- The electric oil gauge; tighten the bolts to 3,2 ± 0,5 daN.m
- The oil filter bracket (new seal); tighten the bolts to 1 ± 0,2 daN.m
- The oil filter
- The filter element protective cover; tighten to 2,5 ± 0,2 daN.m
- The dipstick