Refitting: engine (EW10A) Citroen C5 I facelift

Recommended tools

Refitting

Assembling the connecting rods/pistons

EW10J4S engine

Refit

• The gudgeon pin (2)
• The circlips (1) (new)

Method with PEUGEOT tooling

Place the tool [3] on tool [2]

Open the clamp "a"

Fully unscrew the pressure screws "b"

Fit the new pin (2) of the first piston on the tool [4]

Screw the tool [5] on the tool [4] (without tightening) (fully)

Position the piston (3) on the tool [3] and guide it using the handle, pin and guiding end piece assembly

Insert the pin (at "d")

Screw in the tappets until the piston makes contact (at "b")

Tighten the nuts (at "c")

Remove the pin (at "d")

Clamp the piston (3)

Place the conrod with its cap (without bearing shell) in the piston and centre it with the handle/pin/cone assembly

Adjust the height of the plate "e" to bring it into contact with the conrod

Adjust the position of the base "f" to obtain a clearance of A = 0,1 mm

Place the connecting rod little end on an electric heating plate

Place a piece of tin filler on each small end "g"

Heat until the piece of tin melts (temperature of 250°C approximately)

Fit the conrod into the piston, orientating the lubrication hole "h"

Rapidly insert the gudgeon pin (1) fully home

Wait a few seconds before removing the piston/con.rod assembly

Wipe off the drop of filler

Proceed likewise for the other three bearing sets

Method with CITROËN tooling

Place the gudgeon pin (2) on the tool [4]

Screw the handle [5] onto the tool [4] (without tightening)

The pin (2) must rotate freely

Place the tool [3] on tool [1]

Put piston (3) on tool [3]: directing arrow "Dist" upwards

Centre the whole assembly with mandrel [4] and the piston gudgeon pin

Retain the piston using clamp on the positioning base clamp

Place the connecting rod little end on an electric heating plate

Place a piece of tin filler on the small end "g"

Heat until the piece of tin melts (temperature of 250°C approximately)

Fit the conrod into the piston, orientating the lubrication hole "h": directing arrow "Dist" upwards

Rapidly insert the gudgeon pin (2) fully home

Wait a few seconds before removing the piston/con.rod assembly

Wipe the drop of tin

Proceed likewise for the other three bearing sets

Crankshaft

Place the grooved half shells (7) on the cylinder block(4)

Oil the half-bearing shells

Fit the crankshaft (6)

Position end float shims (5), rotating them round the crankshaft (grooved face on crankshaft side)

Check: crankshaft end float

Fit tools [6] and [7] onto the cylinder block (4)

Fit the dial gauge [8] onto supports [6] and [7]

Refit

• The crankshaft bearing caps casing (9)
• The bolts (8); tighten to 1 ± 0,1 daN.m

Push the crankshaft back and forth in the cylinder block

Set the dial gauge to zero

Push the crankshaft back and forth, on the opposite side, in the cylinder block

There should be a 0,06 to 0,15 mm endfloat

Adjust the crankshaft endfloat; using endfloat shims (if necessary)

Remove

• The bolts (8)
• The crankshaft bearing caps casing (9)

Crankshaft main bearing cap casing

Check that the locating dowels are in place (at "j")

Replacing a pin (if necessary)

• Insert 50% of the length of the pin into the bearing cap casing
• Crimp the pin; using a pin drift
• Flatten the top at "k" to secure the pin

Apply "AUTOJOINT NOIR" type sealing paste to the periphery of the bearing cap casing (9)

Refit

• The crankshaft bearing caps casing (8)
• The bolts (8) (M11)
• The bolts (10) (M6)

Tightening procedure

• Pre-tighten the bolts (8) to 1 ± 0,1 daNm
• Tighten the bolts (8) to 2 ± 0,2 daN.m
• Angular tightening 72 ± 5°; using tool [16]
• Tightening of the bolts (10) to 1 ± 0,1 m.daN

Connecting rod/piston assemblies

Position the rings with the ring pliers

The face of sealing ring (12) marked TOP should be uppermost

Direct ring gap (12) 180° with respect to ring gap (11)

Place the connecting rod/piston assembly in the tool [9] (lubricate all around)

Let the lower section (B) of the piston protrude to allow it to be correctly guided

Refit the correct upper half-bearing shell (see data)

Oil the cylinders

Observe the marks made during the dismantling operation

Arrow "Dist" of piston is directed towards the valve timing gear

Keep the assembly cone [9] in perfect contact with the sealing face of the cylinder head and centred in relation to the cylinder

Engage the piston, properly positioning the scraper ring

Proceed likewise for the other three bearing sets

Turn the cylinder block over

Refit

• The lower bearing shells (lubricated)
• The big end caps

Refit the conrod cap screws (14) (lubricated)

Using tools [12] and [14]

• Pre-tighten the bolts (14) to 1 ± 0,1 daNm
• Tighten the bolts (14) to 2,3 ± 0,2 daN.m
• Angular tightening 46 ± 5°

Oil pump

Apply "AUTOJOINT NOIR" type sealing paste around the edge of the sealing face of the oil pump

Refit

• The oil pump (16)
• The bolts (15); tighten to 0,8 ± 0,1 daN.m (coat the screws with LOCTITE FRENETANCH)

Sealing ring (timing side)

Place the tool [10b] on tool [10a]

Fit the new sealing ring (17) using the tool [10a]

Remove the tool [10b]

Fit the sealing ring (17) against the cylinder block; using tool [10a]

Sealing ring (flywheel side)

Place the tool [11b] on tool [11a]

Fit the new sealing ring (18) using the tool [11a]

Remove the tool [11b]

Fit the sealing ring (18) against the cylinder block using tool [11a]

Sump

Refit

• The anti-emulsion panel (20); tightening to 1,9 ± 0,2 daN.m
• The oil pump strainer (19) (with its new seal); tightening to 1,1 ± 0,1 daN.m

Check that pin is present (at "m")

Refit the sump (21)

Insert the bolts until they make contact without tightening them

Place a straightedge at "n" and adjust the sump so as to align it with the face of the cylinder block

Tighten the bolts (22), (24) of the sump (23) to 0,8 ± 0,2 m.daN

Cylinder head

Insert cylinder head gasket (25) (new)

Refit

• The cylinder head (27)
• The bolts (26)

Cylinder head tightening

Tightening procedure; use the tools [13], [14]

• Pre-tightening to 1,5 ± 0,2 daN.m (order from 1 to 10)
• Tighten to 5 ± 0,5 daN.m (order from 1 to 10)
• Slacken the bolts by 360° ± 2° (1 turn) (order from 10 to 1)
• Tighten to 2 ± 0,25 daN.m (order from 1 to 10)
• Angular tighten to 285° ± 5 ° (order from 1 to 10)