WarningObserve the safety and cleanliness recommendations
Tooling
Equipment
- Dial gauge
- Dial gauge support
- Approved cleaning product
- Grease type MOLYCOTE RAPID
- Seal paste (index "E10")
- Loctite (type "LOCTITE 570")
| tool | reference | designation |
|---|---|---|
| [750-T] | clip for fitting the piston rings on the engine | |
| [0194-L] | crankshaft ring seal fitting drift: (timing gear side) | |
| [0194-M] | seal fitting mandrel: crankshaft (flywheel side) | |
| [0194-P] | conrod half shell centring tool (thickness 2 + 3 mm) | |
| [0194-QZ] | crankshaft main bearing cap casing half shells positioning template | |
| [0194-C] | flywheel stop | |
| [0194-N] | camshaft carrier assembly peg | |
| [0194-W] | flywheel stop |
Preliminary operations
NoteClean the parts and the joint faces before refitting any of them
WarningThe parts must be clean and free from any trace of abnormal wear or impact
Check the condition of the following components (see corresponding procedure)
- Cylinder block
- Crankshaft
- Conrods
- Pistons
Refitting
WarningAdhere to the tightening torques
Preparing the cylinder block
Refit
- The grooved bearing shells (1)
- The crankshaft lateral clearance thrust washers (3) (lubrication grooves on the crankshaft side)
- The piston base jets (2)
NoteFor checking, rectification or replacement of these parts, refer to the data sections
Adjusting the crankshaft endfloat
Fit the crankshaft
Position
- The dial gauge support
- The dial gauge
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 0,07 to 0,322 mm endfloat
WarningSelect upper and lower adjusting shims of the same thickness for the same face of the crankshaft
Oil
- The crankshaft bearing faces
- The half bearing shells
WarningDo not apply oil to the cylinder block/crankshaft main bearing cap casing contact area
Remove the crankshaft
Connecting rod/piston assemblies
WarningNote the position and the matching of the conrod caps and conrods
Mark the position of the piston / conrod assemblies in relation to the corresponding cylinders
- Identify with the colour mark "b": on big end cap (clutch side)
- Mark the direction of fitting of the connecting rod: the boss "a" is oriented to the timing end
"c" engraving "DIST"
"d" spring retaining slots
"e" boss
"f" ring gap
"g" ring gap
"h" ring gap
WarningMark the orientation of the conrod in relation to the piston
WarningMark the direction of fitting of the pistons, the arrow (at "c") oriented to the timing end
NoteThe piston shafts are free-fitted in the little ends and the pistons, then laterally immobilised by means of two stop rings
Check the condition of the following components
- The conrods (7)
- The pistons (5)
- The piston shafts (6)
Refit the piston rings (8), (9) and (10)
NoteThe piston ring surfaces marked "TOP" must face upwards
Oil the piston shafts (6)
WarningObserve the direction of the conrod in relation to the piston
Refit
- The connecting rod (7)
- The piston (5)
- The shaft (6)
- The gudgeon pin retaining rings (4)
WarningObserve matching of the conrods/cylinders
WarningDirect the marking "DIST" engraved on the piston to the exhaust camshaft side and direct the arrow to the timing belt side
Check that the piston ring gaps "f", "g", "h" are facing in the right direction
Fit the tool [750-T]
NoteLet the lower section "A" of the piston protrude to allow it to be correctly guided
Oil
- The pistons
- The cylinders
- The conrod bearing shells
Refit the connecting rod/piston assemblies
Remove the tool [750-T]
WarningUse the adapted surfaces of the tools [0194-P]
Fit the half bearing shells (11) on the connecting rods (7); using the tools [0194-P]
Remove the tools [0194-P]
NoteTake care with the positioning of the connecting rod bearing shells (11)
Oil the upper bearing shells positioned on the connecting rods (7)
Fit the crankshaft
WarningObserve pairing of the conrods/big end caps
WarningKeep to the direction of fitting of the conrod caps (6) (do not damage the connecting rods)
Fit the half bearing shells on the big end caps; using the tools [0194-P]
Remove the tools [0194-P]
Oil the half-bearing shells
Lubricate the crankshaft crank pins lightly
Refit the big end caps (12) onto their respective conrods
Fit the bolts (13) (new)
Tighten the fixing bolts (13) to the correct torque
Crankshaft main bearing cap casing
Position the tools [0194-QZ] and [0194-N] on the crankshaft main bearing cap casing
Refit the smooth lower bearing shells (14)
Remove tools [0194-QZ] and [0194-N]
Check that the 10 centring pins are present on all the bearings (at "j")
Apply a bead of "E10" sealant to the edge of the cylinder block (at "k")
Fit the crankshaft main bearing cap casing on the cylinder block
WarningThe positioning operation must not take longer than 5 minutes (sealing)
NoteIt is essential to replace the bolts (15), (16), (17)
Refit the tools [0194-N] (as "l", "m")
WarningThe positioning operation must not take longer than 5 minutes
Apply thread lock on the threads of the 10 bolts (15)
Pre-tighten the bolts (15), (16), (17) by hand
Remove the tools [0194-N]
Tighten the fixing bolts (15), (16), (17) to the correct torque
Oil pump
Apply a bead of "E10" sealant to the edge of the cylinder block (at "n")
WarningThe positioning operation must not take longer than 5 minutes (sealing)
Fit the centralising pins (18)
Lubricate the interior of the oil pump with clean engine oil
Refit
- The oil pump (19)
- The bolts (20)
Tighten the fixing bolts (20) to the correct torque
Oil suction strainer - lower cover
Refit
- The oil suction strainer (23)
- The bolts (21)
- The lower gauge guide (22)
Oil sump (all engines except DV6U)
(24) oil sump
Apply a strip of sealing paste "E10" (at "p")
WarningThe positioning operation must not take longer than 5 minutes (sealing)
Refit
- The 2 studs (26)
- The oil sump (24)
- The 2 nuts (27)
- The bolts (25)
Immerse the 2 caps (28) in a bath of sealing product for 4 minutes minimum
Fit the bolts (28) until they are in contact with the base of the spot facing
Oil sump (engine DV6U)
(29) lower cylinder block
Apply a strip of sealing paste "E10" (at "q")
WarningThe positioning operation must not take longer than 5 minutes (sealing)
Refit
- The lower cylinder block (29)
- The bolts (25)
- The 2 studs (27)
- The 2 nuts (26)
Immerse the 2 caps (28) in a bath of sealing product for 4 minutes minimum
Fit the bolts (28) until they are in contact with the base of the spot facing
(30) oil sump
Apply a strip of sealing paste "E10" (at "r")
Refit the 2 studs (33)
Tighten the studs (33)
Refit
- The oil sump (30) (Of steel)
- The 2 nuts (32)
- The 8 securing bolts (31)
Ring seals (crankshaft)
WarningDo not lubricate the exterior of the sealing ring
WarningCheck the condition of the lip of the ring seal on its support
WarningCheck the absence of any mark on the bearings of the sealing ring
Fit tool [0194-M] on the crankshaft (flywheel side)
Refit the ring seal (34); using tool [0194-M] (hold for 5 seconds)
Remove the tool [0194-M]
Fit tool [0194-L] on the crankshaft (oil pump side)
Refit the ring seal (35); using tool [0194-L] (hold for 5 seconds)
Remove the tool [0194-L]
Piston protrusion
Clean the surfaces to be checked
NoteCheck the protrusion of the pistons in relation to the cylinder head seal surface ((2 check points "t"))
Place the dial gauge bracket on the cylinder block
Fix the dial gauge on the bracket
Set the dial gauge to zero (at "s")
Measure the height difference (at "t")
Calculate the average of the 2 values measured
NoteMaximum gap between two consecutive cylinders = 0,10 mm select the thickness of the cylinder head gasket in relation to the protrusion of the pistons. use the highest piston as a reference
Oil filter support
WarningTake care with the positioning of the seal in its location
Refit
- The oil filter bracket (38) fitted with a new seal
- The 4 bolts (37)
- The engine oil pressure switch seal (36)
- The engine oil pressure switch (36)
Crankshaft gear
WarningTake care not to distort the target (41) when refitting the crankshaft sprocket (39)
Refit
- The keyway of the crankshaft timing pinion
- The crankshaft gear (39) (carefully)
- The (40) bolt
Engine flywheel / double damped flywheel (according to equipment)
"A" single flywheel
"B" double damped engine flywheel
WarningUse new screws (42)
Refit
- The flywheel (43)
- The 6 bolts (42) (new)
WarningCheck the presence of the centring pins for the clutch mechanism (at "u")
"C" first possibility: DV engines all types
"D" second possibility: DV engines all types (not DV6U)
WarningTurn the crankshaft pulley to drive the engine in its normal direction of rotation (clockwise)
First possibility: (all engine types)
- Position a spacer of 8 mm between the tool [0194-W] and the engine casing (at "v")
- Fit the tool [0194-W]; using a bolt and a nut
Second possibility: (all engines except DV6U)
- Turn the crankshaft pulley to drive the engine in its normal direction of rotation (clockwise)
- Peg the engine flywheel; using tool [0194-C] (at "w")
WarningProceed bolt by bolt in the order shown (order from 1 to 6)
Tighten the 6 bolts (42) to the specified torque
Coolant pump - coolant inlet manifold
WarningTake care to position the coolant pump (46) seal in its location
Refit
- The dipstick cap (according to equipment)
- The oil level and temperature sensor (51) fitted with a new seal (according to equipment)
- The offset prevention angle bracket (48)
- The engine speed sensor (49)
- The guide roller of the timing belt (46)
- The timing roller tensioner (47)
- The coolant manifold (44)
- The coolant pump (45) complete with a new seal
- The bolts (50)
WarningProceed bolt by bolt in the order shown (order from 1 to 7)
Tighten the fixing bolts (50) to the correct torque