Refitting: DW10 engine (DW10ATED4) Citroen C8 I

Tooling

Refitting

Preparing the cylinder block

Refit

• The piston base jets (4); tighten to 1 daN.m
• The grooved bearing shells (1)
• The lateral shims (2) and (3) (lubricating grooves "a" on the crankshaft side)
• Determine the thickness of the crankshaft bearing cap shells, by using the table in the specifications chapter

Adjusting the crankshaft endfloat

Fit the crankshaft

Position

• The dial gauge support [1]
• The dial gauge support [2]
• The dial gauge [3]

Press on the end of the crankshaft in the cylinder block

Set the two gauges to zero

Press on the opposite end of the crankshaft in the cylinder block

There should be a 0,07 to 0,32 mm endfloat

Crankshaft bearing caps

Bearing caps 2/3/4 and 5

Oil

• The crankshaft seats "b"
• The half bearing shells (7)

Refit

• The half bearing shells (7)
• The main bearing caps (5)
• The lateral shims (6) of bearing no. 2
• The bearing cap screws (5) (without tightening)

Bearing cap no. 1

Place E4 sealing paste in the angles and extremities "c" of bearing no. 1

Position tool [4] on the cap of bearing no. 1 (8)

The shim slide must be in the extension of surface of the bearing cap

Tighten the clamp [4a]

Place the bearing shell (9) on the bearing cap

Insert side seals (10) in the bearing cap groove, with the minimum protrusion at "d"

Oil both faces of the shim plates [4b] on tool [4] above the lip at "e"

The lateral seals should stand proud at least one millimetre

Engage the bearing cap/side seal assembly by tilting it in the cylinder block

Position the main bearing on the centralising bushes

Do up the 2 screws of the bearing cap (8)

Remove the tool [4] sideways

Tightening the bearing caps

Tightening

• The cylinders 2,5 (order from 1 to 10)
• Tighten by an angle of 60 ± 5 ° with tool [5] (order from 1 to 10)

Assembling the conrod/piston/piston ring assemblies

Refit the piston rings (11)

Refit

• The circlip (15)
• The connecting rod (14)
• The shaft (12)
• The circlip (13)

Connecting rod/piston assemblies

Check that the piston ring gaps "h", "j", "k" are facing in the right direction

Place ring collar [7]

Fit the half bearing shells (16) on the connecting rods (14)

Oil

• The cylinders
• The half bearing shells (16)

Refit the connecting rod/piston assemblies

Fit the half-shells conrod caps

Oil the half-bearing shells

Position the conrod caps (17)

Fit the bolts (18) (new)

Tightening method for the screws (18)

• Tighten to 2 daN.m
• Tighten by an angle of 70 ° with tool [7]

Rear bearing shell seal ring

Refit the ring seal; using a mallet

Remove the tool [6a]

Engine flywheel

Fit the 2 screws of the tool [8]

Refit the engine flywheel (19)

Centralise the engine flywheel using the cones of the tool [8]

Refit the 6 bolts (20) (new)

Remove the tool [8]

Refit the last two screws (20) (new)

Fit the tool [9]

Tightening procedure

• Pre-tighten the bolts (20) to 1,5 dan.m
• Tighten the bolts (20) to 4,7 m.daN

Oil pump

Refit simultaneously

• The pinion (24)
• The chain (25)
• The oil pump (21)

Refit the bolts (22) (respect the marks made at the time of removal)

Tightening method for the screws (22)

• Pre-tightening to 0,7 daNm
• Tighten to 0,9 daN.m

Push the pinion (24) towards the cylinder block

Refit the key (23)

Engage the pinion (24) on the keyway (23) of the crankshaft

Front sealing panel

Deposit a bead of "E4" on the sealing plate (26)

Refit

• The sealing panel (26)
• The bolts (27); tighten to 1,4 daN.m

Crankshaft seal ring (timing side)

Refit the ring seal; using tool [17a]

Remove the tool [17a]

Lower cover

Deposit a sealing bead of "E10" on the surround of the cylinder block

Remove

• The sump (28)
• The 2 bolts (30)
• The 20 bolts (29)

Tighten the bolts (29) and (30) to 1,6 m.daN

Clutch

Refit

• The clutch disc
• The clutch mechanism (32)
• The bolts (31)

Centre the clutch disc using the tool [18]

Fit the tool [9]

Tighten the bolts (31) to 2 m.daN

Remove the tool [9]

Heat exchanger - oil filter

Coat the threading of the screw (35) with the product (E6) (cylinder block side)

Refit the heat exchanger (34)

Tighten the banjo bolt (35) to 5,8 daNm

Refit

• The oil filter (36)
• The switch (33) (equipped with a new seal); tighten to 3,2 daN.m

Piston protrusion

Fit dial gauge support [19] to the cylinder block

Secure dial gauge [3] to support [19]

Set the dial gauge [3] to 0 (at "l")

Record the height difference at "m"

Cylinder head (DW10TD and DW10ATED engines)

Check for the presence of the centring pins at "n"

Peg the camshaft; using tool [20]

Refit

• Cylinder head gasket (new)
• The cylinder head

Brush and oil the threads of the cylinder head bolts

Cylinder head tightening (DW10TD and DW10ATED engines)

Tightening procedure

• Pre-tightening to 2,2 daNm
• Tighten to 6 daN.m
• Untighten by 1 turn (360°)
• Tighten to 6 daN.m
• Angular tightening of 220 ± 5 °; using tool [5]

Refit

• The seal (37) (new)
• The seal (39) (new)
• The vacuum pump (38)

Tighten

• Tighten the bolts to 2 m.daN
• Tighten the nuts to 2 daN.m

Refit the cylinder head cover equipped with a new gasket

Tighten the screws (40) by hand

Tighten the bolts (40) to 1 m.daN (order from 1 to 9)

Cylinder head (engine DW10ATED4)

Position the pistons at mid-stroke (horizontal keyway (23))

Refit

• The cylinder head gasket
• The cylinder head
• The cylinder head bolts

Tightening procedure

• Pre-tightening to 2,2 daNm
• Tighten to 6 daN.m
• Untighten by 1 turn (360°)
• Tighten to 6 daN.m
• Angular tightening of 220 ± 5 °; using tool [5]

Refit

• The slide pad (41)
• The valve rockers (42) with their hydraulic followers (respect the marks made on removal)

Camshafts

Position the chain (44) on the pinions (45) and (43)

Bring the links marked in black "o" and "r" onto the teeth marked "p" and "q" on the camshaft drive pinions (45) and (43)

Refit the chain and camshaft assembly

Apply sealing product LOCTITE 518 around the camshaft bearing cap cover (49)

Refit

• The camshaft bearing cap cover (49)
• The 28 bolts (47)
• The 8 pillar screws (48)
• The camshaft chain tensioner (50)
• The exhaust camshaft drive hub (51)
• The (46) bolt

Peg the exhaust camshaft drive hub (51) using tool [20]

Pre-tighten

• The 28 screws (47) by hand (in the order shown)
• The 8 studs (48) by hand (in the order shown)

Tighten

• The 28 bolts (47) to 1 daNm (in the order shown)
• The 8 bolts (48) to 1 daNm (in the order shown)

Sealing ring (exhaust camshaft)

Refit the ring seal; using tool [22]

Remove the tool [22]

Refit

• The cylinder head cover (53)
• The 13 bolts (52)

Tighten the 13 bolts (52) to 0,9 m.daN (order from 1 to 13)

Refit and adjust the camshaft position sensor (engines all types)

Refit

• The camshaft position sensor (55)
• The (54) bolt

Adjustment

• Push back the camshaft position sensor to the end of the slots
• Adjust the airgap of the camshaft position sensor 1,2 mm

Tighten the bolt (52) to 2 daN.m

High pressure fuel pump

Refit

• The bracket (57)
• The bolts (56)

Tighten the bolts (56) to 2 m.daN

Refit

• The fuel high pressure pump (58)
• The 3 bolts (60)
• The (59) bolt

Tighten the 3 bolts (60) to 2 m.daN

Tighten the bolt (59) to 2,2 daN.m

Timing gear (prior to RPO No.: 9127)

Refit

• The camshaft pinion (74) and its fixing screw (61)
• The bolts (62)
• The crankshaft pinion (69)
• The fuel high pressure pump pinion (66)
• The nut (65)
• The tensioning roller (67)
• The (68) bolt
• The coolant pump (70) (equipped with a new seal)
• The engine mounting (64)
• The screws (73) and (63)
• The roller tensioner (72)
• The (71) bolt

Tightening torques

• Tighten the bolt (61) to 4,3 daN.m
• Tighten the bolt (68) to 4,3 daN.m
• Tighten the nut (65) to 5 m.daN; using tool [27]
• Tighten the 10 (73) diameter screws to 4,5 m.daN
• Tighten the 8 mm (63) diameter screw to 2 m.daN

Fit the crankshaft setting rod; Using the tool [10] or [14] (depending on the flywheel)

Set the camshaft hub; using tool [20]

Retighten the screws (62) by hand

Turn the pinion (74) in a clockwise direction so that it is at the end of the slot

Refit the timing belt (75) on the crankshaft sprocket (69)

Retain the belt with the tool 23

The bolt with the washer "s"

• Roller tensioner (67)
• Fuel high pressure pump pinion (66)
• Camshaft pinion (74)
• Water pump pinion (70)
• Roller tensioner (72)

Remove the tool [20]

Fit the tension measuring instrument [24] to the belt strip "t"

Turn the roller tensioner (72) anti-clockwise, using tool [25], to obtain an excess tension of 106 ± 2 SEEM units

Tighten the roller tensioner bolt (71) to (72) to 2,5 daNm

Remove one screw (62) from pinion (74) in order to check that the bolts are not against the end of the slots

Tighten the bolt (62) to 2 daN.m

Remove tools [25], [24], [20] and [14]

Turn the crankshaft 8 turn(s) in the direction of running

Fit tool [10] or [14] (depending on the flywheel)

Slacken the bolts (62)

Fit the tool [20]

Loosen the screw (71) to free the roller tensioner (72)

Fit the tool [24]

Rotate the roller tensioner anti-clockwise with tool [25] to obtain a tension of 51 ± 3 SEEM units

Tighten the roller tensioner bolt (71) to (72) to 2,5 daNm

Tighten the bolts (62) to 2 m.daN

Remove the tool [24]

Fit the tool [24]

The tension figure must be 51 ± 3 seem units

Remove tools [20], [24] and [10] or [14] (depending on the flywheel)

Turn the crankshaft 2 turn(s) in the direction of running

Fit

• Tool [10] or [14] (depending on the flywheel)
• The tool [20]

Remove tools [20] and [10] or [14] (depending on the flywheel)

Timing belt (from RPO No.: 9128)

Peg the engine flywheel; Using the tool [10] or [14] (depending on the flywheel)

Peg the crankshaft pinion (69) by inserting the tool [16] on the left hand side of the key

Fit the tool [20]

Place the timing belt (75) on the pulley (74)

Fit the tool [15] (tighten moderately)

Reposition the timing belt, with the section "t" well-tensioned, in the following sequence

• Fuel high pressure pump pulley (66)
• Roller tensioner (67)
• Crankshaft gear (69)
• Water pump pinion (70)
• Roller tensioner (72)

Fit the tension measuring instrument [24] to the belt strip "t"

Remove tools [15] and [16]

Turn the roller tensioner (72) anti-clockwise, using tool [25], to obtain an excess tension of 98 ± 2 SEEM units

Tighten the roller tensioner bolt (71) to to 2,5 daNm

Lock the flywheel by means of tool [9]

Refit the accessories drive pulley

Tightening of the accessories pulley screw tightening to 7 m.daN

Remove tools [20], [24] and [10] or [14] (depending on the flywheel)

Turn the crankshaft 8 turns in the normal direction of rotation

Peg

• The crankshaft Using the tool [10] or [14] (depending on the flywheel)
• The camshaft drive pulley; using tool [20]

Lock the flywheel; using tool [9]

Unscrew

• The accessories pulley
• The bolt (71) of the roller tensioner (72)

Fit the tool [24]

Rotate the roller tensioner with tool [25] to reach a tension of 54 ± 2 SEEM units

Tighten the roller tensioner bolt (71) to (72) to 2,5 daNm

Remove the tool [24]

Fit the tool [24]

The tension figure must be 54 ± 3 seem units

Tighten the ancillary drive belt fixing bolt to 7 daNm

Remove tools [20], [24] and [10] or [14] (depending on the flywheel)

Turn the crankshaft 2 turns in the normal direction of rotation

Peg

• The crankshaft Using the tool [10] or [14] (depending on the flywheel)
• The camshaft drive pulley using tool [20]

Refit tool [9]

Place a jack with a wooden shim under the oil sump to support the engine on removal of the right-hand engine mounting

Refitting (engines all types) (continued)

Refit

• The lower timing cover (78)
• The intermediate timing cover (77)
• The top timing cover (76)

Refit

• The ancillary drive pulley (81)
• The washer (80)
• The (79) bolt

Fit the tool [9]

Tighten the bolt (79) to 5 daN.m. finish with an angular tightening of 62 ± 5 °

Remove the tool [9]

Diesel injector (DW10TD and DW10ATED engines)

Remove the closers (7)

• From the diesel injector holes
• From the diesel injectors

Refit

• The shims (86)
• The seals (84)
• The sealing rings (85) (new)
• The diesel injectors (83)
• The clamps (87)
• The cups (88)
• The nuts (82) (new) (without tightening)

Refit the diesel injector high pressure supply pipes as follows

• Fit the diesel injector pipes for cylinders 2 and 4
• Tighten the unions on the diesel injectors and on the fuel high pressure common rail by hand to the end of the thread
• By means of the tools (82) tighten to 2 dan.m the nuts 4 fixing the cylinder injectors 3 and [27], [32]
• Fit the diesel injector pipes for cylinders 1 and 3
• Tighten the unions on the diesel injectors and on the fuel high pressure common rail by hand to the end of the thread
• By means of the tools (82) tighten to 1 dan.m the nuts 3 fixing the cylinder injectors 3 and [27] et [32]

Apply a counter-torque at "u"

Tighten the unions on the diesel injectors to 2,5 daN.m; by means of tools [27], [30] and [32]

Tighten the unions on the fuel high pressure common injection rail to 2,5 ± 0,2 m.daN using tools [27], [32] and [30] or [31] (depending on the type of high pressure fuel common injection rail)

Diesel injector (engine DW10ATED4)

Preparing a diesel injector

• Clip the flange (89) on its circlip
• Fit the centring ring (85) on the diesel injector (83)

Refit

• The new seals (84)
• The diesel injectors (83)
• The nuts (90) (without tightening)

Refit

• The engine degassing tube
• The fuel high pressure common injection rail (94)
• The oil trap with the hose (92)
• The 4 new high pressure fuel pipes (91)
• The high pressure fuel pipes (93)

Fully tighten manually to the end of the thread

• The unions of the tubes (91) on the diesel injectors
• The unions of the tubes (91) on the fuel high pressure injection common rail
• The union of tube (93) on the fuel high pressure pump
• The union of tube (93) on the fuel high pressure injection common rail

Refit the holding clips of the fuel high pressure tubes

Tighten the nuts (90) to 0,4 daN.m; using tools [26] and [11]

Observe the following angular tightening method

• Position the zero marked "v" of the tool [28] to face the operator
• Move the detachable index "w" of the tool [28] and place it opposite graduation 45 °
• Tighten progressively and in one single action, bringing the mobile index "w" opposite the zero (marking "v") of the tool [28]
• Carry out an angular tightening of 45 ± 5° of the nuts (90); by means of tools [26], [28] and [29]

Apply a counter-torque at "x"

Tighten the unions on the diesel injectors to 2,5 daN.m; by means of tools [30], [32] and [27]

Tighten the high pressure common rail fuel unions to 2,5 m.daN; by means of tools [12], [32] and [27]

Refit the diesel injector fuel return rail

Apply a counter-torque (at "x")

Tighten the union (95) to 2,5 da.Nm; using tools [30] and [27]

Tighten the union (96) to 2,5 da.Nm; by means of tools [30], [32] and [27]

Refit

• The fuel supply and return piping
• The fuel filter (97) (complete)

Refit

• The exhaust manifold gasket
• The exhaust manifold (102)
• The 8 spacers with the 8 nuts (103)
• The heat exchanger (100)
• The tube (98)
• The collars (99) and (101); using tool [13]