Re-assembling: engine (DV4TD) Peugeot 207 Compact I

Engine flywheel

Position

• The flywheel (1) on the crankshaft
• The 6 bolts (2) (new screws)

Place the tool [3] in the hole located in the crankshaft bearing cap housing (at A)

Tightening method for the screws (2) (in the order indicated)

• Stage 1: pre-tightening to 2,5 daNm (order from 1 to 6)
• Stage 2: slacken the bolts (order from 1 to 6)
• Stage 3: pre-tightening to 0,8 daNm (order from 1 to 6)
• Stage 4: tighten to 1,8 ± 0,2 daN.m (order from 1 to 6)
• Stage 5: angular tightening to 75° (order from 1 to 6)

Clutch mechanism

Centre on the flywheel; using tool [43]

• The clutch friction plate (3)
• The clutch mechanism (4)

Fit the bolts (5); tightening to 2 ± 0,2 daN.m

Accessories drive pulley

Fit

• The pulley (6)
• The washer (7)
• The bolt (8) pre-coated with LOCTITE 273

Tightening of the bolt (8)

• Tightening to 3 ± 0,3 daN.m
• Angular tighten to 180 ± 5 °

Remove the peg [3]

Vacuum pump

Check that the vacuum pump location is free of residual jointing compound

Fit the vacuum pump (9) (new seals)

Tighten the 2 vacuum pump fixing bolts to 2 ± 0,2 m.daN

EGR valve

Position

• The tube (10) (equipped with a new seal); tighten the 2 bolts to 0,5 m.daN
• The tube (11); tighten the fixing bolt on the cylinder head to 1 ± 0,1 daNm
• The EGR valve (12) (equipped with a new seal); tighten the 2 bolts to 1 ± 0,1 daN.m

Fit 2 new clips (13)

Coolant inlet manifold

Fit

• The bracket (15); tightening to 1 ± 0,1 daN.m
• The coolant inlet manifold (14) (equipped with a new seal); tightening to 1 ± 0,1 daN.m

Exhaust manifold - turbocharger

Position

• The exhaust manifold seal (16)
• The exhaust manifold (17)
• The spacers (18)
• The 10 nuts (19); tightening to 2,5 ± 0,2 daN.m

Fit

• The 2 studs (21) (on the exhaust manifold (17)); tightening to 1 ± 0,1 daN.m
• The 2 studs (22) (on the turbocharger (20)); tightening to 1 ± 0,1 daN.m
• The turbocharger outlet duct (23)
• The 4 new screws (24); tightening to 2,5 ± 0,2 daN.m
• The (25) bolt; tightening to 0,5 ± 0,1 daN.m
• The turbocharger lubrication return end piece (26) (equipped with a new seal); tightening to 2 ± 0,2 daN.m
• The turbocharger (20) (on the exhaust manifold (17))

Tighten the 4 new fixing nuts securing the turbocharger on the exhaust manifold; tightening to 2,5 ± 0,2 daN.m

Fit the turbocharger lubrication return pipe (27) (fix using metal clips)

Position

• The turbocharger lubrication pipe (28)
• The union bolts (29), (30) fitted with new seals (moderately tighten)

Position the turbocharger lubrication pipe (28) in accordance with the gap "A" = 15 mm between the pipe and the machined assembly surface of the turbocharger cold turbine

Tighten the union bolt (29) to 2,5 ± 0,2 daNm

Position the turbocharger lubrication pipe (28) in accordance with the distance "B" = 65 mm between the pipe and the surface (rod side) of the crimp of the turbocharger regulation capsule

Tighten the union bolt (30) to 3 ± 0,3 daNm

Re-assembling

Fit

• The oil pressure switch (31); tightening to 3,2 ± 0,3 daN.m
• The upper dipstick guide (32); tightening to 1 ± 0,1 daN.m (on cylinder block)
• The bolt; tightening to 1 ± 0,1 daN.m
• The turbocharger heat shield (33); tighten the 2 bolts to 1 ± 0,1 daN.m

Fit

• The electric oil gauge (according to equipment); tightening to 2,7 ± 0,2 daN.m
• The fuel return pipe (34) (diesel injector holder)
• The vacuum pipes (35) ("EGR" electrovalve control)
• The fuel filter (36)
• The fuel filter support; tightening torque to 0,5 da.Nm
• The repriming pump
• The fuel pipes (37)
• The electrical harness (38) (diesel injector holder)

Fit

• The resonator (39) (oil the seal); tightening to 0,8 ± 0,1 daN.m
• The air filter assembly (check the position of the centring pins)
• The 2 bolts (40); tightening to 0,5 ± 0,1 daN.m
• The flow meter (41); tightening to 0,4 ± 0,1 daN.m
• The turbocharger (42) air inlet union
• The turbocharger (43) air outlet union

Accessory supports

Assembling: accessories - accessory supports

Assembling: accessories - accessory supports

Assembling: accessories - accessory supports

Assembling: accessories - accessory supports

Assembling: accessories - accessory supports