Engine re-assembly (DW12TED4) Peugeot 607 I

Refit

• The piston base jets (4) (tightening torque to 1.0 ± 0.1 da.Nm)
• The grooved half-shells (1)
• The side shims (2) - (3) (lubrication grooves (a) on the crankshaft side)
• Determine the thickness of the crankshaft bearing cap bushings

Fit the crankshaft

Position

• The dial gauge support [18]
• The dial gauge support [19]
• The dial gauge [16]

Press axially on the crankshaft in the cylinder block

Set the dial gauge to zero

On the opposite side, press axially on the crankshaft in the cylinder block

The side clearance must be between 0,07 and 0,32 mm

Oil

• The crankshaft seatings
• The half bearing shells

Refit

• The half bearing shells
• The main bearing caps (5)
• The side shims (6) (bearing no. 2)
• The bearing cap bolts (5) (without tightening it)

Apply FORMETANCH sealing compound to the corners and ends (b) of main bearing no. 1

Place tool [20] on the cap of bearing no. 1

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

Tighten the clamp [20a]

Position the half-shell (7) on the bearing cap

Place the side seals (8) in the groove of the bearing cap with the minimum of projection at (c)

Oil the two surfaces of the shims [20b] on the tool [20] above the heel at (d)

The side seals must have a minimum protrusion of approximately 1 mm

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

Position the main bearing on the centralising bushes

Tighten the 2 bolts in the bearing cap

Remove the tool [20] sideways

Tightening (from 1 to 10)

• The cylinders 2.5 ± 0.2
• Angular tightening to 60 ± 5° (using tool [21])

Refit the piston rings (9)

Refit

• The stop ring (10)
• The connecting rod (11)
• The shaft (12)
• The stop ring (13)

Check the direction of the gaps (g) - (h) - (j) in the piston rings

Position the piston rings collar [23]

Fit the half-shells (14) on the conrods (11)

Oil

• The cylinders
• The half bearing shells

Refit the conrods/pistons assemblies by using the fitting ring

Fit the half-shells conrod caps

Oil the half-bearing shells

Position the conrod caps (15)

Fit new bolts (16)

Tightening procedure (bolts (16))

• Tightening torque to 1.0 ± 0.1 da.Nm
• Slacken by 180 degrees
• Tightening torque to 2.3 ± 0.1 da.Nm
• Angular tightening to 45 ± 5° (using tool [21])

Refit the sealing ring using a mallet

Remove the tool [22a]

Fit the 2 bolts in tool [24] diagnonally in place of the 2 bolts

Refit the flywheel (17)

Centralise the engine flywheel using the cones of the tool [24]

Refit the 6 fixing bolts (18) in the engine flywheel (17)

Remove the tool [24]

Refit the last two bolts (18) fixing the engine flywheel (17)

Position the flywheel stop (tool [1])

Tighten the engine flywheel fixing bolts

• Pre-tighten the bolts (18) to 1.5 ± 0.1 dan.m
• Tighten the bolts (18) to 4.7 ± 0.4 m.daN

Remove the tool [1]

Balance shafts

Peg the engine flywheel (using tool [2])

Fit the adjustment 2 spacers [25]

Position the blind holes (k) of the balance shafts upwards

Insert the points Ø 5 mm of the tool [26] in the blind holes (k)

Fit the tool clamp [27] on the tool [26]

Lightly tighten the bolt of tool [27]

Refit the balance shafts ecu (19)

Engage the balance shafts ecu (19) on its centralising pins

Remove

• The tool [27]
• The tool [26]
• The flywheel peg

Refit the 8 bolts (20)

Tighten the 8 bolts (20) to 2.2 ± 0.2 m.daN (follow the order indicated)

Fit the tools [28a] - [28b]

Push the drive shaft to the stop

Set the dial gauge [16] to zero

Push the drive shaft back in the other direction

Measure the clearance

Remove the tools [14a] - [14b] - [3]

Fit the tools [28a] - [28b] - [16]

Push the driven balance shaft to the stop

Set the dial gauge [16] to zero

Push the driven balance shaft in the other direction

Measure the clearance

Fit the tools [28a] - [28b] - [16] - [29] - [30]

Lock the drive balance shaft with the tool [29]

Position the tolerance measurement rule [30] on the driven balance shaft, on the centre line of the balance shafts

Tighten the bolt in the tool [30]

Set the dial gauge [16] to zero

Record the tolerance using the tool [30]

Remove the tools

Fit

• The tolerance measurement rule [30]
• The dial gauge bracket stem [28a]
• The dial gauge support [28b]
• The dial gauge [16]

Fit the tolerance measurement rule [30] on the centre line of the balance shafts

Tighten the bolt in the tool [30]

Set the dial gauge [16] to zero

Press on the balance shaft at (l) (to the stop)

Record the tolerance using the tool [30]

Unscrew the bolt of the tool [30]

Rotate the crankshaft in the normal direction of engine rotation in such a way as to obtain a quarter turn of the balance shafts

Reposition the rule giving the tolerance [30]

Set the dial gauge [16] to zero

Record the tolerance using the tool [30]

Carry out again 7 times the operation for recording the tolerance (1 crankshaft turn)

Take into consideration the minimum tolerance value when selecting the adjustment spacers (in the table below)

Remove

• The tools [30] - [16] - [28b] - [28a]
• The 8 bolts (20)
• The balancing shafts housing (19)
• The adjustment spacers [25]

Refit

• The spacers determined in relation to the minimum tolerance and the table
• The balancing shafts housing (19)
• Tighten the 8 bolts (20) to 2.2 ± 0.2 m.daN (follow the order indicated)

Check the adjustment

• Carry out 9 tolerance checks according to the method previously described
• The clearance should be between 0,01 and 0,07 mm

A: play less than 0,01 mm; select the thickest spacer before the one used

Example: thickness determined 1,43 mm; if the play is insufficient when checked fit a 1,45 mm thick spacer

B: play greater than 0,07 mm; select the finest spacer after the one used

Example: thickness determined 1,31 mm; if the play is too great when checked fit a 1,29 mm thick spacer

Refit the oil pump

Apply a AUTOJOINT OR bead of sealant around the edge of the cylinder block

Refit

• The cylinder block (21)
• The 2 bolts (22)
• The 20 bolts (23)

Tighten the bolts (23) - (22) to 1.6 ± 0.2 m.daN

Refit

• The clutch disc
• The clutch mechanism (24)
• The bolts (25)

Centre the clutch disc using the tool [32]

Fit the tool [1]

Tighten the bolts (25) to 2.0 ± 0.1 m.daN

Remove the tool [1]

Coat the bolt threads (26) with the product FRENBLOC on the cylinder block side

Refit the heat exchanger (27)

Tighten the bolt (26) to 5.8 ± 0.2 daN.m

Refit

• The oil filter (28)
• The oil pressure switch (29) (fitted with a new seal) (tightening torque to 3.2 ± 0.2 da.Nm)

Place the dial gauge bracket [13] on the cylinder block

Fix the dial gauge [16] on the bracket [13]

Set the dial gauge [16] to zero (as (m))

Check the difference in height at (n)

Position the pistons at mid-stroke

Refit

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

Fit

• The camshaft
• The diesel high pressure pump
• The timing belt

Tightening procedure

• Pre-tighten to 2.2 ± 0.2 daNm
• Tightening torque to 6.0 ± 0.5 da.Nm
• Unscrew by 1 turn(s) (360°)
• Tightening torque to 6.0 ± 0.5 da.Nm
• Angular tightening to 220 ± 5° (using tool [21])

Refit

• The roller tensioner guide (30)
• The valve rockers (31) controlling the valves with their hydraulic tappets (mark their positions)

Refit

• The lower timing cover (32)
• The intermediate timing cover (33)
• The top timing cover (34)
• The pulley (35)
• The washer (36)
• The (37) bolt

Fit the tool [1]

Tighten the bolt (37) to 4.0 ± 0.4 daN.m

Remove the tool [1]

Preparation for fitting a diesel injector

• Clip the clamp (38) onto its retaining ring
• Position the centralising ring (39) on the diesel injector (40)

Refit

• The seals (41) (new)
• The diesel injectors (40)
• The nuts (42) (without tightening it)

Refit

• The engine degassing tube
• The fuel high pressure common injection rail (43)
• The oil remover with the hose (44)
• The 4 new fuel high pressure pipes (45)
• The new fuel high pressure pipes (46)

Fully tighten manually to the end of the thread

• The pipe connectors (45) on diesel injectors
• The pipe connectors (45) on the fuel high pressure common injection rail
• The union for the pipe (46) on the high pressure fuel pump
• The pipe connector (46) on the fuel high pressure common injection rail

Refit the clips separating the fuel high pressure pipes

Tighten the nuts (42) to 0.4 ± 0.04 dan.m (using the tools [37] - [38])

Observe the following angular tightening method

• Position the identifying zero (x) of the tool [39] facing the operator
• Move the detachable index (w) of the tool [39] and place it opposite graduation 45 °
• Gradually tighten the bolt, in a single operation, bringing back the detachable index (w) opposite the identifying zero (x) of the tool [39]
• Carry out angular tightening by 45 ± 5° of the nuts (42) (using the tools [37] - [39] - [40})

Tighten the unions on the diesel injectors to 2.5 ± 0.2 daNm using tools [41] - [42] - [38]

Tighten the unions on the high pressure common injector rail to 2.5 ± 0.2 daNm using the tools [43] - [42] - [38]

Refit the diesel injector fuel return rail

Tighten the union (47) to 2.5 ± 0.2 da.Nm (using the tools [41] - [38])

Tighten the union (48) to 2.5 ± 0.2 da.Nm (using the tools [41] - [42] - [38])

Refit

• The fuel supply and return piping
• The fuel filter assembly (49) from its bracket

Refit

• The exhaust manifold seal
• The exhaust manifold (50)
• The 9 spacers with the 9 nuts (51)
• The heat exchanger (52)
• The pipe (53)
• The clips (54) - (55) (using tool [10])