Re-assembling: engine (EW10J4) Peugeot 607 I

Place the tool [8c] on tool [7]

Open the clamp (a)

Fully unscrew the pressure screws (b)

Fit the gudgeon pin (1) of the first piston on the guide end piece [8]

• [8a] EW7J4 engine
• [8b] EW10J4 engine
• [8c] EW10D engine

Tighten the handle [9] (to the maximum) by hand without using force

Position the piston on the tool [8c], with the arrow and the dist marking facing upwards

Position the piston on the tool [8a] - [8b] - [8c] (depending on the engine) and guide it with the handle, pin and guide adaptor assembly

Insert the pin (d)

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

Tighten the nuts: as (c)

Remove the pin (d)

Clamp the piston (2)

Place the connecting rod with its cap (without shells) in the piston and centralise it with the handle/gudgeon pin end piece assembly

Adjust the height of the support (e) to bring it into contact with the conrod

Adjust the position of the support (f) to obtain a clearance of A = 0.1 mm

Place the connecting rods on an electric heater

Place a scrap of tin solder (g) on each little end

Apply heat until the weld melts (temperature of 250 °C) (approximately)

Place the conrod in the piston, positioning 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

Fit the grooved main bearing half-shells (5), on the cylinder block side (6)

Oil the half-bearing shells

Fit the crankshaft (3)

Position the thrust washers (4) by making them turn on the crankshaft (grooved face on the crankshaft side)

Check: crankshaft end float

Position the tools [10] - [11] on the cylinder block

Fix the dial gauge [12] on the brackets [10] - [11]

Refit

• The crankshaft main bearings cap castings (8)
• The 10 bolts (7); tightening to 1.0 ± 0.1 daN.m

Press axially on the crankshaft 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 an endfloat of 0.06 to 0.15 mm

Remove

• The 10 bolts (7)
• The crankshaft main bearings cap castings (8)

Check the presence of the pins (j)

Replacement of a pin (if necessary)

• Insert 50% of the length of the pin into the bearing cap casing
• Insert the pin at "(k)" using a drift
• Caulk the beading(k) to immobilise the pin

Apply sealant AUTOJOINT NOIR around the edges of the main bearing cap castings

Refit

• The crankshaft main bearings cap castings (8)
• The 10 bolts (7)
• The 16 bolts (9)

Tightening torques

• Pre-tighten the bolts (7) to 1.0 ± 0.1 daNm; using the tools [16] - [22]
• Pre-tighten the bolts (9) to 0.2 ± 0.1 daNm
• Pre-tighten the bolts (7) to 1.0 ± 0.1 daNm
• Slacken the bolts (7)
• Tighten the bolts (7) to 2.0 ± 0.1 daN.m
• Carry out angular tightening of 70 ± 1 °
• Tighten the bolts (9) to 1.0 ± 0.1 daN.m

Fit the rings using ring pliers

The face of sealing ring (11) marked TOP should be uppermost

Turn the gap of the ring (11) 180 degrees in relation to the gap of ring (10)

Position the piston/conrod assembly through the adapted ring [13a] - [13b] (lubricate the edges)

Allow portion (B) of the piston to protrude, in order to provide a guide for it

Refit the correct upper half-bearing shell

Lubricate the cylinders

Respect the marks made on dismantling

The piston arrow is directed towards the timing gear

Maintain contact between the whole of the piston rings assembly bush [13a] - [13b] and the joint face of the cylinder block, centralised in relation to the cylinder

Engage the piston taking care to correctly position the oil control ring (uflex)

Proceed in the same way for the other assemblies

Turn the cylinder block over

Oil

• The sleeves
• The lower half-shells

Refit the conrod caps

Refit the (lubricated) big end cap bolts (13)

Using the tools [17] - [22]

• Pre-tighten the bolts (13) to 2.3 ± 0.1 daNm
• Carry out angular tightening of 45 ± 5 °

Coat the oil pump joint surface with sealing compound AUTOJOINT NOIR

Refit: the oil pump (14)

Coat with LOCTITE FRENETANCH the bolts (15)

The bolts (15)

Tighten the bolts (15) to 0.8 ± 0.1 daN.m

Place the tool [14b] on tool [14a]

Fit the new sealing ring (16) using the tool [14a]

Remove the tool [14b]

Position the sealing ring with tool [14a] using the cylinder block as a support

Place the tool [15b] on tool [15a]

Fit the new sealing ring (17) using the tool [15a]

Remove the tool [15b]

Position the sealing ring (17) with tool [15a] using the cylinder block as a support

Refit

• The panel (19)
• Fill gearbox (18) with oil and ensure correct level
• Coat the cylinder block joint face with a thin even coat of AUTOJOINT NOIR sealing compound

Check that pin (I) is present

Refit the sump (20)

Offer up the bolts until there is contact, without tightening them

Position an adjusted rule at (m) and adjust the sump to align it with the surface of the cylinder block

Tighten the bolts (21) and the bolts (22) of the sump to 0.8 ± 0.2 dan.m

Refit

• The flywheel (23)
• The screws (24) (new)

Fit the tool [18]

Move the bolts (24) until there is contact with the engine flywheel

In order 1 - 5 - 3 - 7 - 2 - 6 - 4 - 8

• Tighten the bolts to 2.0 ± 0.2 daN.m
• Tighten 26° ± 3 degrees

Put the cylinder head gasket (25) in place (new)

C - EW10D engine

D - EW7J4 - EW10J4 engines

Refit

• The cylinder head (27)
• The 10 bolts (26)

Tightening torques; use the tools [17] - [22]

• Pre-tighten to 1.5 ± 0.2 daNm
• Tightening to 5.0 ± 0.5 daN.m
• Slacken the bolts by 360 ± 2° (1 turn(s))
• Tightening to 2.0 ± 0.25 daN.m
• Angular tightening to 285 ± 5°

Refit

• The hydraulic followers
• The rockers
• The camshafts

Coat the joint face of the camshaft main bearings cap castings with sealant AUTOJOINT NOIR as a uniform bead of approximately ø 3,5 mm

Replace the camshaft main bearings cap castings on the cylinder head

Check the protrusion of the camshaft in relation to the cylinder head E = 8.0 ± 0.2 mm

Offer up the 23 fixing bolts (28) and tighten them until there is contact

Tighten the bolts to 0.9 ± 0.1 daN.m

Refit the coolant pump

Tighten the coolant pump

Proceed bolt by bolt in the order shown (1 - 2 - 3 - 4)

• Pre-tighten to 0.3 ± 0.1 daNm
• Pre-tighten to 0.8 ± 0.1 daNm
• Pre-tighten to 1.4 ± 0.1 daNm

Refit

• The roller tensioner (40)
• The (39) bolt
• The casing (31)
• The pinion (30)
• The (29) bolt
• The pinion (33)
• The (32) bolt
• The tensioning roller (35)
• The (34) bolt
• The crankshaft gear (36)
• The flange (37)
• The (38) bolt
• The tool [19]

Immobilise the exhaust camshaft using an open-ended spanner on the flats (q)

Tighten the bolt (29)

• Pre-tighten to 3.0 ± 0.5 daNm
• Tightening to 7.5 ± 0.7 daN.m

Immobilise the intake camshaft using an open-ended spanner

Tighten the bolt (32)

• Pre-tighten to 3.0 ± 0.5 daNm
• Tightening to 7.5 ± 0.7 daN.m

Position the camshaft setting rods using the tool [20]

Immobilise the intake camshaft using using the tool [26]

Refit

• The inlet camshaft dephaser (44) (vtc)
• The variable timing camshaft bolt (new)
• The pinion (41)
• The (42) bolt

Tighten the variable timing camshaft bolt

• Pre-tighten to 3.0 ± 0.5 daNm
• Tightening to 5.5 ± 0.5 daN.m

Fit a new variable timing camshaft cap (43)

Remove the tool [26]

Cut out a piece of worn timing belt (r) to a minimum length of 10 teeth and insert between the camshaft pulleys in order to immobilise them

Tighten the bolt (42)

• Pre-tighten to 3.0 ± 0.5 daNm
• Tightening to 8.5 ± 0.5 daN.m

Insert the pins to locate the camshaft pulleys using the tools [20] - [21]

Refit the belt (45) on the crankshaft pinion (36)

Retain the belt (45) using the tool [23]

Fit the timing belt (observing the following order)

• The crankshaft gear (36)
• The tensioning roller (35)
• The intake camshaft pulley (33)
• The exhaust camshaft pulley (30)
• The coolant pump (46)
• The roller tensioner (40)

Remove

• The tool [23]
• The tool [20] from the exhaust camshaft pulley

Turn the roller tensioner (40) in the direction of the arrow (t) using a hexagonal recessed spanner at (u)

Position the index (y) correctly at (w) using a hexagonal recessed spanner (u)

Then bring the index (y) to its setting position (x) turning the roller tensioner in the direction of the arrow (v)

Tighten the roller tensioner bolt (40) to 2.1 ± 0.2 daN.m

Turn the crankshaft 10 turns in the normal direction of rotation

Set the rods in the intake camshaft pulley using tool [20] or [21]

Fit the tools [20] - [21] - [19] (depending on engine type)

If it is possible to fit tool [19], continue replacement operations

Immobilise crankshaft; using tool [25]

Loosen screw (38) to release pinion (36) from crankshaft

Position flange (37) at timing point; using tool [25]

Fit the tool [19]

Immobilise crankshaft; using tool [25]

Assemble with steel washer (gold colour)

• Tightening to 4.0 ± 0.2 daN.m
• Angular tightening to 53 ± 4°; using tool [22]

Assemble with sintered steel washer (colour of metal)

• Tightening to 4.0 ± 0.2 daN.m
• Angular tightening to 40 ± 4°; using tool [22]

Remove the tools [20] - [21] - [19] - [25] (depending on engine type)

Refit

• The timing housings (52), (47)
• The engine mounting (48)
• The roller tensioner (49)
• The pulley (50)
• The bolts (51)

Tighten the bolts (51) to 2.1 ± 0.2 daN.m

Refit

• The cylinder head cover (54)
• Cylinder reference sensor (55)
• The 22 bolts (53)
• The ignition coils block (57)
• The 3 bolts (56)

Offer up the bolts (53) until they contact the cylinder head covers (54)

Tighten the bolts (53) to 1.1 ± 0.1 daN.m

Coat all round the gasket with sealant

Refit

• The cylinder head covers onto 2 wooden shims
• The seal by hand into its housing

Position the gasket as far as the end, using a 33 mm diameter tube

Refit

• The cylinder head cover (59)
• The VTC solenoid valve (60) using a standard long socket
• The sparking plugs
• The fixing bolts (58) in the ignition coil block

Tighten

• The bolts of the cylinder head cover; to 0.9 ± 0.1 dan.m
• The vtc solenoid valve (60); to 0.7 ± 0.1 dan.m
• The sparking plugs; to 2.25 ± 0.2 dan.m

C - EW10D engine

D - EW7J4 - EW10J4 engines

Refit

• An exhaust manifold seal or a (new) heat shield
• The exhaust manifold (61)
• The nuts (62)
• The air circulation pipe (63)
• Tighten the nuts (62) to 3.5 ± 0.3 daN.m

Replace the seal on the water outlet housing

Replace the connecting pipe (65) for the water outlet housing coolant pump on the water outlet housing

Refit together the pipe connecting the coolant pump (65) with the water outlet housing (64)

Refit

• A new seal on the pre-catalyst
• The nuts (68) (without tightening it)

Turn the clip (69) to hook it onto the welded bolt (aa)

Refit

• The egr pipe (73) and its clip
• The nut (66)
• The (71) bolt

The nuts (68)

• The nut (74)
• The (72) bolt
• The (71) bolt; tightening to 0.4 ± 0.1 daN.m
• The (70) bolt

Refit

• The heat shield (67)
• The heat shield (67) fixing bolts
• The oxygen and proportional sensors

Refit

• The EGR valve (74) (according to equipment)
• The valve or the pump (75)
• The panel (76)
• The clutch disc
• The clutch mechanism (77)
• Centre the disc by means of tool [24]
• Refit the bolts (78)
• Tighten the bolts (78) to 2.0 ± 0.2 daN.m
• Remove the tool [24]

C - EW10D engine

D - EW7J4 - EW10J4 engines

Refit

• The knock sensor (80); 2.0 ± 0.5 daNm
• The oil filter bracket (81)
• The oil filter (82)
• The injection pipe (83)
• The securing bolts (84)
• Soundproofing (85) of the petrol injection rail
• The high pressure pipe (79): 2.6 ± 0.3 daNm

Refit

• The inlet manifold (89) together with the throttle housing and the injection rail
• The nuts (87)
• The bolts (86)
• The clip (88)

Tighten the fixings of the inlet manifold (86) and (87) to 2.0 ± 0.5 dan.m