Stripping engine (DW12TED4) Peugeot 607 I

Stripping

Remove

• The clips (1) - (3) (using tool [10])
• The heat exchanger (2)
• The 9 nuts (4) with their spacers
• The exhaust manifold (5)
• The exhaust manifold seal

Remove

• The oil filter (6)
• The heat exchanger (7)
• The fuel filter (8) (complete)
• The fuel filter support

Remove

• The high pressure pipe (9)
• The 4 high pressure pipes (10)
• The oil remover with the hose (11)

Remove

• The fuel high pressure common injection rail (12)
• The oil pressure switch (14)
• The expansion pipe (13)

Peg the engine flywheel (using tool [2])

Fit the tool [1]

Remove

• The tool [2]
• The 6 bolts (15)
• The clutch mechanism (16)
• The clutch disc
• The timing belt
• The injection pump

Remove

• The bolts (17)
• The bracket (18)

Remove

• The bolts (19)
• The tool [1]
• The flywheel (20)
• The vacuum pump (21)
• The bracket (22)
• The swirl chamber control pump (23)
• The water outlet housing (24) with its seal

Remove the fuel return rail (plug the holes using tool [8])

Position the tool [7] on the nuts (25) in such a way that it is supported at (a) under the diesel injector

Loosen the 2 nuts (25) gradually, in alternation

Remove

• The 2 nuts (25)
• The diesel injector (26)
• The centralising ring
• The copper seal

Carry out the same operation for the other diesel injectors

Remove the cylinder head cover (27)

Remove

• The bolts (28)
• The hub (29)
• The sealing ring (30)
• The camshafts (31) - (32) with the drive chain (33) (simultaneously)
• The valve rockers controlling the valves with their hydraulic tappets (mark their positions)

Slacken the 10 bolts (34) (using tool [5]) (follow the order indicated)

Remove

• The 10 bolts (34) (using tool [5])
• The cylinder head
• The cylinder head gasket

Remove

• The 20 bolts (35) (length 21 mm)
• The 2 bolts (36) (length 40 mm)
• The oil sump (37)

Remove

• The bolts (38)
• Sealing plate (39) with the sealing ring

Remove the bolts (40) (mark their positions)

Push the pinion (41) back towards the cylinder block

The chain (42)

Remove (simultaneously)

• The oil pump (43)
• The pinion (41)
• The chain (44)
• The O-ring

Remove

• The 8 bolts (45)
• The balancing shafts housing (46)
• The spacers

Remove

• The 8 bolts (47) (using tool [12])
• The big end caps (48)

Remove

• The bolts (49)
• The main bearing caps (50)
• The side shims (bearing no. 2)

Remove

• The crankshaft seal (51)
• The crankshaft (52)
• The side shims (53) (bearing no. 2)
• The cylinder block shell bearings (54)

Remove the conrod/piston assemblies (55) from above

Remove

• The stop ring (56)
• The shaft (57)
• The stop ring (58)
• The piston (59)
• The shoes (60)
• The half bearing shells (61)

Remove

• The bolts (62)
• The piston base jets (63)