Refitting: engine (DT17TED4) — Engine — Power unit — Peugeot 607 I facelift (2004-2010)

Refitting: engine (DT17TED4) Peugeot 607 I facelift

WarningObserve the safety and cleanliness recommendations

WarningThere are no replacement parts for the crankshaft/cylinder block assembly. dismantling/re-assembling the crankshaft/cylinder block is prohibited

WarningCheck the flatness of the cylinder heads. maximum permissible bow = 0,03 mm

WarningCheck the flatness of the gasket surfaces of the cylinder block: over the total surface of each upper surface: maximum permissible bow = 0,1 mm. over 150 x 150 mm zones: maximum permissible bow = 0,05 mm. over 25 x 25 mm zones: maximum permissible bow = 0,025 mm

WarningAlways replace all the gaskets and ring seals

WarningClean the gasket faces with an approved descaling product "D2". do not use abrasives or sharp tools on the joint faces. the gasket faces must not have any traces of knocks or scores

Refitting: cylinder block

WarningClean the joint face with the approved removal product: index "D2" (at "a"). do not use abrasives or sharp tools on the joint faces. the gasket faces must not have any traces of knocks or scores

WarningRefit the oil return siphon without the screw, before the closing plate

Fit a new closing plate (2) fitted with its rings seal

NoteThe closure plate is fitted with its ring seal, its gasket and a plastic fitting ring

Oil the bearing surface on the crankshaft

Offer up the closure plate (2) fitted with its plastic fitting ring "b" onto the crankshaft

Fit the closure plate by pushing until it is in contact with the engine block. Then remove the plastic fitting ring in the opposite direction

Refit the fixing screws of the closing plate; tighten to the correct torque (tightening in a cross pattern)

WarningUse a new detection target. keep electric and magnetic sources away from the detection target (risks of destruction)

WarningThe foolproofing of the detection target is by fitting tool [1L]

Refit: the detection target; using tool [1La]

Fit the tool [1La]

Fit and tighten: the bolts [1Lb]

WarningPosition the hole in the detection target (3) opposite the positioning pin of tool [1Lc] (at "c")

Position, the new detection target on tool [1Lc]

WarningThe foolproofing of the detection target is by fitting tool [1Lc] on tool [1La]

Fit

Tool [1Lc] fitted with the detection target on tool [1La]
The nut [1Ld]; screw fully home

Remove the tool [1L]

Refit the engine speed sensor (no setting is necessary)

WarningClean the joint face with the approved removal product index "D2" (at "d"). do not use abrasives or sharp tools on the joint faces. the gasket faces must not have any traces of knocks or scores

WarningRefit: an oil seal gasket (4) (new)

Check the presence of the centring pins (as "e")

Over a container, lubricate with new engine oil through the holes at "f", "g" taking care not to oil the seal of the pump (4) and the contact surface (at "h")

20 cl of engine oil (as "f")
5 cl of engine oil (as "g")

Turn the oil pump turbine 5 turns to distribute the oil in the body of the pump (clockwise)

Train the excess into the container

Clean: the oil pump body (if necessary)

Fit: the oil pump and its seal (4) (new)

Refit: the mounting bolts of the oil pump; tighten to the correct torque (tightening in a cross pattern)

Refit: the crankshaft sealing ring (5); using tool [1F]

Fit on the crankshaft ring seal (5) onto tool [1Fa]; using tool [1Fb]

Remove the tool [1Fb]

Oil the bearing surface on the crankshaft

Fit the tool [1Fa] fitted with the crankshaft ring seal (5)

Tighten the bolt (6) to its stop (tighten moderately)

Remove

The (6) bolt
The tool [1Fa]

WarningClean the joint face with the approved removal product: index "D2". do not use abrasives or sharp tools on the joint faces. the gasket faces must not have any traces of knocks or scores

Refit and torque tighten

The oil deflector (8)
The 5 bolts (7)

WarningClean the joint face with the approved removal product index "D2". do not use abrasives or sharp tools on the joint faces. the gasket faces must not have any traces of knocks or scores

WarningTo guarantee the sealing place a knob of joint compound (E10) 8 mm in diameter at the interfaces of the ceiling faces at "j", "k", "l", "p" before refitting the engine sump gasket

WarningCheck for the presence of centring pegs (as "m", "n")

Refit

The preformed lower engine casing gasket
The sump

Refit and torque tighten

The 10 bolts (M8 (9)) (from 1 to 10)
The 8 bolts (M6 (10)) (from 11 to 18)

WarningIf changing the sump block, the oil sump has to be secured with self-tapping screws, which have to be ordered with the new sump block

Refit and torque tighten

The lower oil gauge guide (13) (with a new seal)
The oil suction strainer (11) (with a new seal)
The bolts (12)
The bolts (14)
The oil level sensor (with a new seal)
The engine speed sensor
The oil sump (with a new seal)
The oil sump securing screws (tightening in a cross pattern)

NoteProcedure for tightening the fixing screws of the oil sump (tightening in a cross pattern)

Do up the screws until there is contact between the oil sump and the sump block (without tightening it)

Slacken the bolts by 2 turns

Tighten to the specified torque (tightening in a cross pattern)

WarningFit new starter ring gear fixing bolts (15)

Refit the starter ring gear. tighten to the specified torque (tightening in a cross pattern)

Fit the crankshaft setting rod; using tool [1k]

NoteAfter pegging, the cylinder N°1 at the timing end on the rear cylinder bank is at 30° before top dead centre

WarningRefit a new bolt to secure the crankshaft pulley

Refit

The crankshaft pulley
The crankshaft pulley fixing screw. tighten to the specified torque

WarningClean out with a tap the threads in the crankcase which accommodate the cylinder head screws (M13 x 155 tap)

WarningClean the gasket faces with an approved descaling product index "D2". do not use abrasives or sharp tools on the joint faces. the gasket faces must not have any traces of knocks or scores

WarningClean: the oil supply filter (16) of the turbochargers incorporated in the rear bank of cylinders

Refit: the oil supply filter (16) of the turbochargers incorporated in the rear bank of cylinders

Engine re-assembly

Refitting (cylinder heads)

Check the flatness of the cylinder head: maximum permissible bow = 0,03 mm

Check the flatness of the gasket surfaces of the cylinder block

Over the total surface of each upper surface: maximum permissible bow = 0,1 mm
Over 150 x 150 mm zones: maximum permissible bow = 0,05 mm
Over 25 x 25 mm zones: maximum permissible bow = 0,025 mm

WarningCheck the presence of the centring pins (as "q", " r")

WarningFit a new cylinder head gasket

WarningSelect the thickness of the cylinder head gasket in relation to the protrusion of the pistons

Check the protrusion of the pistons in relation to the cylinder block joint face (at "s")

NoteCalculate the average of the 2 values measured

"t": thickness identification mark

NoteThe shape of the cylinder head gasket is identical (front row of cylinders and rear row of cylinders) but the category may be different

piston protrusion	gasket thickness	number of teeth (at "t")
0,541 to 0,551 mm	1,12 ± 0,05 mm	1
0,552 to 0,603 mm	1,17 ± 0,05 mm	2
0,604 to 0,655 mm	1,22 ± 0,05 mm	3
0,656 to 0,707 mm	1,27 ± 0,05 mm	4
0,708 to 0,760 mm	1,32 ± 0,05 mm	5

WarningThe cylinder head must be refitted with new bolts

Refit

The cylinder heads and their gaskets (new seal)
The cylinder head
The cylinder head bolts (new)

Tightening

Pre-tighten to 2 ± 0,2 daN.m
Tighten to 4 ± 0,4 daN.m
Tighten to 8 ± 0,8 daN.m
Angular tightening to 180 ± 5°

WarningClean any foreign bodies from the valve rockers and cam followers and from their housings on the cylinder head. do not use abrasive products or sharp tools. do not use a scouring product

WarningLubricate with a little engine oil: the valve control rockers with their hydraulic followers

Refit: the valve control rockers with their hydraulic followers (in accordance with the identification made on removal)

WarningBefore refitting the camshafts; clean the gasket faces with an approved descaling product index "D2". do not use abrasives or sharp tools on the joint faces / the camshaft seats. the camshaft seats / the gasket faces must not have any traces of knocks or scores

WarningLubricate with engine oil the cams and camshaft bearings

Position the camshaft chain (17) on the gears (19) and (20)

Align the links "v" and "w" marked in black with the teeth marked "u" and "x" on the camshaft gears (19) and (20)

Position the chain tensioner (18) between the 2 camshafts

Refit the chain and camshaft assembly

"AA": cylinder head on rear bank of cylinders: the camshaft main bearing caps are marked with a digit

"AB": cylinder head on front bank of cylinders: the camshaft main bearing caps are marked with a letter

WarningObserve the following order of fitting

Refit

The 8 camshaft main bearing caps (in order from 9, 8, 7, 6, 4, 3, 2, D, C, B, A, J, G to F)
The 16 bolts (21)

Tightening method for the screws (14)

Pre-tighten the bolts by hand (in order from 9, 8, 7, 6, 4, 3, 2, D, C, B, A, J, G to F)
Pre-tighten the bolts to 0,5 ± 0,1 daNm (in order from 9, 8, 7, 6, 4, 3, 2, D, C, B, A, J, G to F)
Tighten the bolts to 1 ± 0,1 daN.m (in order from 9, 8, 7, 6, 4, 3, 2, D, C, B, A, J, G to F)

Apply "LOCTITE 518" sealing product at "y" and "z" on the camshaft main bearing caps marked "K", "5", "E" and "J"

Observe the following dimensions

"y" =, 3 mm Ø

"z" =, 7 mm Ø

"X" = 3 mm

"Y" = 7 mm

"Z" = 12 mm

WarningDo not block the greasing channels "aa"

Refit the camshaft main bearing caps "K", "5", "E" and "J"

Tightening method for the screws (21)

Pre-tighten the bolts by hand (in order from K, 5, E to J)
Pre-tighten the bolts to 0,5 ± 0,1 daNm (in order from K, 5, E to J)
Tighten the bolts to 1 ± 0,1 daN.m (in order from K, 5, E to J)

NoteRemove the chain tensioner pin

WarningFit new camshaft ring seals

Refit

The camshaft lipped seals (timing gear side / high pressure fuel pump side)
The camshaft pulleys (timing gear side / high pressure fuel pump side)

Refitting: timing gear

Refit

The coolant pump without the pulley
The 2 guide rollers
The roller tensioner; without tightening it

Peg the camshafts; using the tools [1H]

Refit the timing belt on the crankshaft sprocket (23)

Support the timing belt (22) using tool [7]

Turn the camshaft pulleys (34) and (28) clockwise, to place them at end of slots

The bolt with the washer "ac"

Roller tensioner (30)
Camshaft pulley (28)
Roller tensioner (25)
Camshaft pulley (34)
Roller tensioner (32)

NoteIf necessary, turn the pulleys (34) and (28) slightly anti-clockwise (no more than one tooth)

Remove the tool [7]

Using a hexagonal spanner, turn the roller tensioner (31) anti-clockwise

Position the index "af" opposite the notch "ae"

Tighten the bolt (32)

Remove the screws (35) and (27) of the pulleys (34) and (28) to check that the screws (35) and (27) are not at end of slots

WarningIf the screws (35) and (27) are at end of slots, repeat the operations to refit the timing belt. tighten the bolts (35) and (27)

Remove

The camshaft setting rods
The crankshaft setting peg

Turn the crankshaft 8 turns in the normal direction of rotation

Fit the crankshaft setting rod; using tool [1K]

Peg the camshafts (at "ad", "ab"); using tool [1K]

NoteIf it is impossible to refit the tools [1K], slacken the screws (35) and/or (27) of the camshafts and drive the camshafts by means of the central screw (24) and/or (26)

Peg the camshafts (at "ad", "ab")

Tighten the bolts (35) and (27)

Remove: the camshaft setting rods

Turn the crankshaft 8 turns in the normal direction of rotation

Fit the crankshaft setting rod

Peg the camshafts (at "ad", "ab")

Check that the index "af" of the roller tensioner (31) is facing the notch "ae"

WarningIf the position of the index of the roller tensioner is not correct, repeat the operations to refit and tension the timing belt

Remove

The crankshaft setting peg
The camshaft setting rods

Refit

The coolant pump pulley (29)
The camshaft position sensor

Refitting: turbochargers

WarningThe absence of the turbocharger/exhaust manifold seal requires cleaning and checking of the bearing surfaces in contact; check that there are no foreign bodies present in the exhaust manifold and the inlet circuit

Refit the following components (new)

The 2 seals (36) of the exhaust manifolds
The 2 bushes (37) of the exhaust manifold studs (turbocharger side)
The nuts of the 2 exhaust manifolds
The studs (exhaust manifolds)
The copper seals of the 3 banjo bolts of the turbocharger lubrication pipes
The seals of the turbocharger oil return pipes (O-ring seal and paper seal)
The 2 screws (pre-lubricated) of the bottom strengthener bracket
The 2 O-ring seals of the turbocharger air inlet union

Check

The surface condition of the flared parts of the bicones of the pre-catalysers
The surface condition of the manifolds and turbochargers
The presence of the indexing pins (38) on the manifolds
The presence of the bush (37) on the exhaust manifold studs (turbocharger side)
The heat shields of the exhaust manifolds, as to whether they show the slightest sign of damage

Refit the turbochargers on the exhaust manifolds, on the bench; tighten to the specified torque

Before tightening to the final torque; do a trial fitting of the components of the turbochargers, in order to be able to adjust their positions

Refit

The turbocharger/exhaust manifold assemblies (41) (on the cylinder heads)
The 12 nuts (40) (new)

Refit

The 2 strengthener brackets (43) (lower)
The 4 new screws (42)

WarningDuring the operation to refit the oil return pipes, do not bend or twist the pipes

Refit

The oil return pipes (45)
The 6 bolts (44)

Tighten the components of the turbochargers to the correct torques

Refit: the lubrication tube (46) of the 2 turbochargers

Re-assembling (continued)

Connect the 2 power supply connectors to the glow plugs (47)

Refit: the 2 accelerometers (48)

Refit

The assembly (50) of the oil filter support, coolant/oil and coolant/diesel fuel exchangers
The thermostat (46)

Refit

The fuel high pressure pump (53)
The harness (52) between the fuel heat valve and the coolant/diesel fuel exchanger
The high pressure pump drive belt rear cover (54)
The 2 air inlet valve covers (51)

Refit

The oil vapour recovery pipes (56)
The oil vapour recoverer (57)
The vacuum pump (58)
The EGR valves (55)
The oil return trap screw (59)
The fuel high pressure pump belt tensioner (62)
The fuel high pressure pump drive belt (65)
The pulley (61)
The nut (60) using tool [1E]
The pulley (64)
The (63) bolt using tool [1G]

Refitting: injectors

WarningReplace: the 6 high pressure fuel pipes - the 6 seals - the 6 clamps

WarningCoat the diesel injector bodies with a thin layer of grease index "G2"

Refit: on each injector (diesel)

The bracket (67) (new)
The clip (66) (new)
Seal (68) (new)

Refit

The fuel high pressure intermediate rail (75)
The fuel high pressure rails at the injectors (71), (77)
The high pressure fuel pipes (72), (74), (76)
The injectors (70)
The high pressure fuel pipes (69) (injectors side)
The diesel filter support (73)
The dipstick guide
The lifting brackets [1P]

Refit

The fuel return pipes harness (78)
The fuel temperature sensor (79)
The engine mounting (81)
The lower timing cover (83)
The ancillary drive pulley (82)
The rear timing cover (85)
The timing housings (80), (84)

Refit

The inlet air metering unit (89)
The air inlet housing (88)
The tubes (87), (90)
The support (86) of the air duct between the air/air exchanger and the air inlet housing
The alternator bracket (95)
The alternator (94)
The roller (93)
The auxiliary equipment drive belt (92)
The accessories drive belt tensioner (91)

Remove the engine from the engine stand