Refitting: engine (DW10BTED4) Peugeot 607 I facelift

Preparing the cylinder block

Refit

• The piston base jets (4); tightening torque to 1 da.Nm
• The grooved bearing shells (1)
• The 2 crankshaft bearing flanges (2), (3) (lubricating grooves "a" on the crankshaft side)

Determine the thickness of the crankshaft bearing cap shells, by using the table in the specifications chapter

Adjusting the crankshaft endfloat

Fit the crankshaft

Position

• The dial gauge support [1]
• The dial gauge support [2]
• The dial gauge [3]

Push the crankshaft back and forth 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 a 0,07 to 0,32 mm endfloat

Crankshaft bearing caps

Oil

• The crankshaft seats "b"
• The half bearing shells (7)

Refit

• The half bearing shells (7)
• The main bearing caps (5)
• The lateral shims (6) of bearing no. 2
• The bearing cap screws (5) (without tightening)

Place E4 sealing paste in the angles and extremities "c" of bearing no. 1

Place the handle of the tool [4] on the bearing cap N°1 (8)

Tighten the screws on the handle of the tool [4]

Position

• The bearing shell (9) on the bearing cap
• The lateral seals (10) in the groove of the bearing cap

Position the tool [4] on the cylinder block

Put a little oil on the lateral seals (10)

Oil the half bearing shell (9)

Engage the bearing cap together with the lateral seals in the tool [4], tilting it

Slide the bearing cap (8) into its housing, using the handle

Do up the 2 screws of the bearing cap (8)

Remove the tool [4]

Tightening the bearing caps

Tightening procedure

• The cylinders 2,5 (order from 1 to 10)
• Angular tighten to 60 ± 5°, using tool 5] (order from 1 to 10)

Assembling the conrod/piston/piston ring assemblies

Refit the piston rings (11) (as shown in the diagram above)

Refit

• The circlip (15)
• The connecting rod (14)
• The shaft (12)
• The circlip (13)

Connecting rod/piston assemblies

Check that the notches "e", "f", "g" on the rings are correctly oriented

Place ring collar [7]

Fit the half bearing shells (16) on the connecting rods (14)

Oil

• The cylinders
• The half bearing shells (16)

Refit the connecting rod/piston assemblies

Fit the half-shells conrod caps

Oil

• The connecting rod lower half bearing shells
• The connecting rod cap screws
• The nuts (18)

Position the conrod caps (17)

Fit the nuts (18)

Method for tightening the nuts (18)

• Pre-tighten to 2 daNm
• Angular tighten to 70 ± 5°, using tool 5]

Rear bearing shell seal ring

Use the cone [6b] to fit the seal on the tool [6a]

Refit the ring seal (using a mallet)

Remove the tool [6a]

Engine flywheel

Fit the 2 bolts of the tool [8] in place of the 2 bolts diagonally opposed

Refit the engine flywheel (19)

Centre the engine flywheel with the aid of the cones of tool [8]

Refit the 6 fixing screws (20) of the engine flywheel (19)

Remove the tool [8]

Refit the two final fixing screws (20) of the engine flywheel (19)

Fit the tool [9]

Tightening procedure (automatic gearbox)

Tighten the engine flywheel fixing bolts (diagonal tightening)

• Pre-tighten the bolts (20) to 2 dan.m
• Tighten the bolts (20) to 6,6 m.daN

Tightening procedure (manual gearbox)

Tighten the bolts (20) to 4,8 m.daN (diagonal tightening)

Remove the tool [9]

Oil pump

Refit simultaneously

• The pinion (24)
• The chain (25)
• The oil pump (21) and the dipstick tube

Refit the bolts (22) (respect the marks made at the time of removal)

Tighten the bolts (22) to 1,6 m.daN

Push the pinion (24) towards the cylinder block

Refit the key (23)

Immobilise the crankshaft pinion (24) by engaging it on the key (23)

Front sealing panel

Apply a strip of "E10" to the sealing panel (26) (refer to the products catalogue)

Refit

• The sealing panel (26)
• The bolts (27); tighten to 1,4 daN.m

Crankshaft seal ring (timing side)

Refit the ring seal; using tool [17a]

Remove the tool [17a]

Lower cover

Apply a strip of sealant "E10" around the edge of the cylinder block (refer to the products catalogue)

Refit

• The sump (28)
• The 2 bolts (29)
• The 20 bolts (30)

Tighten the bolts (30), (29) to 1,6 m.daN

New clutch

Refit the clutch mechanism (31)

Centre the clutch disc (31) using the centring device at "h" of the tool [21]

Refit the clutch mechanism (32)

Fit the plate "l" of the tool [21]

Bring the 3 screws "k" of tool [21] in contact with the clutch mechanism (32)

Bring the clutch mechanism in contact with the engine flywheel, using the lever "j" of tool [21]

Fit 3 screws to secure the clutch mechanism

Bring the 3 screws into contact with the clutch plate (32)

Remove the plate "l" and the centring device "h" of tool [21]

Fit 3 more screws to fix the clutch mechanism

Bring the 3 screws into contact with the clutch plate (32)

Tighten the 6 clutch mechanism fixing bolts (32) to 2 daN.m

Reused clutch

Resetting of the clutch wear adjustment to zero

Fit the plate "l" of tool [21] on the flywheel

Release the wear adjustment system by tightening the clutch mechanism slightly; using the lever "j" of tool [21]

Compress the springs (33); by means of a screwdriver

Remove the plate "l" of tool [21]

Refit the clutch (follow the procedure "new clutch mechanism")

Piston protrusion

Fit dial gauge support [19] to the cylinder block

Secure dial gauge [3] to support [19]

Set the dial gauge [3] to 0 (at "n")

Record the height difference at "m"

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

Cylinder head

Position the pistons at mid-stroke (horizontal keyway (23))

Fit a new cylinder head seal

Before reusing the cylinder head bolts, check their length

Refit

• The cylinder head
• The cylinder head bolts

Tightening procedure

• Pre-tightening to 1,5 daNm
• Tighten to 6 daN.m
• Angular tighten to 220 ± 5 °; using tool [5]

Oil and refit

• The chain pad (35)
• The valve rockers (34) with their hydraulic followers (respect the marks made on removal)

Arm the chain tensioner (36) using a 2 mm dia. pin

Position the chain (38) on the pinions (37) and (39)

Bring the links marked in black "r" and "u" onto the teeth marked "s" and "t" on the camshaft drive pinions (37) and (39)

Lubricate the camshafts with new engine oil

Refit the chain and camshaft assembly

Apply the index "E10" sealing paste to the periphery of the camshaft bearing cap housing (44)

Refit

• The camshaft bearing cap cover (44)
• The 26 bolts (41) (do not place the screws at the marks 1 and 2, see following diagram)
• The 8 pillar screws (40)
• The camshaft chain tensioner (36)
• The pulley (42)
• The (43) bolt (tighten by hand)

Remove the 2 mm dia. pin

Pin the camshaft pulley (42); using tool [20]

Pre-tighten

• The 26 bolts (41) to 0,5 daNm (order from 1 to 26)
• The 8 studs (40) by hand (order from 27 to 34)

Tighten

• The 26 bolts (41) to 1 daNm (order from 1 to 26)
• The 8 bolts (40) to 1,1 daNm (order from 27 to 34)

Remove

• The tool [20]
• The pulley (42)

Refit the ring seal; using tool [22a]

Remove the tool [22]

Timing gear side

Lock the crankshaft using the rod [10]

Refit

• The crankshaft pulley (47)
• The tensioning roller (46)
• The (45) bolt
• The coolant pump (48) (equipped with a new seal)
• The roller tensioner (49)
• The (50) bolt
• The camshaft pulley (42)
• The securing bolt (43)

Tightening of the bolt (43); using tool [18]

• Pre-tighten bolt (43) to 2 daNm
• Angular tighten to 60 (0°; - 5 °)

Arm the roller tensioner; using tool [23]

Fit the tool [20]

Centre the crankshaft pulley (47); using tool [16]

Reposition the timing belt on the camshaft pulley (42)

Fit the tool [14] (tighten moderately)

The bolt with the washer "v"

• Roller tensioner (46)
• Crankshaft pulley (47)
• Water pump pulley (48)
• Roller tensioner (49)

Remove the tools [14, 16, 23]

Move the index "y" to the outside of the plate (at "x"), turning the roller tensioner in the direction of the arrow "w"; using a 6 -sided wrench (as "z")

Tighten the roller tensioner bolt (50) to to 2,1 daNm

Lock the flywheel by means of tool [9]

Tighten the screw of the accessories drive pulley to 5 m.daN

Remove the tools [9, 10, 20]

Turn the crankshaft 4 turn(s) in the direction of running

Peg

• The crankshaft; using tool [10]
• The camshaft drive pulley; using tool [20]

Lock the flywheel; using tool [9]

Unscrew

• The ancillary drive pulley
• The bolt (50) of the roller tensioner (49)

Turn the roller tensioner (49) clockwise; using a 6 -sided wrench (as "z")

Position the index "y" opposite the notch "aa"

Tighten the roller tensioner bolt (50) to to 2,1 daNm

Remove the tools [10], [20]

Tighten the accessories pulley to 5 m.daN

Remove the tool [9]

Turn the crankshaft 2 turn(s) in the direction of running

Refit the tools [10], [20]

Check the position of the index "y", it should be opposite the slot "aa"

Refit tool [9]

Remove the auxiliary equipment drive pulley

Refit

• The crankshaft position sensor target (52)
• The bottom timing cover (51)
• The crankshaft position sensor (53)

Refit

• The accessory pulley (54)
• The bolt (55) with its washer

Tighten the bolt (55) to 7 daN.m; angular tighten to 60 ± 5 °

Remove

• The tool [10]
• The tool [20]
• The tool [9]

Refit

• The top timing cover (56)
• The engine mounting (57)
• The bolts (58)

Tighten the bolts (58) and (45) to 5,6 m.daN

Flywheel side

Refit

• The thermostat (61) (new seal)
• The high pressure pump (60) (new seal)
• The vacuum pump (59) (new seal)

Oil filter side

Refit

• The vacuum tank (63)
• The fuel high pressure common injection rail (62)
• The oil filter support (64) and coolant/oil heat exchanger assembly (with a new filter element)

Diesel injectors and high pressure fuel pipes

Preparing a diesel injector

• Clip the flange (69) on its circlip
• Fit the centring ring (68) in the injector well
• Fit the new copper seal (67) flat in the diesel injector hole

Refit

• The diesel injectors (65)
• The nuts (66); hand-tighten

Refit

• The fuel high pressure tube protectors (71) on the cylinder head
• The diesel injectors fuel return rail (70)
• The 4 high pressure fuel pipes (73)
• The high pressure fuel pipe (72)

Fully tighten manually to the end of the thread

• The unions of the tubes (73) on the diesel injectors
• The unions of the pipes (73) on the fuel high pressure common injection rail
• The union of tube (72) on the fuel high pressure pump
• The union of tube (72) on the fuel high pressure injection common rail

Tighten the nuts (66) to 0,4 dan.m; using the tools [26], [27]

Observe the following angular tightening method

• Position the zero marked "ab" of the tool [28] to face the operator
• Move the detachable index "29"" of the tool [28] and place it opposite graduation 45 °
• Tighten progressively and in one operation; angular tighten to 45 ± 5 °

Pre-tighten the unions (74) on the diesel injectors to 2,3 daN.m; using the tools [13], [24], [25]

Apply a counter-torque at "ad"

Pre-tighten the unions (75) on the high pressure fuel common injection rail to 2,3 daN.m; using the tools [13], [24], [25]

Pre-tighten the connector (76) to 2,3 daNm; using the tools [13], [24], [25]

Apply a counter-torque at "ae"

Tighten; using the tools [13], [24], [25]

• The unions (75) of the pipes on the fuel high pressure common injection rail; tightening torque to 3 da.Nm
• The unions (74) on the diesel injectors; tightening torque to 3 da.Nm; apply a counter-torque at "ad"
• The union (76) on the high pressure fuel pump; tightening torque to 3 da.Nm

Exhaust side

Refit

• The cooling circuit pipe (82) with the coolant inlet housing (80)
• The exhaust manifold (83) with the turbocharger (81)
• The heat exchanger (78) with the EGR valve (77)
• The pipe (79)

Refit

• The oil filler (85) and oil vapour recycling (86) assembly
• The fuel filter support (84)
• The fuel filter (87) (with a new filter element)
• The fuel feed and return pipes

Inlet valve cover

Refit

• The inlet manifold (91) and oil trap assembly
• The tube (89) (without tightening its fixings); using tool [12]
• The camshaft position sensor (88) (without tightening its fixing screw)

Method for tightening the inlet manifold and oil trap fixing bolts

• Pre-tighten the bolts to 0,5 dan.m
• Tighten the bolts to 0,9 m.daN (in the order indicated)

Tighten the pipe fixings (89)

Connect the hose (90); using tool [11]

Camshaft position sensor adjustment (re-used)

Peg the engine flywheel; using tool [10]

Position a 8,5 mm diameter drill (at "af") (between the inlet cylinder head cover (92) and the camshaft position sensor (88))

Tighten the bolt (91) to 0,6 daN.m

Remove the tool [10]

Camshaft position sensor adjustment (new)

Place the camshaft position sensor in contact with the target (camshaft pinion)

Tighten the bolt (91) to 0,6 daN.m

Remove the tool [10]