Refitting: engine (EW12J4) Peugeot 607 I facelift

Recommended tools

[6] mandrel handle

[12] drift for fitting crankshaft lip seal (timing side)

Refitting

Assembling the connecting rods/pistons: method with PEUGEOT tooling

Place the tool [4] on tool [1]

Open the clamp "a"

Fully unscrew the pressure screws "b"

Fit the pin (1) of the first piston on the tool [5]

Tighten the handle [6] by hand, without forcing (fully)

Position the piston on the tool [5] and guide it with the handle, pin and guide end assembly

Insert the pin "d"

Screw in the tappets "b" until the piston makes contact

Tighten the nuts (at "c")

Remove the pin (at "d")

Clamp the piston (2)

Place the conrod with its cap (without bearing shell) in the piston and centre it with the handle/pin/cone assembly

Adjust the height of the plate "e" to bring it into contact with the conrod

Adjust the position of the base "f" to obtain a clearance of "A" = 0,1 mm

Place the connecting rod little end on an electric heating plate

Place a piece of tin filler on each small end "g"

Heat until the piece of tin melts (temperature of 250°C approximately)

Fit the conrod into the piston, orientating the lubrication hole "h" (as shown on the illustration)

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

Assembling the connecting rods/pistons: method with CITRoëN tooling

Place the gudgeon pin (1) on the drift [5]

Tighten the handle [6] onto the mandrel without locking it

The pin (1) must rotate freely

Place the tool [4] on tool [2]

Put piston (2) on tool [4]: position the arrow "Dist" pointing upwards

Centre the whole assembly with mandrel [5] and the piston gudgeon pin

Retain the piston using clamp [3] on the positioning base clamp [2]

Place the connecting rod little end on an electric heating plate

Place a piece of tin filler on the small end "g"

Heat until the piece of tin melts (temperature of 250°C approximately)

Fit the conrod into the piston, orientating the lubrication hole "h" (as shown on the illustration): position the arrow "Dist" pointing upwards

Rapidly insert the gudgeon pin (1) fully home

Wait a few seconds before removing the piston/con.rod assembly

Wipe the drop of tin

Proceed likewise for the other three bearing sets

Crankshaft

Place the grooved half shells (6) on the cylinder block(3)

Oil the half-bearing shells

Fit the crankshaft (5)

Position end float shims (4), rotating them round the crankshaft (grooved face on crankshaft side)

Check: crankshaft end float

Fit tools [8] and [9] onto the cylinder block (6)

Fit the dial gauge [10] onto supports [8] and [9]

Refit

• The crankshaft bearing caps casing (8)
• The 10 bolts (7)

Tighten the 10 bolts (7) to 1 ± 0,1 daN.m

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 0,06 to 0,15 mm endfloat

Remove

• The 10 bolts (7)
• The crankshaft bearing caps casing (8)

Crankshaft main bearing cap casing

Check for the presence of the centring pins at "j"

Replacing 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
• Flatten the top at "k" to secure the pin

Apply "AUTOJOINT NOIR" type sealing paste to the periphery of the bearing cap casing (8)

Refit

• The crankshaft bearing caps casing (8)
• The 10 bolts (7)
• The 16 bolts (9)

Tightening procedure

• Pre-tighten the bolts (7) to 1 ± 0,1 daNm
• Pre-tighten the bolts (9) to 0,2 ± 0,1 daNm
• Slacken the bolts (7)
• Tighten the bolts (7) to 2 ± 0,1 daN.m; angular tighten to 70 ± 1°; using tools [14] and [20]
• Tightening of the bolts (9) to 1 ± 0,1 m.daN

Connecting rod/piston assemblies

Position the rings with the ring pliers

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

Direct ring gap (11) 180° with respect to ring gap (10)

Fit the piston/conrod assembly through the tool (lubricate all around)

Let the lower section (B) of the piston protrude to allow it to be correctly guided

Refit the correct upper half-bearing shell (see data)

Oil the cylinders

Observe the marks made during the dismantling operation

Arrow "Dist" of piston is directed towards the valve timing gear

Keep the assembly cone [11] in perfect contact with the sealing face of the cylinder head and centred in relation to the cylinder

Engage the piston, properly positioning the scraper ring (UFLEX)

Proceed likewise for the other three bearing sets

Turn the cylinder block over

Oil

• The sleeves
• The lower bearing shells

Refit the conrod caps

Refit the conrod cap screws (13) (lubricated)

Using tools [14] and [20]

• Pre-tighten the bolts (13) to 2,3 ± 0,1 daNm
• Angular tightening 45 ± 5°

Oil pump

Apply "AUTOJOINT NOIR" type sealing paste around the edge of the sealing face of the oil pump

Refit

• The oil pump (14)
• The 9 bolts (15) (coat the screws with LOCTITE FRENETANCH)

Pre-tighten the 9 bolts (15) to 0,8 ± 0,1 daNm

Sealing ring (timing side)

Place the tool [12b] on tool [12a]

Fit the new sealing ring (16) using the tool [12a]

Remove the tool [12b]

Fit the sealing ring (16) against the cylinder block; using tool [12a]

Sealing ring (flywheel side)

Place the tool [13b] on tool [13a]

Fit the new sealing ring (17) using the tool [13a]

Remove the tool [13b]

Fit the sealing ring (17) against the cylinder block; using tool [13a]

Refit

• The flywheel (19)
• New bolts (18) (without tightening)

Fit the crankshaft setting rod; using tool [17]

Tighten the bolts (18) to 2 ± 0,2 daN.m

Angular tightening 26 ± 3°

Balance shafts

Fit the 2 adjusting spacers [24]

Preparation of the balancing shafts housing

Introduce the 5 mm dia. pins of the tool [25] into the blind holes "l"

Fit the flange of tool [26] on tool [25]

Lightly tighten the bolt (20) of tool [26]

Refit the balance shaft housing (21)

Engage the balance shaft housing (21) on its centring pins

Remove

• The tool [26]
• The tool [25]

Refit the 8 bolts (22); use the old screws

Tighten the screws (22) by hand

Pre-tighten the bolts (22) to 1 ± 1 daNm

Angular tightening 60 ± 2°; using tool [20]

Checks on the balance shafts: endfloat of the driver shaft

Fit tools [10], [27a] and [27b]

Push the driver shaft to its stop

Set the dial gauge [10] to 0

Push back the drive balance shaft in the other direction

Record the clearance

Remove tools [27a], [27b] and [10]

Checks on the balance shafts: lateral clearance of the driven shaft

Fit tools [10], [27a] and [27b]

Push the driven balance shaft to the stop

Set the dial gauge [10] to 0

Push the driven balance shaft back in the other direction

Record the clearance

Remove tools [10], [27a] and [27b]

Checks on the balance shafts: Check the play between the balancing shafts

Fit tools [10], [27a], [27b], [28] and [29]

Lock the driver balance shaft with tool [28]

Position the rule [29] on the driven balance shaft, in the axis of the balance shafts

Tighten the bolt of the tool [29]

Set the dial gauge [10] to 0

Record the clearance; using tool [29]

Remove tools [10], [27a], [27b], [28] and [29]

Check the play between the balancing shafts / crankshaft

Fit

• The rule [29]
• The dial gauge support rod [27a]
• The dial gauge support [27b]
• The dial gauge [10]

Position the rule [29] in the axis of the balance shafts and tighten the bolt of the tool [29]

Set the dial gauge [10] to 0

Press on the balance shaft (in the direction of the arrow) (to its stop)

Record the clearance; using tool [29]

Loosen the screw of the tool [29]

Turn the crankshaft in the normal direction of engine rotation, so as to obtain a quarter rotation of the balance shafts

Reposition the rule [29]

Set the dial gauge [10] to 0

Record the clearance; using tool [29]

Repeat the clearance measuring operation another 7 times (one rotation of the crankshaft)

Look up the minimum clearance values in the table below, to select the adjustment spacers

Remove

• Tools [29], [10], [27b] and [27a]
• The 8 bolts (22)
• The balance shafts housing (21)
• The adjustment spacers [24]

Refit

• The spacers calculated for the minimum clearances given in the table above
• The balance shafts housing (21)
• Pre-tighten the 8 bolts (22) to 1 ± 0,1 daNm; angular tightening 60 ± 2° (in the order shown) (use new screws)

Check: adjustment

Carry out 9 tolerance checks according to the method previously described

Amount of play outside tolerance

• Clearance less than 0,01 mm: select the thickest spacer before the one used
• Clearance greater than 0,07 mm: select the finest spacer after the one used

Example

• Spacer calculated 1,43 mm: if the clearance is too small when checked, fit a 1,45 mm spacer
• Spacer calculated 1,31 mm: if the clearance is too large when checked, fit a 1,29 mm spacer.

Sump

Refit: the oil pump strainer (23) (new seal)

Check that pin is present (at "m")

Refit the sump (24)

Insert the bolts until they make contact without tightening them

Place a straightedge at "n" and adjust the sump so as to align it with the face of the cylinder block

Tighten the 19 bolts (26) of the sump (24) to 0,8 ± 0,2 m.daN

Tighten the 7 bolts (25) of the sump (24) to 0,8 ± 0,2 m.daN

Cylinder head

Remove the peg [17]

Insert cylinder head gasket (27) (new seal)

Refit

• The cylinder head (28)
• The 10 bolts (29)

Cylinder head tightening

Tightening procedure; use tools [15] and [20]

• Pre-tightening to 1,5 ± 0,21 daN.m (order from 1 to 10)
• Tighten to 5 ± 0,51 daN.m (order from 1 to 10)
• Slacken the bolts by 360 ± 2° (1 turn) (order from 10 to 1)
• Tighten to 2 ± 0,251 daN.m (order from 1 to 10)
• Angular tighten to 270 ± 5 ° (order from 1 to 10)

Coolant pump

Refit the coolant pump

Tightening the coolant pump

• Pre-tighten to 0,3 ± 0,1 daN.m (order 1,2,3,4)
• Pre-tighten to 0,8 ± 0,1 daN.m (order 1,2,3,4)
• Tighten to 1,4 ± 0,1 daN.m (order 2,3,1,4)

Timing side components

Refit

• The roller tensioner (36)
• The (35) bolt (camshaft pinion)
• The pulley (32)
• The (30) bolt
• The VTC hub (33)
• The (31) bolt
• The tensioning roller; roller bolts
• The tool [17]

Immobilise the exhaust camshaft by its flat (at "r")

Tightening of the bolt (30)

• Pre-tighten to 3 ± 0,7 daN.m
• Tighten to 7,5 ± 0,7 daN.m

Immobilise the exhaust camshaft by its flat; using a flat spanner (at "s")

Tighten the bolt (31) (new); using tool [15]

• Pre-tighten to 3 ± 0,5 daN.m
• Tighten to 5,5 ± 0,7 daN.m

Refit the access cap to the bolt (31) (new)

Timing belt

Rotate the engine using the bolt of the crankshaft pulley so as to bring it to the pegging position

A: pinning on the manual gearbox

B: pinning on the automatic gearbox

Fit the crankshaft setting rod; using tool [17]

Fit the timing belt (34), strictly in the following order

• The crankshaft gear (35)
• The tensioning roller
• Inlet camshaft pulley (32)
• Pulley (33) of the exhaust camshaft
• The coolant pump
• The roller tensioner (37)

Refit

• The lower timing cover (38)
• The crankshaft pulley (40)

Refit the crankshaft pulley (39) bolt; tighten to 4 ± 0,4 daN.m (old bolt)

Timing belt overtension

Turn the roller tensioner (37) anti-clockwise; using an Allen key at "t"

Position the index "u" in the overtension zone "w"

Tighten the roller tensioner bolt (36) to 2,1 ± 0,2 daN.m

Remove: the tools [18], [19] from the camshaft pulleys; the tool [17]

Turn the crankshaft 10 turns in the normal direction of rotation

Fit the crankshaft setting rod; using tool [17]

Peg the input camshaft pulley using the tool [19]

Tensioning the timing belt

Slacken the roller tensioner screw (36) supporting the Allen key (as " t "). then bring the index "u" to its adjustment position "v"; turn the roller tensioner clockwise

Remove tools [17] and [19]

Turn the crankshaft 2 turns in the normal direction of rotation

Checking the belt tension

Refit tool [17]

Slacken the crankshaft pulley fixing bolt (39) to permit the phasing of the crankshaft sprocket

Refit the crankshaft pulley (39) bolt (new) (pre-coated bolt)

Tighten the bolt (39) to 4 ± 0,4 daN.m

Angular tightening 40 ± 4°; using tool [20]

Remove the tool [17]

Timing gear side

Refit

• The top timing cover (41)
• The engine mounting

Engine top

Refit

• The cylinder head covers (43,) (45)
• The cylinder reference sensor (44)
• The 22 bolts (42)
• The ignition coils block (47)
• The 3 bolts (46)

Do up the bolts (42) until they contact the cylinder head covers

Tighten the bolts (42) to 1,1 ± 0,1 daN.m

Exhaust manifold side

Refit

• The exhaust manifold gasket
• The exhaust manifold (49)
• The heat shield (48)
• The 10 nuts (50)
• Tighten the nuts (50) to 3,5 ± 0,3 daN.m

Refit

• The seal (52)on the water outlet housing
• The thermostat (51) - the pipe (53) linking coolant outlet housing/coolant pump

Repairing the holes

Drill, thread and place a tight thread

Check the stability of the repair made

Clutch end

Refit

• The EGR valve (55) (according to equipment)
• The valve (54) (according to equipment)
• The panel (56)
• The clutch disc
• The clutch mechanism (57)

Centre the clutch disc using the tool [22]

Refit the 6 bolts (58)

Tighten the 6 bolts (58) to 2 ± 0,2 daN.m

Remove the tool [22]

Inlet side

Refit

• The air distributor seal (59)
• The engine venting pipe (64)
• Knock sensor (60)
• The oil filter bracket (63)
• The heat exchanger (61)
• The oil filter (62)

Tighten the knock sensor (60) to 2 ± 0,5 m.daN

Refit

• The air inlet manifold (68) fitted with the throttle carrier housing and the injection rail
• The 2 nuts (65)
• The 6 bolts (66)
• The oil filler and separator housing (68)

Tighten the 8 inlet manifold fixings (65), (66) to 2 ± 0,5 daNm