Re-assembling: engine (EW10A) Peugeot 807 I

Recommended tools

Re-assembling

Sealing ring (timing side)

Fit tool [1b] on the tool [1a]

Fit the new oil seal (1); using tool [1a]

Remove the tool [1b]

Fit the oil seal (1) in contact with the cylinder block; using tool [1a]

Sealing ring (flywheel side)

Fit tool [2b] on the tool [2a]

Fit the new oil seal (2); using tool [2a]

Remove the tool [2b]

Fit the oil seal (2) in contact with the cylinder block; using tool [2a]

Refit

• The flywheel (3)
• New bolts (4) (without tightening)

Fit the tool [3]

Tightening method for the screws (4)

• Pre-tightening to 2 ± 0,2 daN.m (order from 1 to 8)
• Tighten by an angle of 23° ± 5°; using tool [4] (order from 1 to 8)

Refit: (according to equipment)

• The clutch disc; centre using the tool [8]
• The clutch mechanism; tightening to 2 ± 0,2 daN.m

Immobilise the camshafts by their flats (at "a")

Refit

• Interior timing cover (9)
• The inlet camshaft (8) dephaser pulley
• The (7) bolt; pre-tighten to 3 ± 0,5 m.daN, then tighten to 8,5 ± 0,5 daNm
• The inlet camshaft dephaser cap
• The exhaust camshaft pulley (6)
• The (5) bolt; pre-tighten to 2 ± 0,2 m.daN, then tighten to 11 ± 1 daNm

Refit the coolant pump using a new seal

Tightening method for the screws

• Pre-tightening to 0,8 daNm (order from 1 to 4)
• Tighten to 1,4 ± 0,1 daN.m (order from 1 to 4)

Fit the crankshaft setting rod; using tool [5]

Peg the camshafts; using the tools [6]

Refit

• The crankshaft gear (14)
• The tensioning roller (13); pre-tighten to 1,5 ± 0,1 m.daN, then tighten to 3,7 ± 0,4 daNm
• The roller tensioner (16) (without tightening)

Install the timing belt (12) (in the order shown)

• Crankshaft gear (14) (hold the timing belt, using tool [7])
• Roller tensioner (13)
• Intake camshaft pulley (11)
• Exhaust camshaft pulley (10)
• Coolant pump (15)
• Roller tensioner (16)

Remove the tools [5], [6], [7]

Rotate the tensioning roller (16) in the direction of the arrow "b"; using an Allen key at "c"

Position the index "g" in position "e"; using an Allen key at "c"

Then bring the index "g" to its setting position "f", by rotating the tensioning roller in the direction of the arrow "d"

Tighten the roller tensioner (16) bolt to 2,1 ± 0,2 daN.m

Turn the crankshaft clockwise through 10 revolutions

Check

Pin the camshaft pulleys; using tool [6]

Fit the crankshaft setting rod; using tool [5]

Remove the tools [5], [6]

Re-assembling (continued)

Fit the tool [3]

Refit

• The engine mounting (18)
• The roller tensioner (19); tightening to 2 ± 0,3 daN.m
• The lower timing cover (22)
• The top timing cover (17)
• The crankshaft pulley (20)
• The (21) bolt; pre-tighten to 4 ± 0,4 daNm, then angular tightening 40 ± 4°; using tool [4]

Remove the tools [3], [4]

Refit

• The cylinder head cover (25)
• The bolts (24) (without tightening)
• The camshaft dephaser (23) control electrovalve
• The cylinder reference sensor (26)
• The ignition coil rail (28)
• The bolts (27)

Tightening method for the screws (24)

• Pre-tighten to 0,5 ± 0,2 daN.m (order from 1 to 11)
• Tighten to 1,1 ± 0,1 daN.m. (order from 1 to 11)

Fit

• An exhaust manifold seal (new seal)
• The exhaust manifold (30)
• The nuts (new) (29); tighten to 3,5 ± 0,3 daN.m
• The oxygen sensors (at "j"); tightening to 4,7 ± 0,5 daN.m
• The lower and upper heat shield

Refit

• The pipe linking coolant outlet housing/coolant pump (33)
• The seal on the water outlet housing
• The thermostat (32)
• The panel (31)
• The EGR electrovalve (according to equipment)
• The air inlet valve (according to equipment)

Reconnect and clip the electrical harnesses (at "k")

Refit

• Knock sensor (36); tightening to 2 ± 0,2 daN.m
• Seal
• The oil filter bracket (35); tightening to 1,5 ± 0,1 daN.m
• Oil dipstick tube (34)

Connect the connector (at "l")

Refit

• The air inlet manifold fitted with the throttle housing and the injection rail (37)
• The bolts (38); tighten to 2,2 ± 0,5 daN.m

Connect and clip the electrical harnesses attached to the air inlet manifold (37)