Refitting: engine (DV4TED) Peugeot Bipper I

Preliminary operations

Check the condition

• Cylinder block
• Crankshaft
• Conrods
• Pistons

Cylinder block

Fit

• The piston base jets (1) (tightening torque to 2.0 da.Nm)
• The grooved half-shells (2)
• The thrust washers (3) (lubrication grooves on the crankshaft side)

Check - crankshaft end float

Position the crankshaft in the cylinder block

Position

• The dial gauge support [21]
• The dial gauge support [22]
• The dial gauge [23]

Press axially on the crankshaft in the cylinder block

Set the dial gauge to zero

On the opposite side, press axially on the crankshaft in the cylinder block

The side clearance must be between 0,07 and 0,322 mm

Determine the category of smooth half-shells on the crankshaft main bearing cap castings

Lightly oil the contact surface of the top half-shells with the crankshaft

Remove: the crankshaft

Check the direction of the gaps (a - b - c) in the piston rings

Position the piston rings collar [41]

Deposit a light film of clean engine oil in the cylinders

Insert the rod and piston assemblies in the cylinder block

Position the connecting rod main bearing shells (4) (using the tools [14])

Oil the upper half shells located on the big ends

Position the crankshaft on the bearings and big ends

Fit the half-shells (5) conrod caps (6) (using the tools [14])

Lightly oil the crankshaft crank pins

Fit: the big end caps (5)

Fit the new big end cap bolts (7)

Method of tightening the 2 bolts (7) of each rod in turn

• Tightening torque to 1.0 da.Nm
• Slackening: Angle of 180°
• Tightening torque to 1.0 da.Nm
• Angular tightening to 100 ± 5°

Position the tools [15 - 13] on the crankshaft main bearing cap casting

Fit the smooth lower half-shells (8)

Check the presence of the 10 centring pins on all the bearings (as (d))

Apply a E10 bead of sealant around the edge of the cylinder block (as (e))

Fit the main bearing caps to the cylinder block

Tightening - sump cover

Fit the 2 centralising pins [13] (as (f - g))

Nip up the bolts (9) and (10)

Remove the 2 centralising pins [13]

Stage 1 - pre-tighten (in order)

• The 10 new crankshaft main bearing cap bolts (9) (tightening torque to 1.0 da.Nm - from 1 to 10)
• The 14 seam bolts (10) (tightening torque to 0.6 da.Nm - from 1 to 14)
• Tightening of seam screws (11) (tightening torque to 0.8 da.Nm)

Stage 2: slacken the 10 bolts (9) (Angle of 180°)

Stage 3 (tighten in the sequence indicated): the 10 bolts (9) (tightening torque to 3.0 da.Nm - from 1 to 10)

Stage 4 (tighten in the sequence indicated)

• The 10 bolts (9) (Angle of 140° - from 1 to 10)
• The 14 seam bolts 10 (tightening torque to 0.8 da.Nm - from 1 to 14)

Oil pump

Apply a E10 bead of sealant around the edge of the cylinder block (as (h))

Position: the centralising pins (12) (oil pump)

Fit the oil pump (13) with its new sealing joint (14)

Pre-tighten the oil pump fixing bolts (tightening torque to 0.5 da.Nm - from 1 to 8)

Tighten the oil pump fixing screws to 0.9 m.daN (from 1 to 8)

Filter gauze - sump

Lubricate the interior of the oil pump with clean engine oil

Position

• Fill gearbox (15) with oil and ensure correct level (tightening torque to 0.7 da.Nm)
• The lower gauge guide (16)
• The oil sump centring studs (17) (tightening torque to 0.7 da.Nm)

From around the edge of the main bearing cap casting remove a sealing bead of E10 (as (i))

Around the edge of the housing base remove a sealing bead of LOCTITE 570 (as (j))

Position

• The oil sump (18)
• The 2 nuts (19) (tightening torque to 1.0 da.Nm)
• The 16 bolts (20) (tightening torque to 1.0 da.Nm)

Fit the 2 caps (21) on

Coolant pump

Fit the coolant pump (22) fitted with its new sealing joint (23)

Pre-tighten: the securing bolts on the coolant pump (tightening torque to 0.3 da.Nm - from 1 to 7)

Tighten the coolant pump mounting bolts to 1.0 dan.m (from 1 to 7)

Assembly - sealing rings (crankshaft)

Flywheel side

Fit the tool [12] (to crankshaft)

Fit the new sealing ring (24) using the tool [12]

Remove

• The tool [12]
• The bracket (sealing ring)

Fluid pump side

Fit the new sealing ring (25) using the tool [11]

Remove

• The tool [11]
• The bracket (sealing ring)

Check - piston protrusion

(X) = 10 mm

Clean the checking surfaces

Check the protrusion of the pistons in relation to the cylinder head seal surface (2 check points (k))

• Place the dial gauge bracket [42] on the cylinder block
• Fix the dial gauge [23] on the bracket [42]
• Turn the crankshaft to the top dead centre of the piston without going beyond it
• Set the dial gauge to zero (as (l))
• Check the difference in height at (k)
• Calculate the average of the values measured

Repeat the procedure for the remaining pistons

The highest mean value determines the thickness of the cylinder head seal to be fitted

Cylinder head

Check that the various seal surfaces are clean (cylinder block - cylinder head)

Position

• The cotter
• The crankshaft gear (26)
• The (27) bolt

Fit the crankshaft setting rod (using tool [1])

Fit

• The centralising pins (28)
• The cylinder head gasket (29)
• The cylinder head (30)

Fit the cylinder head bolts which have previously been coated with grease MOLYKOTE G RAPID on the threads under the bolt heads

Cylinder head tightening

Tighten the bearing carrier screws in the order indicated (using tool [19])

Stage 1: pre-tighten: the cylinder head bolts (tightening torque to 2.0 da.Nm - from 1 to 10)

Stage 2: tighten: the cylinder head bolts (tightening torque to 4.0 da.Nm - from 1 to 10)

Stage 3: tighten: the cylinder head bolts (Angle 230° - from 1 to 10)

Camshaft housing

Lubricate the hydraulic compensation swivel joints (31)

Position

• The 8 hydraulic compensation ball joints 31
• The rockers (32)

From around the edge of the cylinder head remove a sealing bead E10 (as (m))

Position the tools [13] in the holes (n) of the lower camshaft carrier

Fit

• The lower camshaft holder on the cylinder head
• The securing bolts (camshaft housing)

Draw up the bolts (in the order from 1 to 13)

Remove the tools [13]

Tighten the lower camshaft holder bolts (tightening torque to 1.0 da.Nm - from 1 to 13)

From around the edge of the lower camshaft carrier remove a sealing bead E10 (as (o))

Put the camshaft in place in the lower camshaft carrier

Position the tools [13] in the holes (p) of the upper camshaft carrier

Fit

• The upper camshaft holder
• The securing bolts (Upper camshaft holder)

Draw up the bolts (in the order from 1 to 12)

Remove the tools [13]

Tighten the bolts of the upper camshaft holder (tightening torque to 1.0 da.Nm - from 1 to 12)

Assembly - camshaft sealing ring

Fit a new camshaft sealing ring (using tool [10])

Remove

• The tool [10]
• Sealing ring bracket

Assembly - camshaft pinion

Fit: the camshaft gear (33) (using tool [27])

Tighten the bolt (34) to 4.5 daN.m

Remove the tool [27]

Peg the camshaft gear (33) (using tool [2])

High pressure pump - supply rail

Fit

• The diesel high pressure pump bracket (35) (tighten the 3 bolts to 2.2 m.daN)
• The diesel high pressure pump (36) (tighten the 3 bolts to 2.25 m.daN)
• The rear support (37) (tighten the 2 bolts (38) to 2.0 m.daN)

Fit

• The split ring (39) on the rear bracket (37)
• The rear support (40) (tighten the bolts (41 - 42) to 1.0 m.daN)
• The supply rail (43) (tighten the bolts (44) by hand)
• The drive pinion (high pressure pump)

Immobilise the high pressure pump pinion (using tool [9])

Fit: the gear fixing nut (tightening torque to 5.0 da.Nm)

Remove the tool [9]

Injectors

Remove the diesel injector well blanks [26]

Position in the cylinder head

• The new copper seals (45)
• The new sealing rings (46)
• The injectors (47) (in accordance with the marks made on removal)
• The clamp thrust pins (48)
• The clamps (49)
• The securing bolts ((50)) (finger tighten)

Assembly - high pressure pipes (fuel)

Remove the closing caps 26 as the tubes are fitted

Fit: the new high pressure fuel pipes (51 - 52)

Tighten the unions by hand

Pre-tighten

• The connectors (53) while retaining the connectors on injector at (q) (using the tools [29 - 31 - 34])
• The pipe (54) (holding the pump union at (r) - using the tools [29 - 31- 34])
• The unions (55) (using the tools [29 - 31 - 33])

Tighten

• The connectors (53) while retaining the connectors on injector at (q) (using the tools [30 - 31 - 34])
• The pipe (54) (holding the pump union at (r) - using the tools [30 - 31- 34])
• The unions (55) (using the tools [30 - 31 - 33])

Tighten the 2 bolts (44) (using tools [29] and [35] - tightening torque to 2.3 da.Nm)

Tighten the bolts (50) of the injectors (tightening torque to 2.5 da.Nm)

Timing belt

Fit

• The inertia roller fixing stud on the cylinder block (tightening torque to 1.0 da.Nm)
• Roller tensioner: Tighten the roller fixing nut (tightening torque to 3.5 da.Nm)
• The roller tensioner: In the slack position tighten the roller fixing nut (tightening torque to 1.0 da.Nm)

Fit the timing belt, run well tensioned, in the following order

• Crankshaft gear (26)
• Roller tensioner
• The camshaft gear (33) (ensuring that the belt is placed correctly against the roller)
• High pressure pump pinion
• Coolant pump (22)
• Roller tensioner

Slacken the roller tensioner (56) bolt

Using a hexagonal wrench, move the roller tensioner index (t) to the middle of checking zone (s) turning the tensioner clockwise

Tighten the bolt (56) to 2.5 daN.m

Remove the tools [1 - 2]

Turn the crankshaft 10 turns in the normal direction of rotation

Fit the tools [1 - 2]

Check that the index (t) of the roller tensioner is correctly positioned

If this is not the case, restart the belt fitting operation

Remove the tools [1 - 2]

Fit

• The engine speed sensor (57) (tightening torque to 0.5 da.Nm)
• The offset prevention angle bracket (58) (tightening torque to 0.5 da.Nm)

Remove bolts (27)

Timing covers / integral intake system (lower)

Fit

• The intermediate right engine mounting (59) (tighten the 4 bolts to 5.5 m.daN)
• The lower timing cover (60) (tighten the 5 bolts to 0.5 m.daN)
• The pre-heat plugs connection strip (61) (tighten the 4 nuts to 0.3 dan.m)

Fit: the lower integral intake system (62)

Tighten the bolts (65) to 1.0 m.daN (from 1 to 10)

Fit: the camshaft phase sensor (63)

Adjust the air gap between the sensor (63) and the pinion fibre ring (33) to X = 1,2 mm

If the sensor (63) is new, place the locating pin (u) of the sensor with one of the fibre rings 3 of the pinion (33)

Fit: the timing cover (64) (tighten the 5 bolts to 0.5 m.daN)

Coolant outlet housing

Fit the coolant outlet elbow (66) with a new joint

Pre-tighten: the 4 securing bolts (tightening torque to 0.3 da.Nm)

Tighten the securing bolts to 0.7 dan.m

Oil filter bracket

Fit: The oil filter bracket (67) fitted with a new seal

Tighten the 4 bolts (tightening torque to 1.0 da.Nm)