Re-assembling: engine (SOFIM) Peugeot Boxer I

Refit the piston rings

(d) engraving

• Engine type
• Category of piston diameter
• Make

(e) conrod number

(f) groove for piston cooling orifice

Refit

• The stop ring (1)
• The connecting rod (3)
• The shaft (2)
• The stop ring (4)

Refit

• The piston base jets (5); insert the lug (g) in its housing in the cylinder block
• The bolts (6); tightening torque to 4 ± 0,4 da.Nm

Refit

• The grooved half-shells (7)
• The half-shell (8) with flange (flywheel side)
• The crankshaft

Oil

• The crankshaft seatings
• The half bearing shells

Refit

• The seals (9)
• The half bearing shells (flywheel side)
• The half-shell (8) with flange (flywheel side)

Determination of the category of half-shells

• Use tool [16]
• Cut 5 pieces from the plastic gauge [16] to the same width as the half-shells
• During this operation, the crankshaft must not rotate

Position the plastic threads on the crankshaft journals

Fit

• The crankshaft main bearings cap castings
• The securing bolts

Tighten the mounting bolts progressively

• Tightening torque to 5 ± 0,5 da.Nm
• Angular tightening to 90°

Slacken the bolts

Remove the main bearing cap casting

Compare each width (in mm) of flattened plastic wire at its widest point with the graduations on the paper envelopes

The value read indicates the running clearance

Clean the plastigage threads and oil the crankshaft

Select the category of bearing half-shells

Match the mark (h) on the main bearing cap casting with the mark (i) on the cylinder block

Fit the crankshaft main bearing cap casting on the cylinder block

Oil the fixing bolts on the main bearing cap casting

Tighten the mounting bolts progressively

• Tightening torque to 5 ± 0,5 da.Nm
• Angular tightening to 90°

Position the tools [2] - [3]

Press axially on the crankshaft in the cylinder block

Set the dial gauge [2] to zero

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

There should be an endfloat of 0,06 to 0,21 mm

Cut out the excess seal at (j) (if necessary)

Position the main bearing on the centralising bushes

Refit

• The seal (moisten the seal before refitting)
• Diesel injector extractor (11)
• The 2 bolts (12); tightening torque to 0,75 ± 0,1 da.Nm

Refit

• The seal (moisten the seal before refitting)
• Diesel injector extractor (13)
• The 7 bolts (14); tightening torque to 2,5 ± 0,2 da.Nm

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

Position the piston rings collar [4]

Fit the half-shells (15) on the conrods (16)

Oil

• The pistons
• The dipstick guide

Fit the half-shells conrod caps

Oil the half-bearing shells

Determination of the category of half-shells

• Use tool [16]
• Cut 4 pieces from the plastic gauge [16] to the same width as the half-shells

Place the plastic wires [16] on each of the crankshaft crank pins

Refit

• The big end caps (17)
• The bolts (18)

Tighten the mounting bolts progressively

• Tightening torque to 5 ± 0,5 da.Nm
• Angular tightening to 60°

Slacken the bolts (18)

Remove the conrod caps

Compare each width (in mm) of flattened plastic wire at its widest point with the graduations on the paper envelopes

The value read indicates the running clearance

Clean the plastigage threads and oil the crankshaft

Select the category of bearing half-shells

Refit

• The oil pump strainer (19)
• Diesel injector extractor (13)
• The bolts (20); tightening torque to 2,5 ± 0,2 da.Nm

Refit

• The sump (21)
• Diesel injector extractor (13)
• The bolts (22); tightening torque to 1,8 ± 0,2 da.Nm

Match the marks (l) of the engine flywheel and (m) on the cylinder block, made at the time of their removal

Fit the tool [1]

Refit

• The flywheel (23)
• The bolts (24)

Tighten the mounting bolts (24) progressively

• Tightening torque to 3 ± 0,3 da.Nm
• Angular tightening to 90°

Refit

• The clutch mechanism (25)
• The bolts (26)

Centre the clutch disc using the tool [5]

Tighten the bolts (26) to 3 ± 0,3 m.daN

Remove the tool [1]

Place the dial gauge bracket [6] on the cylinder block

Fix the dial gauge [2] on the bracket [6]

Set the dial gauge to zero (as "n")

Check the difference in height at (p)

Position the pistons at mid-stroke

Refit

• The cylinder head gasket (position the marks ALTO on the intake and exhaust manifolds side)
• The cylinder head
• The bolts

Pre-tighten to 6 ± 0,6 daNm

Tightening torque to 6 ± 0,6 da.Nm

Angular tightening to 180°

Refit

• The vacuum pump (45)
• The bolts (46); tightening torque to 1,8 ± 0,2 da.Nm

Refit

• The heat exchanger (47)
• The bolts (48)

Bolts (48)

• Length: 56 mm; tightening torque to 7 ± 0,7 da.Nm
• Length: 74 mm; tightening torque to 8 ± 0,8 da.Nm

Refit

• The oil pump (49)
• The bolts (50)

Bolts (50)

• Diameter: M8 tightening torque to 2,5 ± 0,2 da.Nm
• Diameter: M12 tightening torque to 6 ± 0,6 da.Nm

Refit

• The dipstick guide (51)
• The u bolt (52)
• The nuts (53)

Refit the injection pump

Refit

• Refit the coolant pump (55) using a new seal
• The bolts (56)
• The roller tensioner (57) and the bracket
• The nut (58)
• The nut (59)

Refit

• The cylinder head cover (60)
• The nuts (61)

Refit

• The oil pressure switch (70)
• The pipe (69)
• The air intake manifold

Couple the 2 pipes (71) on the inlet manifold

Refit

• The style cover (72)
• The bolts (73); tightening torque to 1 ± 0,1 da.Nm

Refit

• The casing (75)
• The bolts (74)

Position the tool [1] on the engine flywheel

Refit

• The accessory pulley (77)
• The (76) bolt; tightening torque to 20 ± 2 da.Nm

Remove the tool [1]

Refit

• The alternator (81) with its clip
• The bolts (80) - (78) - (79) and their washers

2.8 TD - 2.8 TDI engines

2.8 HDI engine

Refit the ancillary belt

Place the tool [15] on the span (z) - (x)

Tighten the adjustment screw (86), screw (87) and screw (88) to obtain the tensioning figure

• The tension value should be between 100 and 144 SEEM units (new belt)
• The tension value should be between 62 and 76 SEEM units (re-used belt)

Tighten the bolts (87) - (86) - (88) to 5 ± 0,5 m.daN

Remove the tool [15]