Dismantling: engine (DW8B) Peugeot Partner I facelift

Tooling

[1] toothed sector for locking the flywheel

[2] injection pump setting pin Ø 6

[3] flywheel locating peg (TDC)

[4] bolts H M8

[5], 6016-T, (-).0132 AA toothed belt pinion locking tool

[6], 149-T, (-).0188 L set of levers for releasing the cylinder head

Removing: accessories

Exhaust manifold side

Separate the exhaust gas recycling pipe (5) from the exhaust manifold (6) and from the air inlet manifold (3)

Remove

• The TDC sensor (1)
• The vacuum pump (2)
• The inlet manifold (3)
• The exhaust manifold (6)
• The inlet manifold (4) and the exhaust gas recycling pipe (5) simultaneously
• Coolant inlet housing (7) (and connecting hoses)

Near the fuel pump

Remove

• Fast idle cable (8)
• The fuel filter (11) (well + filter)
• The cover (13)
• The thermostat
• The thermostat (12)
• High-pressure fuel pipes (9)
• The degassing hose (10)

Timing gear side

Remove

• The bolts (14)
• The pulley (15)
• The fuel pump cover (17)
• The top cover (16)
• The sump (18)
• The upper cylinder head cover
• The lower cylinder head cover

Peg the flywheel with tool [3]

Clutch

Fit the tool [1]

Remove

• The bolts (20)
• The clutch mechanism (19)
• The clutch disc

Timing gear

Peg

• The camshaft gear (27) using tool [4]
• The fuel pump drive gear (32) using tool [2]

Slacken the bolts (26), (29) and (31) using tool [5]

Remove

• The roller tensioner (24)
• The timing belt (30)
• The (21) bolt
• The crankshaft gear (22)
• The coolant pump (23)
• The engine mounting (25)
• The bolts (29)
• The (26) bolt
• The camshaft gear (27)
• The peg [4]
• The camshaft hub (28)
• The bolts (31)
• The fuel pump drive gear (32)
• The peg [2]
• The tensioning roller (33)

Remove

• The oil filter (36)
• The (37) bolt
• The heat exchanger (34)
• The oil pressure switch (35)

Remove

• The bolts (38)
• The flywheel (39)
• The tool [1]

Cylinder head

Slacken the 10 bolts (follow the recommended sequence)

Remove

• The 10 bolts
• The cylinder head
• The cylinder head gasket

Fuel pump (LUCAS DIESEL or BOSCH equipment)

Remove

• The bolts (40)
• Rear fixing
• The fuel pump (41)

Remove

• The bolts (42)
• The bracket (43)

Sump

Steel sump

Remove

• The bolts (44)
• The oil sump (45)
• The seal

Aluminium sump

Remove

• The bolts (46)
• The oil sump (47)

Front sealing panel

Remove

• The bolts (48)
• The sealing panel (49) and its seal

Oil pump

Remove

• The bolts (51) (mark their location)
• The (54) bolt
• The pick-up unit (53)

Push the pinion (56) towards the cylinder block

The chain (57)

Remove together

• The oil pump (52)
• The chain (50)
• The pinion (56)
• The spacer (55)

Big end caps

Remove

• The 8 nuts (58)
• The big end caps (59)

Crankshaft bearing caps

Remove

• The bolts (60)
• The main bearing caps (61)
• The thrust washers (bearing N° 2)

Crankshaft

Remove

• The crankshaft hub (63) seal (62)
• The crankshaft (63)
• The thrust washers (bearing N° 2)
• The cylinder block shell bearings
• The piston base jets

Connecting rods / pistons

Remove the connecting rod/piston assemblies (64) (from above)

Disassembling the connecting rod/piston assemblies

Remove

• The circlip (65)
• The shaft (66)
• The circlip (68)
• The piston (70)
• The piston rings (67)
• The half bearing shells (69)