B1BG0YK1 - 406D9 DW10 ENGINE

REASSEMBLY ENGINE (CYLINDER BLOCK)

1 - REASSEMBLY

Place the cylinder block on the stand .

Carefully clean all the seal surfaces using scouring product .

Clean the threads and taps .

Do not use sharp or abrasive tools .

The joint faces must not have any trace of knocks or scores .

Fit :

• the oil level sensor (1) : tightening torque 2.7 da.Nm
• the oil pressure sensor (2) : tightening torque 3.2 da.Nm
• the oil pipe plugs (3) and their seals : tightening torque 3.4 da.Nm

Refit the piston base spray jets (4), Tighten the bolts to 1 da.Nm .

Fit the grooved main bearing half-shells (5), on the cylinder block side .

Lubricate the crankshaft main bearings .

Fit :

• the crankshaft (6)
• the side stop thrust washers (7), grooved surface in contact with the crankshaft

NOTE : THICKNESS OF THE STOP THRUST WASHERS .

APPLY (E10) SEALING COMPOUND TO THE CORNERS AND ENDS (A) OF MAIN BEARING NO. 1 .

PLACE TOOL [6] ON THE CAP OF BEARING NO. 1 :

• the shim slide (8) must be in the extension of surface (9) of the bearing cap
• tighten the clamp (10)

Refit the side seals (11) in the groove of the main bearing cap, with the minimum protrusion at (B) .

Lubricate the two surfaces of the feelers (12) .

PLACE THE FEELERS (12) ON TOOL [6] ABOVE THE HEEL (13) OF THE MAIN BEARING CAP .

The side seals (11) must have a minimum protrusion of approximately 1.5 mm (Maximum = 4 mm) .

Engage the cap/side seal assembly in the cylinder block, by tilting the assembly .

Position the main bearing on the centralising bushes .

Tighten the 2 bolts (14) .

REMOVE THE TOOL [6] SIDEWAYS .

IMPERATIVE : the new side seals are supplied to the correct length and must not be cut, if the protrusion is too great, repeat the fitting operation .

Position :

• the side stop thrust washers grooved surface in contact with the crankshaft
• the bearing caps (15)

IMPERATIVE : MARKING AND DETERMINING OF THE BEARING HALF SHELLS .

Tighten :

• the bolts (16) to 2.5 da.Nm + 60°

FIT THE DIAL GAUGE [7] USING TOOLS [8] - [9] .

This end float should be between 0.07 and 0.32 mm .

Adjust the clearance by adjusting the thickness of the side stop thrust washers .

FIT A NEW OIL SEAL (16) USING THE TOOL [1C + 1D] .

Refit the seal by tapping with a mallet to the limit .

Remove the tool with a rotating movement .

IMPERATIVE : the outer face of the lip seal must be free of all traces of oil .

Con rod positioning .

Check that the new main bearing shell is fitted on the con rod big end .

MARKING AND DETERMINING OF THE BEARING HALF SHELLS .

IMPERATIVE : piston and pin must match .

Assemble the connecting rods and pistons directing the notches (17) to the side opposite the recesses (18) on the pistons .

Fit :

• the oiled gudgeon pins
• the new retaining rings

Ensure that the con rods turn freely on their pins .

Fit the rings using piston ring pliers .

IMPERATIVE : turn the word TOP stamped on the rings to face upwards .

Position the ring gaps at 120 degrees to the scraper ring gap .

IMPERATIVE : direct the recesses (18) to the side opposite the oil filter fixing (19) .

Oil the piston rings and cylinder jackets .

Insert the con rod/piston assembly in the corresponding cylinder using a ring compressor .

Fit the big end cap with a new oiled main bearing shell .

IMPERATIVE : line up the cap bearing shell notch (20) with the con rod bearing shell notch (17) .

IMPERATIVE : always fit new connecting rod cap nuts .

Clean : The bolts, The nuts .

COAT THE BIG END NUTS (THREAD AND CONTACT SURFACE) WITH G10 .

Tightening is carried out in two stages .

Stage 1 :

• tighten the nuts to 20 da.Nm

Stage 2 :

• finally tighten by turning through 70 °, USING THE TOOL [3]

(X) = 10 mm .

Clean the checking surfaces .

FIT THE DIAL GAUGE [7] ON THE BRACKET [15] .

Turn the crankshaft .

Place the needle of the dial gauge on one of the checking points (Checking point C) .

Continue turning the crankshaft until the piston reaches TDC ; Read the value .

Turn a quarter turn backwards .

Move the piston to the Top Dead Centre value without ever exceeding it .

Zero the dial gauge .

MOVE THE DIAL GAUGE/BRACKET ASSEMBLY [7] AND [15] OVER THE CYLINDER BLOCK .

Read the value .

Place the needle of the dial gauge on one of the checking points (Checking point D) .

Zero the dial gauge .

Read the value .

Calculate the average of the 2 values measured .

Continue in the same way for the other three cylinders .

NOTE : maximum gap between 2 pistons : = 0.07 mm .

WARNING : the highest average value determines the thickness of the gasket .

Fit :

• the cotter (22)
• the drive pinion (24) for the oil pump on the crankshaft
• the oil pump by placing the chain on the gears

Tighten the bolts to 1.6 da.Nm .

Fit :

• the dipstick tube (25)

TIGHTEN THE BOLT : 0.9 da.Nm + E3 .

COAT THE PLATE (26) WITH E10 SEALING COMPOUND .

Fit :

• the seal carrier plate (26)
• tightening torque : 1.5 da.Nm

FIT A NEW OIL SEAL (27) USING THE TOOL [1B] + [1C] .

FIT A NEW LIP SEAL USING TOOL [1B] + [1C] + Bolt (28) .

Remove the tool with a rotary movement .

IMPERATIVE : the outer face of the lip seal must be free from all traces of oil .

Fit the pump (29) using a new seal .

Tighten the bolts to 1.5 da.Nm .

1 - 1 - ALUMINIUM OIL SUMP

NOTE : for engines fitted with an aluminium oil sump, check that the dowel pin (30) is present .

COAT THE SUMP GASKET SURFACE WITH A BEAD OF (E10) SEALING COMPOUND .

IMPERATIVE : ensure that the bead of sealing compound goes right round each of the threaded holes in order to guarantee a tight seal .

Fit the sump, Tightening torque : 1.6 da.Nm .

SCREW THE TWO THREADED RODS OF THE TOOL [1K] INTO THE CRANKSHAFT .

Check that the centralising pin is present .

Refit the flywheel (32) .

RETAIN THE ENGINE FLYWHEEL (32) IN PLACE USING THE CENTRING PINS AND FASTENERS OF THE TOOL (1K) .

INSERT THE FLYWHEEL STOP [1I] .

CLEAN AND COAT WITH (E3) THE BOLTS .

1st fitting : Single engine flywheel .

CLEAN AND COAT WITH (E3) THE BOLTS .

Tightening torque : 4.75 da.Nm .

2nd fitting : Double flywheel .

IMPERATIVE : following any work: when disassembling the double flywheel from the crankshaft, always replace the double flywheel bolts .

Fit the pre-coated bolts .

Tightening torque : 4.8 da.Nm .