Engine assembly (Peugeot 307)

Install the grooved main bearings from the side of the cylinder block.

Lubricate the bearing surface with a thin layer of engine oil.

Install the crankshaft to the cylinder block.

Install thrust washers so that the side with the groove is on the side of the crankshaft.



Check the axial play of the crankshaft by reinstalling the crankcase of the main bearing caps 2 (pic. 3.63) and fix it with 10 bolts 1, tightening them to 10 Nm.

Install a bracket with a dial indicator on the engine block so that the measuring tip of the indicator rests on the end of the crankshaft.

Move the crankshaft along the axis to one side until it stops and set the indicator to 0. Move the crankshaft along the axis to the other side until it stops and fix the value on the indicator. The nominal value of the axial clearance of the crankshaft is 0.06-0.15 mm. If the clearance exceeds the allowable value, it is necessary to install thicker thrust half rings.

Turn out bolts and remove a case of covers of radical bearings.




Check for presence of centering sleeves 1 (pic. 3.64) in the crankcase of the main bearing caps. If necessary, replace or install new centering sleeves. Insert the centering sleeve halfway into the crankcase of the main bearing caps and fix them in this position with the special tool 2.

Apply AUTOJOINT NOIR around the perimeter of the main bearing cap housing.

Install the main bearing cap housing.




Consistently (see fig. 3.62), tighten the main bearing cap housing bolts in several stages:

• 1st - tighten the M11 bolts to a torque of 10 Nm;
• 2nd - tighten the M6 bolts to a torque of 5 Nm;
• 3rd - unscrew the M11 bolts;
• 4th - tighten the M11 bolts to a torque of 10 Nm;
• 5th - tighten the M11 bolts to a torque of 20 Nm;
• 6th - tighten the M11 bolts at an angle of 70°± 5°;
• 7th - tighten the M6 bolts to a torque of 10 Nm.

After tightening the bolts, check that the crankshaft turns easily and smoothly.

Turn the engine crankshaft so that the piston of the 1st cylinder is at BDC.



Install the piston rings on the pistons. Label «TOP» on the second piston compression ring must point towards the piston crown (pic. 3.65). The lock of the second compression piston ring must be rotated 180°in relation to the first compression ring. The oil scraper ring does not have a lock.

Before installing the piston in the cylinder, the piston rings must be compressed using a special sleeve or a compression band clamp.


Install a predetermined grade upper bearing into the connecting rod and lubricate its running surface with a thin layer of engine oil.

Lubricate the surface of the cylinders with a thin layer of engine oil.

Install the piston with piston rings in the cylinder, while the special sleeve or tie band should be firmly pressed against the cylinder block and located exactly in the center of the cylinder liner. The arrow on the piston must point towards the toothed belt.

Using a hammer handle, insert the piston into the cylinder, while making sure that the oil scraper piston ring is correctly installed.

Turn over the cylinder block.

Install the lower bearing into the connecting rod cap and lubricate its working surface with a thin layer of engine oil.

Install the connecting rod cover and secure it with bolts, tightening them to a torque of 23 Nm and then tightening by an angle (45±5) °. Lubricate the bolts with a thin layer of engine oil beforehand.

Install the rest of the pistons in the same way.

Apply sealing paste AUTOJOINT NOIR to the mating surface of the front cover with oil pump.




Install front cover 2 (pic. 3.66) with oil pump on the cylinder block.

Coat the threads of the front cover bolts with LOCTITE FRENETANCH to prevent them from loosening.

Fix the front cover 2 with the oil pump with bolts, tightening them with a torque of 8 Nm.

Clean the mounting locations of the front and rear crankshaft oil seals.

Lubricate the seal lips with engine oil before installing them.

Using drifts, install the front and rear crankshaft oil seals.

Install and bolt the anti-oil emulsification plate.

Install and bolt the oil pickup with a new gasket with strainer.

Apply a thin, even layer of AUTOJOINT NOIR sealing paste to the mating surface of the cylinder block with oil pan.



Check the presence of the guide pin 3 on the cylinder block (pic. 3.67).

Reinstall oil pan 2.

Screw in the oil pan mounting bolts until the bolt heads contact the oil pan, but do not tighten the bolts.

Place a metal ruler on the end of the cylinder block and, moving the pallet, install it so that it is flush with the cylinder block.



Tighten bolts 1 and 3 (see fig. 3.61) fixing the oil pan with a torque of 8 Nm.

Use a tap to clean the threads in the crankshaft for attaching the flywheel.

Clean the mating surfaces of the crankshaft and flywheel.

Reinstall the flywheel and screw in new bolts until the bolt heads contact the flywheel.



Turning the flywheel, align the blind hole on the flywheel with the hole in the cylinder block, and special tool 1 (see fig. 3.59) block the flywheel from turning.



In the sequence shown in fig. 3.68, tighten the flywheel mounting bolts to a torque of 20 N·m, then tighten them in the same sequence by an angle (26±3) °.

Remove the flywheel locking tool.

Rotate the crankshaft until the pistons are in the middle of their stroke.

Check for the presence of dowel sleeves in the cylinder block.

A new cylinder head gasket must be removed from the packaging immediately before installation.



Install the gasket on the guide bushings 1 (pic. 3.69), while the inscription «TOP» should be directed towards the head and located on the side of the oil filter.

Install the cylinder head.

Before reusing the bolts, measure the length of the bolts to the base of the head, which should be (144,5±0,5) mm.

Lightly coat the threads of the cylinder head bolts with MOLYKOTE G RAPID PLUS grease, insert the bolts and hand-tighten.



In the sequence shown in fig. 3.70, tighten the cylinder head bolts in several steps:

• 1st - tighten with a torque of 15 Nm;
• 2nd - tighten with a torque of 50 Nm;
• 3rd - unscrew the bolts one turn (360°);
• 4th - tighten with a torque of 20 Nm;
• 5th - tighten the corner (285±5).

In the future, additional tightening of the cylinder head bolts is not required.

If removed, reinstall hydraulic tappets, stoppers and camshafts.



Apply AUTOJOINT NOIR sealing paste to the mating surface of the crankcase of the camshaft covers in an even layer with a diameter of 3.5 mm (pic. 3.71).

Install the camshaft cover housing to the cylinder head.

Note. Turn the camshafts to ensure accurate installation of the crankcase covers.

Check camshaft protrusion A (pic. 3.72) from the cylinder head, which must be within (8,0±2,0) mm.

Install bolts 1 and screw them in until the bolt heads come into contact with the crankcase of the camshaft covers.

In the sequence shown in fig. 3.72, in several stages, tighten the bolts of the crankcase of the camshaft covers:

• 1st - tighten with a torque of 5 N·m;
• 2nd - tighten with a torque of 10 Nm.

Check the presence of the centering sleeves and install the water pump.



In the sequence shown in fig. 3.73, tighten the water pump mounting bolts in several stages:

• 1st - tighten with a torque of 3 Nm;
• 2nd - tighten with a torque of 8 Nm;
• 3rd - tighten with a torque of 14 Nm.

Establish a tension roller 3 of a toothed belt and fix it with a bolt 4 (pic. 3.74).

Install the rear toothed belt guards.

Install the guide roller 8 of the toothed belt and fix it with the bolt 9.

Install the toothed belt pulley 12, flange 10 on the crankshaft and screw in the central bolt 11.

Install the timing belt pulley to the exhaust camshaft. Holding the camshaft flat with a wrench from turning, screw in the pulley mounting bolt and tighten the torque first to 30 Nm, and then to 75 Nm.

Install and secure the toothed belt pulley to the intake camshaft in the same manner.

Use special tools 5 and 6 to secure the camshafts from turning.



Check that the center bolt 4 (pic. 3.75) the pulley fastenings are not tightened and the pulley 2 can rotate slightly.

Install toothed belt 5 on crankshaft pulley 2.

Using the special tool 1, fasten the toothed belt 5 to the crankshaft pulley 2.

Pull belt leg A to turn crankshaft pulley 2 as far as it will go against flange 3.

Install the timing belt in sequence on the guide pulley 8, the intake camshaft pulley, the exhaust camshaft pulley, the water pump 2 and the tension pulley 3 (see fig. 3.74).

Remove special tool 1 (see fig. 3.75).

Remove special tools 5 and 6 (see fig. 3.74), fixing the camshafts from turning.



For hexagon 3 (pic. 3.76) turn the tension roller 1 counterclockwise to the position where pointer 2 aligns with the imaginary line W.

Attention! When pointer 2 is aligned (see fig. 3.76) with an imaginary line W, it must pass through the notch X at an angle of at least 10°. Otherwise, replace the tension roller or tension roller and toothed belt.

Then for hex 3 (see fig. 3.76) turn the tension roller 1 in the direction of the arrow V until the pointer 2 aligns with the notch X.

Attention! The pointer must not move beyond the notch X, otherwise repeat the operations for tensioning the toothed belt.

Tighten the tension roller mounting bolt to 20 Nm.

Attention! The tension roller must not rotate when tightening its fastening bolt, otherwise repeat the operations for tensioning the toothed belt. The hexagon for turning the tensioning roller must be below the connecting plane of the cylinder head Z (see fig. 3.76). Otherwise, replace the tension roller or tension roller and toothed belt.

Rotate the cranked motor 10 revolutions without any pressure or external influences being applied to the toothed belt.

Special tools 5 and 6 (see fig. 3.74) secure the intake camshafts from turning.

Check that pointer 2 is aligned with notch X. Otherwise, repeat the toothed belt tensioning operations.

Special tool 1 (see fig. 3.74) secure the engine crankshaft from turning.

Tighten the central bolt of the toothed belt pulley on the crankshaft:

• bolt with steel washer (golden color) torque of 40 Nm and tighten it by an angle (53±4) °;
• annealed steel bolt with washer (metallic color) torque of 40 Nm and tighten it by an angle (40±4) °.

Reinstall the top 4 (see fig. 3.60) and bottom 3 toothed belt covers.

Install the engine mount 5 and idler 6.

Install the accessory drive belt pulley 2 and fix it with bolts 1.



Install cylinder head covers 2 (pic. 3.77).

Install the current phase sensor in cylinder 3.

Install the ignition coil unit 5 and secure it with bolts 4.

Establish fastening bolts and screw them before contact of heads of bolts with covers of heads of the block of cylinders.



In the sequence shown in fig. 3.78, in several stages, tighten the bolts of the cylinder head covers:

• 1st - tighten with a torque of 5 N·m;
• 2nd - tighten with a torque of 15 Nm.

Install the exhaust manifold gasket or a new heat shield.

Install the exhaust manifold and secure it with nuts, tightening them to 35 Nm.

Install the coolant outlet block gasket.

Replace the water pump coolant outlet block connector on the coolant outlet block.

Install the water pump coolant outlet assembly connecting pipe assembly with the coolant outlet assembly.

Install a new gasket to the catalytic converter.



Turn clamp 9 (pic. 3.79) so that it can be put on the welded bolt 6.

Establish a tube 4 systems recirculation of the fulfilled gases and fix it with a collar.

Screw the nut 5 onto the welded bolt 6.

Screw nuts 8.

Screw in bolts 3, 2 and 1. Tighten bolt 2 to 4 Nm.

Install the heat shield 7 and fix it with bolts.

Install oxygen sensors.

Install the EGR valve.



Remove plate 2 (see fig. 3.55) on the coolant outlet.

Lubricate the splines in the hub of the clutch disc with a thin layer of special grease based on molybdenum disulphide.

Install the clutch disc to the flywheel.

Install the clutch assembly, lining up the holes in the clutch housing with the flywheel guide pins. When reinstalling a previously removed clutch pressure plate, check that the marks made before removal are aligned.

Tighten the clutch mounting bolts so that the clutch disc is pressed, but at the same time can still move to the sides.



Using a special centering mandrel 1 (pic. 3.80) or an old transmission input shaft, center the clutch disc on the flywheel.

After centering the driven disk, gradually tighten the bolts 3 securing the clutch cover 2 diagonally to a torque of 20 Nm.

Remove the mandrel from the driven disk.

Install the knock sensor and secure with the bolt, tightening it to 20 Nm.

Install the oil filter support and oil filter.



Install air distributor 1 (pic. 3.81) together with the distribution rail for fuel injection and secure with nuts 2 and bolts 3, tightening them to a torque of 20 Nm.

Connect the pipe of the cooling system and secure it with a clamp 4.