Disassembling the engine (Peugeot 206)

Place the washed and cleaned engine on a disassembly stand (if there is no stand, the engine can be secured on a flat surface).

Disassemble the engine in the following order:

1. Loosen the cylinder head cover mounting nuts and remove the cover with the gasket.



2. Remove the spacer bushings 2 (figure 3.5) and an oil-deflecting screen.

3. Remove the exhaust manifold heat shield.





4. Remove the exhaust manifold 4 (figure 3.6) and its gasket.

5. Unscrew the oil filter 8.

Note: On some engines (depending on the configuration) a heat exchanger can be installed under the oil filter, into which a threaded extension is screwed for installing the oil filter.

6. Remove the threaded fitting and heat exchanger, if installed (see figure 3.6).

7. Remove the dipstick from the guide tube.

8. Remove the dipstick guide tube.

9. Use a wrench to remove the oil pressure indicator sensor, if installed (depending on the configuration) (see figure 3.6).

10. Use a wrench to unscrew the oil pressure indicator lamp sensor.



11. Remove block 3 from the intake manifold installation side (depending on the engine type) (figure 3.7) ignition coils.

12. Remove the fuel rail with injectors.



13. Remove the intake manifold.

14. Remove the cooling system thermostat unit from the end of the cylinder head.

15. Unscrew the coolant temperature sensor from the end of the cylinder head.

16. Remove the lifting eyes for the power unit from the cylinder head.

17. Remove the knock sensor (it is located on the cylinder block under the intake manifold).



18. Remove the three timing belt covers (figure 3.8).





19. Lock the crankshaft flywheel with tool 7 (figure 3.9) to fix it (a pin or bolt with a diameter of 6 mm can be used as a retainer), inserting it into the hole in the front left flange of the cylinder block.

20. Loosen the generator drive pulley mounting bolts and remove the pulley.

21. Loosen the timing belt tensioner mounting bolt.

22. Loosen and remove the timing belt.

23. Remove the timing belt tensioner roller.

24. Lock the camshaft toothed pulley using tool 0132A, unscrew its mounting bolt and remove the pulley.

25. Remove the toothed pulley from the crankshaft.

26. Loosen the coolant pump mounting bolts. Remove the coolant pump with the gasket from its seat in the cylinder block.

Note: If complete disassembly of the engine is not required, the cylinder head can be removed as a complete assembly with pipelines and auxiliary units.

27. Unscrew bolts 1 (figure 3.10) cylinder head fastenings and remove it together with the camshaft. If necessary, disassemble the cylinder head. To separate the head from the cylinder block, use the 0153-Q tool kit; these devices are L-shaped levers (figure 3.11), which are inserted into the holes of the head mounting bolts (see figure 3.4).

Note: It is necessary to unscrew the cylinder head mounting bolts starting from the periphery in a spiral, moving towards the center of the head.

28. Remove the cylinder head gasket.

Warning! Operation item 29 is only for engines with an aluminum alloy cylinder block.

29. Install two clamping plates 1 on the cylinder block (figure 3.12) to hold the cylinder liners. The plates are mounted on bolts that are screwed into the holes for the cylinder head mounting bolts.



30. Remove bushings 1 (figure 3.13) for centering the head on the cylinder block.

31. Remove tool 0132-QZ (see figure 3.4) for fixing the engine flywheel.



32. Install stopper 1 into the hole in the cylinder block (figure 3.14) flywheel.

Warning! Operations 33–37 are only for engines with an aluminum alloy cylinder block.

33. Loosen the mounting bolts and remove the cover with pump 1 (figure 3.15) cooling systems.

34. Remove the cooling system pump centering pins from the cylinder block.

35. Remove the sealing ring.

36. Remove the cooling system pump.

37. Remove the oil channel plug.

Warning! Operations 38-39 are only for engines with a cast iron cylinder block.

38. Loosen the mounting bolts and remove pump 1 (figure 3.16) cooling systems.

39. Remove plug 2 of the oil channel.



40. Loosen the mounting bolt and remove the toothed pulley 1 (figure 3.17) crankshaft.

41. Remove spacer washer 2 from the crankshaft end.



If the clutch was not removed during disassembly of the power unit, then remove the clutch housing with the pressure plate assembly and the clutch disc (figure 3.18).

42. Loosen the mounting bolts and remove flywheel 3 from the crankshaft.

43. Remove plug 4 of oil channel.

Warning! Operations 44–61 are only for engines with an aluminum alloy cylinder block.

44. Unscrew the bolts securing the lower crankshaft main bearing cap housing from the cylinder block (figure 3.19).

45. Turn the engine over with the crankcase facing up.

46. Unscrew the nuts and bolts securing the pan.



47. Remove the tray 3 (figure 3.20).



48. Loosen the oil pump mounting bolts and remove the oil pump 1 (figure 3.21) with oil receiver.

49. Remove the oil pump centering pin.



50. Loosen the mounting bolts 2 (figure 3.22) and remove the lower crankshaft main bearing cap housing.

51. Remove the engine crankshaft oil seal (from the valve timing side).

52. Remove the engine crankshaft oil seal (from the flywheel side of the crankshaft).



53. Remove gear 5 (figure 3.23) and the oil pump drive chain.

54. Remove the key from the crankshaft groove.

55. Loosen the connecting rod bolt nuts and remove the connecting rod caps.

56. Remove the crankshaft from the main bearing seats.

57. Remove the upper crankshaft main bearing shells.

58. Remove the thrust half rings from the crankshaft center support.

Note: Mark the connecting rod cap shells before removal to ensure they are installed in the same locations during reassembly.

59. Remove the clamping plates 1 (figure 3.24), holding the cylinder liners.

60. Remove the liners from the cylinder block together with the pistons and connecting rods attached to the pistons. If the liners are to be reused, mark their locations in the cylinder block.

Warning! Operations pp. 61-79 are only for engines with a cast iron cylinder block.

61. Thoroughly clean all mating surfaces with D2 to remove any remaining metal.

62. Unscrew the nuts and bolts securing the pan.



63. Remove the tray 4 (figure 3.25).

64. Remove the front crankshaft oil seal holder.

65. Remove the front oil seal from the holder.

66. Loosen the oil pump mounting bolts and remove the pump with the oil receiver.

67. Remove the oil pump centering pin.

68. Remove the oil pump drive gear and chain.

69. Remove the key from the crankshaft groove.



70. Loosen the mounting bolts and remove the holder 1 (figure 3.26) rear crankshaft oil seal.

71. Remove the rear oil seal from the holder.

Note: Mark the bearings and caps before removal so that they are installed in the same locations during reassembly.

72. Unscrew the nuts of the connecting rod bolts, remove the covers 1 (see figure 3.27) connecting rods.

73. Loosen bolts 2 securing the crankshaft main bearing caps and remove the caps together with the lower liners.

Note: The crankshaft main bearings are marked 1 through 5, mark 1 (first bearing) located on the flywheel side of the engine.

74. Remove the thrust half rings from the main bearing seat No.2 (they are located in the cylinder block).

75. Remove the crankshaft from the main bearing seats.

76. Remove the upper main bearing shells from the beds.



77. Install the cylinder block as shown in Figure 3.28.

78. Remove the pistons together with the connecting rods, having previously marked their locations in the cylinder block (if they are to be reused during engine assembly).



79. Remove the injectors 1 (see figure 3.29) oil cooling of the piston bottom.