2. Turn the cylinder block over to its normal position and check that the liner seats are absolutely clean. Even the slightest trace of dirt in the sockets can eventually cause the cylinder head gasket to leak. If you have not replaced the sleeves, they should be installed in their original locations, observing the marks made during disassembly. Check that the sleeves are clean and that their lower surfaces are free of dirt, traces of old sealant, etc.
3. Insert the sleeves into the block (without pads yet) and using a dial gauge, measure the amount of their protrusion above the upper surface of the cylinder block. For each sleeve, measurements are taken at four points, spaced 90° apart. If a dial gauge is not available, a ruler and feeler gauge probes can be used (see photo).
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(Information posted on the website: PeugeotBook)
4. All 4 numbers obtained for each sleeve must be the same: if they differ from each other by more than 0.02 mm, then the sleeve is at an angle.
5. Select a gasket of the required thickness for each sleeve, which would ensure the correct protrusion of the sleeve above the block. In this case, the difference in the amount of protrusion between adjacent sleeves should also not go beyond the specified limits. It is permitted to use no more than one gasket for each sleeve. If you have any problems, check to see if there is any dirt between the sleeve and the block and how accurately you measured. New sleeves can be swapped around in the block. If you still cannot get the desired result, the cartridges may be deformed and should be taken to a specialist for inspection.
6. After selecting gaskets for all the liners, install the liners with gaskets in the cylinder block and again check the amount of protrusion and the absence of distortions (see section 8).
7. If you have not replaced the pistons, they should be installed in the original liners, using the marks made during disassembly. Before installing the piston into the sleeve, the piston ring locks must be correctly positioned. The lock of the lower oil scraper ring expander should be located immediately above the axis of the piston pin, and the locks of the thin rings that are part of the oil scraper ring should be offset by 20-50 mm in different directions from the lock of the expander (see B/Figure 1.17). The locks of the middle and upper compression rings must be offset by 120° in opposite directions from the lock of the expander.
8. Clean the bearing seats in the lower connecting rod heads thoroughly and install the lower connecting rod bearing shells into them (see photo). Lubricate the inside of the cylinder liners with clean engine oil and, using a suitable piston ring compressor, insert the first piston with the connecting rod into its cylinder liners (see photo). Check that the sleeve gasket is properly seated and insert the sleeve into the block while guiding the connecting rod toward the crankpin (see photos). Check that the sleeve is correctly inserted into the block and the piston is correctly inserted into the sleeve. Old parts should have marks made on them during disassembly, and these marks should be aligned. If you are installing new sleeves, you should mark them according to their position.
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9. After installing all the sleeves with the connecting rod and piston groups, fix the sleeves with special metal strips so that they do not move during the installation of the connecting rod caps (see photo). Wipe and dry the covers thoroughly and install the lower connecting rod bearing shells into them. Lay out the caps in order and install them on the connecting rods, after thoroughly lubricating the connecting rod journals and bearing shells with clean engine oil (see photo). Check that the locating tabs on the bearing shells are mated on the same side. Install the connecting rod cap retaining nuts and tighten them to the specified torque (see photo).
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10. Check the crankshaft for free rotation.