Engine block, oil pan and timing case
1 – oil pan, 2 – timing drive housings, 3 – engine cylinder block, 4, 5 – plugs, 6 – oil drain plug
Crank mechanism
1 – crankshaft, 2 – bearing shells, 3 – front bearing cap, 4 – flywheel, 5 – connecting rod, 6 – shells, 7 – piston pin, 8 – piston, 9 – piston rings, 10 – thrust half rings for adjusting the axial play of the crankshaft
1. Remove the oil vapor drain pipes and the coolant hose.
2. Remove the receiver and lift bracket in the XUD 9 engine.
3. Remove the generator and belt.
4. Remove the pulley attached to the end of the camshaft, the pump and the belt.
5. For XUD 7TE engines, remove the intake manifold, turbocharger and exhaust manifold.
6. Remove the drive housing and the support element located on the central bolt.
7. Remove the crankshaft pulley and lower plastic cover.
8. Remove the glow plugs.
9. Turn the engine crankshaft to a position that allows the elements of the valve timing system to be locked: the holes in the crankshaft and fuel filter pulleys must be in a position that corresponds to the position of the threaded holes made behind the pulleys.
10. Insert the locking bolts 7.0153 G and tighten them by hand (see figure Method of fixing elements of the camshaft drive):
- screw one long bolt into the camshaft pulley;
- screw two short bolts into the fuel pump pulley.
11. Unscrew the camshaft pulley mounting bolt and the central fuel pump mounting nut.
12. Release the drive belt tension roller by unscrewing the nut (1, see figure Adjusting the Timing Belt Tensioner Roller) axle bolt and bolt (2):
- press the tension roller at (3) using a 9.53 mm square wrench (3/8 inch junior Fac) to compress the spring.
13. Screw in the bolt and nut.
14. Remove the toothed belt. Do not bend the toothed belt. It should not have contact with oil, water, coolant or grease.
15. Remove the high pressure fuel pump and pump pulley.
16. Remove the camshaft and crankshaft pulleys.
17. Remove the coolant pump and seal (5 bolts).
18. Remove the upper bolt and nut of the tension roller axle.
19. Remove the tension roller, push rod and spring.
20. Remove the engine bracket and roller.
21. Remove the fuel pump bracket and the two bracket mounting guide pins from the engine block.
22. Remove the cylinder head cover and engine block.
23. Unscrew the bolt and remove the support element near the manifold.
24. Remove the cylinder head cover.
25. Unscrew the camshaft bearing caps one by one and remove the camshaft. The bearing caps are marked 1 through 3 (No. 1 on the flywheel side).
26. Loosen the cylinder head mounting bolts in a spiral pattern, starting from the outside (reverse order of screwing).
27. Remove the bolts and washers.
28. Use a lever to tilt the engine forward to remove the pin.
29. Remove the cylinder head and gasket.
30. Remove the flywheel.
31. Turn the engine over.
32. Remove the oil pan.
33. Remove the timing drive side seal cover and remove the paper gasket.
34. Remove the three oil pump mounting bolts.
35. Remove the chain and sprocket with key secured to the end of the crankshaft.
36. Remove the connecting rod caps, mark their order and method of attachment.
37. Remove the main bearing caps and liners, as well as the thrust washers.
(Original is located at: www.PEUGEOTBOOK.ru)
38. Remove the crankshaft.
39. Remove the connecting rod-piston assemblies.
40. Remove the grooved bearings installed in the engine cylinder block.
41. Unscrew the oil channel plugs (1) and the oil pressure sensor. Clean the oil channels. Install the plugs and sensor.
42. In the connecting rod-piston kit, remove the pin retaining spring ring and remove the pin.
43. In XUD 7TE engines, remove the piston cooling oil supply nozzle.
44. Clean all oil passages thoroughly.