Placement of oil channel plug between filter and main channel
1 – channel between the filter and the main channel
Placement of main oil channel plugs
2, 3 – main channels |
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Installing the sealing ring from the flywheel side of the engine
Places of application of the product "Rectijoint" for sealing the main bearing #1 of the crankshaft on later model engines
1, 2 - places of application "Rectijoint"
Installing the sealing ring in the front bearing housing
1. All O-rings, seals and gaskets should be replaced.
2. Lubricate the rubbing surfaces with motor oil.
3. Observe the factory markings and marks made during disassembly.
4. In XUD 7TE engines, install an oil supply nozzle for piston cooling.
5. Install grooved liners in the engine block and smooth liners in the main bearing caps.
6. Install the crankshaft and main bearing caps No.3, 4 and 5.
7. Install the thrust washers with the copper-plated surface facing the crankshaft, then install the No.2 main bearing cap.
8. Clean the mating surface of the engine block and bearing cap No.1, removing all traces of grease from them.
9. Place a small amount of sealant on the engine block at the top of the bearing grooves #1 "Loctite Frenetanch".
10. Install the bearing cap on the adjusted fixture 7.0153 A1, equipped with additional elements A2 (thickness 0.15 mm) and use the bolt to secure the cover to the fixture's clasp.
11. Lubricate the additional elements and secure the bearing cover in such a way as not to deform the side seals:
- place the 45° tilted cover assembly into the socket;
- straighten the knot;
- lower slowly;
- secure the cover with one bolt;
- remove the device in a horizontal plane.
12. Tighten the bearing cap bolts to 70 Nm.
13. On later models, to prevent oil leakage in the area of the crankshaft main bearing during repairs, a sealant called "Rectijoint". Remedy "Rectijoint" should be applied to the ends (1, see figure Application areas "Rectijoint" for sealing the main bearing No.1 of the crankshaft on later model engines) main bearing No.1 in accordance with the previously given instructions and in the bends of this bearing.
14. Check if the crankshaft rotates freely.
15. Install a dial indicator on the engine cylinder block on the valve timing side: use tools 8.0110 GY and 0.0117.2.
16. Check the crankshaft axial clearance, which should be 0.07–0.32 mm.
17. Install the sealing ring on the flywheel side using special tool 7.0153 C. Before doing this, lubricate the working surface, seat and ring with oil.
18. Place the piston ring locks evenly around the piston perimeter and secure the connecting rod-piston units. The characteristic recesses in the piston bottoms should be directed toward the fuel pump. The connecting rod bearing protrusions are installed on the same side.
19. Tighten the connecting rod cap nuts to a torque of 50 Nm.
20. Check the crankshaft torque. Use a torque wrench attached to an 8.0110 EZ tip mounted on the crankshaft in place of the flywheel. The measured torque should not exceed 40 Nm.
21. Align the ends of the side seals of bearing cap No.1 by 1 mm relative to the joint surface (a feeler gauge blade should be used).
(Data published on the website peugeotbook.ru)
22. Install the oil pump drive sprocket together with the key and chain, install the seal and cover.
23. Install the sealing ring with the working lips lubricated with oil into the socket (also greased with oil) in the lid.
24. Install the chain on the oil pump sprocket.
25. Install the pump on the engine cylinder block and secure it.
26. Apply a small amount of Peugeot sealing paste to the engine block-cover joint and to the joint surface.
27. Install the oil pan gasket, oil pan and tighten the mounting bolts (the three bolts on the cover are socket head cap screws with a hex socket).
28. Install the gear wheel by screwing the coated ones "Loctite Frenetanch" bolts with a torque of 50 Nm.
29. Check the piston protrusion and valve chamfer.
30. Install the tappets and adjusting plates or main adjusting plates with a thickness of 2.425 mm into the cylinder head.
31. Use an M12x150 tap to clean the threads in the engine cylinder block holes.
32. Turn the crankshaft so that the pistons are at mid-stroke; the pulley keyway should point to nine o'clock.
33. Install the cylinder head gasket and head; the bolt projections must be dry and free of grease.
34. Insert clean bolts. These bolts should be coated under the heads and on the threads "Molykote Rapid". New gaskets should be installed with the convex side facing up.
35. Tighten the bolts in the order shown in the figure Cylinder Head Bolt Tightening Sequence and Valve Positioning.
36. Check and adjust valve clearance.
37. After selecting the eight adjusting plates, place them in the appropriate place and insert the pushers.
38. After applying the product to the working surfaces of the camshaft " Molykoteg Rapid" install the camshaft in the head. The location of the camshaft is determined by the "DIST" sign, which should be on the timing drive side.
39. Clean the mating surfaces of the cylinder head and bearing caps, remove all traces of grease from them.
40. Apply Loctite to the ends of the cylinder head to prevent the threaded connections from loosening spontaneously.
41. Install the bearing caps (No. 1 on the flywheel side) and gradually tighten them to a torque of 15–17.5 Nm.
42. Using tool 7.0153E and the pulley mounting bolt, install new camshaft seals.
43. Install the fuel pump bracket.
44. Install the cylinder head cover and engine block.
45. Install the coolant pump together with the seal. The bolts should be tightened to 10 Nm.
46. Install the fuel pump and valve timing system.
47. In XUD 7TE engines, install the intake manifold.