2. Lubricate pistons and cylinder liners liberally with engine oil.
3. Compress the piston rings with a special clamp bandage so that the rings are fully inserted into the piston grooves and carefully insert the piston assembly with the connecting rod into the bore of each sleeve.
4. Slide a new O-ring onto the liner of each cylinder, paying attention to its correct position (the ring on the sleeve cannot be twisted).
5. Insert the cylinder liners together with the corresponding pistons and connecting rods into the upper part of the cylinder block.
6. Install the pistons in a position in which the arrows on their bottoms will be directed towards the gas distribution drive.
7. Attach the cylinder liners to the cylinder block with special Peugeot plates (attachment 0132 A1Z), screwing each plate with two M10 bolts 40 mm long.
8. Insert main bearings (dry) into the seats of the upper part of the cylinder block and lubricate their sliding surfaces with engine oil.
9. Carefully install the crankshaft into the main bearing seats of the cylinder block.
10. Insert the crankshaft thrust washers with the grooves pointing towards the crankshaft.
11. Measure the longitudinal play of the crankshaft with a dial gauge (correct value 0.1–0.3 mm), by applying the indicator to the end of the shaft on the timing drive side. Based on the measurements, if necessary, replace the thrust washers with washers of the appropriate thickness (same on both sides).
12. Insert connecting rod bearings (dry) into the connecting rod seats and lubricate their sliding surfaces with engine oil.
13. Fit the connecting rod caps together with the bushings, remembering to fit them to the respective connecting rods, and tighten the bolt nuts to 40 Nm.
14. Put the oil pump drive sprocket on the trunnion of the front end of the crankshaft, insert the key into the groove of the trunnion and put the chain on the gear.
15. Insert main bearings (dry) into the seats of the lower part of the cylinder block and lubricate their sliding surfaces with engine oil, mindful of their correct installation (main shells of the second and fourth bearings have grooves).
16. Degrease both connecting surfaces of the two parts of the cylinder block and lubricate them with a thin layer of sealing compound (For example, "Loctite Autojoint").
17. Carefully install the lower section of the cylinder block by pulling the oil pump drive chain over this section of the cylinder block.
18. Insert the ten crankshaft main bearing bolts and tighten them in two steps, first to 20 Nm and then to an angle of 45°.
19. Check whether the connecting rods are correctly connected to the crankshaft crankpins, paying attention to their movements to the sides.
20. Put the drive chain on the oil pump sprocket and install the pump on the cylinder block, paying attention to the position of the oil pump centering sleeve located at the bottom of the cylinder block.
21. Tighten the three oil pump mounting bolts to 8 Nm.
22. Turn the crankshaft several times, checking for smoothness and freedom of rotation.
23. Degrease both surfaces of the connection of the oil pan with the lower part of the cylinder block, lubricate them with a thin layer of sealing compound (For example, "Loctite Autojoint"), install the oil pan on the cylinder block and tighten the oil pan bolts to 8 Nm.
24. Screw in the two bolts connecting the upper and lower parts of the cylinder block on the front wall (from the side of the gas distribution drive) and tighten them to 8 Nm.
25. Screw in the two threaded plugs of the main oil passage located in the front and rear walls of the upper part of the cylinder block, tightening them to a torque of 30 Nm.
26. Install the cylinder block with the oil pan down.
27. Screw in the remaining bolts for both parts of the cylinder block and tighten them to a torque of 8 Nm.
28. Lubricate the lip of the crankshaft rear O-ring with engine oil and press the O-ring with the lip towards the inside of the engine into the rear seat of the cylinder block (flywheel side) using the appropriate mounting tool.
29. push in (all the way) in the front seat of the cylinder block (drive side) crankshaft front O-ring using the appropriate mounting tool.
30. Install the spacer ring and crankshaft pulley on the front end of the crankshaft; screw in the crankshaft pulley bolt by hand.
31. Install the flywheel on the rear end of the crankshaft and temporarily secure it with bolts.
32. Fix the flywheel with the special tool.
33. Lubricate the flywheel mounting bolts with "Loctite Frenetanch" and tighten them to 65 Nm.
34. Tighten the crankshaft pulley bolt to 110 Nm.
35. Insert the sealing ring of the coolant pump into the bore of the cylinder block (in the right wall of the cylinder block in the upper front part), and also adjust the coolant pump housing to the cylinder block using two centering sleeves and tighten the four bolts securing the pump to the cylinder block: two M6 bolts to 30 Nm and two M8 bolts to 50 Nm.
36. Remove two Peugeot special plates (attachment 0132 A1Z) fixing the cylinder bushings by unscrewing their fastening bolts.
37. Degrease the connecting surfaces of the cylinder block and cylinder head with the head gasket.
38. Insert the two cylinder head dowels into the holes in the top surface of the cylinder block on the water pump side.
39. Put the pulley on the camshaft and screw the bolt of its fastening by hand.
40. Insert a dowel into the hole for fixing the camshaft pulley and fix the camshaft.
41. Install a new cylinder head gasket on the upper surface of the cylinder block and install the head on it.
42. Install on the cylinder head all five brackets of the valve lever shaft with levers and their axis, paying attention to the correct installation of the intermediate fingers of each bracket of the valve lever shaft in their holes in the cylinder head.
43. Lightly coat the threads of the cylinder head bolts with Molykote G Rapi12 Plus. Screw in these bolts first by hand and then tighten them in two stages: first to 20 Nm and then to an angle of 240°, in order from the middle outward, moving in a spiral.
44. Install the tension roller and screw in its bolt by hand.
45. Check that the camshaft and crankshaft are correctly installed.
46. Fit the toothed belt first on the crankshaft pulley and then on the camshaft pulley. Tension the toothed belt with a slight force using a tension roller.
47. Remove the camshaft and crankshaft locating pins, and insert the Peugeot special tool into the tensioner roller (fixture 0132 X) for tensioning the toothed belt, or a suitably fitted 10 cm long rod forming a one-way lever with a 1.5 kg weight hanging at the end of the lever arm.
48. Loosen toothed belt tensioner bolt and tighten to 23 Nm.
49. Tighten camshaft pulley to 80 Nm.
50. Slowly turn the crankshaft in the direction of working rotation two turns by turning the crankshaft pulley bolt, and then fix the flywheel with the dowel pin.
51. Loosen the idler pulley bolt and lightly press the belt so that the pulley turns. In this position, the camshaft locating pin must not be inserted.
52. Tighten the idler pulley bolt to 23 Nm, remove the adjusting rod from the flywheel, slowly turn the crankshaft again in the direction of working rotation two turns and fix the flywheel again with the adjusting rod.
53. Slowly loosen the tensioner pulley bolt so that the weight of the tool tensions the toothed belt, then tighten the idler pulley bolt to 23 Nm and check that the camshaft locating pin can be inserted in this position. If so, remove both locating rods (camshaft and crankshaft).
54. Adjust valve clearances with a feeler gauge (intake valve clearance 0.2 mm, exhaust - 0.4 mm).
55. Install three-piece toothed belt guard and tighten bolts to 6 Nm.
56. Insert the sheet casing into the cylinder head (oil reflector) and two spacers, as well as install a new valve cover gasket and the cover itself, tightening its fastening bolts to a torque of 16 Nm.
57. Lubricate the end of the oil level indicator tube with "Loctite Frenetanch" and insert it into the cleaned socket, and then tighten the tube fastening to a torque of 15 Nm.
58. Fasten the oil pressure switch to the top of the cylinder block above the oil filter stand with a torque of 27.5 Nm.
59. Screw the oil filter by hand with the gasket lubricated with engine oil to the oil filter support.
60. Insert a special mandrel into the flywheel to center the clutch. Insert clutch disc and clutch drive. Screw in the six bolts securing the drive part of the clutch to the flywheel, tightening them in several stages - the final tightening torque of the bolts is 10 Nm - and remove the clutch centering mandrel.
61. Install the ignition timing plate above the flywheel by screwing the two bolts to the rear wall of the cylinder block.
62. Install (if present) crankshaft position sensor (TDC sensor) in the rear wall of the cylinder block and carefully press it against the flywheel surface as far as it will go. Screw in the sensor housing bolt and mark this position of the sensor. Carefully loosen the cage bolt and move the sensor back a little by about 1 mm; tighten the sensor housing bolt in this position.
63. Install the piston of the 1st cylinder (counting from the flywheel) in the TDC position and turn the distributor housing to such a position that the electrode of the 1st cylinder in the cover is under the distributor rotor. Fix the distributor in this position.