2. Generously lubricate the pistons and cylinder liners with engine oil.
3. Compress the piston rings with a special clamping band so that the rings are completely inserted into the piston grooves and carefully insert the piston and connecting rod assembly into the hole of each sleeve.
4. Place a new sealing ring on each cylinder sleeve, making sure it is positioned correctly (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. Set the pistons in a position in which the arrows on their bottoms point towards the valve timing drive.
7. Attach the cylinder liners to the cylinder block using special Peugeot plates (device 0132 A1Z), screwing each plate with two M10 bolts 40 mm long.
8. Insert the main bearings (dry) into the sockets 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 half rings with the grooves facing the shaft.
11. Measure the crankshaft longitudinal play with a dial indicator (the correct value is 0.1–0.3 mm), applying the indicator to the end of the shaft on the timing drive side. Based on the measurements, if necessary, replace the thrust half rings with rings of the appropriate thickness (the same on both sides).
12. Insert the connecting rod bearings (dry) into the connecting rod sockets and lubricate their sliding surfaces with engine oil.
13. Install the connecting rod caps together with the bearing shells, remembering to fit them to the corresponding connecting rods, and tighten the bolt nuts to a torque of 40 Nm.
14. Place the oil pump drive sprocket on the journal of the front end of the crankshaft, insert the key into the groove of the journal and place the chain on the gear.
15. Insert the main bearings (dry) into the sockets of the lower part of the cylinder block and lubricate their sliding surfaces with engine oil, remembering to install them correctly (the main bearing shells of the second and fourth bearings have grooves).
16. Degrease both surfaces of the connection 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 part of the cylinder block by pulling the oil pump drive chain over this part of the cylinder block.
18. Insert ten crankshaft main bearing bolts and tighten them in two stages: first to 20 Nm and then to an angle of 45°.
19. Check whether the connecting rods are correctly connected to the crankshaft journals, paying attention to their lateral movements.
20. Place 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 smooth and free rotation.
23. Degrease both surfaces of the oil pan connection 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 a torque of 8 Nm.
24. Screw in two bolts connecting the upper and lower parts of the cylinder block on the front wall (from the timing drive side) and tighten them to a torque of 8 Nm.
25. Screw in the two threaded plugs of the main oil channel, 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 facing down.
27. Screw in the remaining bolts securing both parts of the cylinder block and tighten them to a torque of 8 Nm.
28. Lubricate the lip of the rear crankshaft seal ring with engine oil and press the seal ring, with the lip facing the inside of the engine, into the rear seat of the cylinder block (from the flywheel side) using the appropriate mounting device.
29. Press (until it stops) into the front cylinder block socket (from the drive side) front crankshaft seal ring using the appropriate mounting tool.
30. Install the spacer ring and crankshaft pulley onto the front end of the crankshaft; screw in the crankshaft pulley mounting bolt by hand.
31. Install the flywheel onto the rear end of the crankshaft and temporarily secure it with bolts.
32. Fix the flywheel using a special device.
33. Lubricate the flywheel mounting bolts with "Loctite Frenetanch" and tighten them to a torque of 65 Nm.
Article based on material from the website www.PeugeotBook.ru
34. Tighten the crankshaft pulley mounting bolt to 110 Nm.
35. Insert the coolant pump sealing ring into the cylinder block hole (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 bushings and tighten the four bolts securing the pump to the cylinder block: two M6 bolts with a torque of 30 Nm and two M8 bolts with a torque of 50 Nm.
36. Remove two special Peugeot plates (device 0132 A1Z) fastening the cylinder liners by unscrewing their fastening bolts.
37. Degrease the surfaces of the cylinder block and cylinder head with head gasket.
38. Insert the two cylinder head centering bushings into the holes in the top surface of the cylinder block on the coolant pump side.
39. Place the pulley on the camshaft and screw in its mounting bolt by hand.
40. Insert the installation rod into the hole for fixing the camshaft pulley and fix the camshaft.
41. Install a new cylinder head gasket on the top surface of the cylinder block and install the head on it.
42. Install all five valve lever axle brackets with the levers and their axle onto the cylinder head, paying attention to the correct installation of the intermediate pins of each valve lever axle bracket in their holes in the cylinder head.
43. Lubricate the threads of the cylinder head bolts with a small amount of Molykote G Rapi12 Plus. First screw these bolts in by hand, then tighten them in two stages: first with a torque of 20 Nm, and then at an angle of 240°, in order from the middle outwards, moving in a spiral.
44. Install the tension roller and screw in its bolt by hand.
45. Check that the camshaft and crankshaft are installed correctly.
46. Place the timing belt first on the crankshaft pulley and then on the camshaft pulley. Tighten the timing belt with a little force using the tension roller.
47. Remove the camshaft and crankshaft adjusting rods and insert the special Peugeot tool into the tension roller (fixture 0132 X) for tensioning the toothed belt or a suitably adjusted 10 cm long rod forming a one-sided lever with a 1.5 kg weight hanging at the end of the lever arm.
48. Loosen the timing belt tension roller bolt and tighten it to a torque of 23 Nm.
49. Tighten the camshaft pulley to 80 Nm.
50. Slowly turn the crankshaft in the direction of working rotation by two turns, turning the crankshaft pulley mounting bolt, and then fix the flywheel with the installation rod.
51. Loosen the tension roller bolt and press lightly on the belt so that the roller turns. In this position, the camshaft setting rod should not be inserted.
52. Tighten the tension roller bolt to a torque of 23 Nm, remove the adjusting rod from the flywheel, slowly turn the crankshaft again in the direction of working rotation by two turns and fix the flywheel again with the adjusting rod.
53. Slowly loosen the tension roller bolt so that the weight of the tool causes tension on the timing belt, then tighten the tension roller bolt to 23 Nm and check whether the camshaft adjusting rod can be inserted in this position. If so, remove both adjusting rods (camshaft and crankshaft).
54. Using a feeler gauge, adjust the valve clearances (inlet valve clearance 0.2 mm, outlet valve clearance 0.4 mm).
55. Install the three-piece timing belt cover and tighten the mounting bolts to 6 Nm.
56. Insert the sheet metal cover into the cylinder head (oil deflector) and two spacers, and also install a new valve cover gasket and the cover itself, tightening its mounting 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, then tighten the tube mount to a torque of 15 Nm.
58. Secure the oil pressure sensor to the top of the cylinder block above the oil filter support with a torque of 27.5 Nm.
59. Screw the oil filter with the gasket, lubricated with engine oil, onto the oil filter support by hand.
60. Insert a special mandrel for centering the clutch into the flywheel. Insert the clutch disc and the leading part of the clutch. Screw in the six bolts that secure the leading 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 mandrel for centering the clutch.
61. Install the ignition timing plate above the flywheel by screwing 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 until it stops against the flywheel surface. Screw in the sensor cage bolt and mark this position of the sensor. Carefully loosen the cage bolt and move the sensor back a little by approximately 1 mm; tighten the sensor cage 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 a position so that the electrode of the 1st cylinder in the cover is under the distributor rotor. Fix the distributor in this position.