Car engine overhaul Peugeot 406

Engine specifications
Cylinder head Maximum non-flatness of mating surfaces: – XU engines 0.05 mm – XUD engines 0.07 mm Swirl chamber protrusion in diesel engines 0 – 0.03 mm Valves Valve plate diameter Inlet valve: – petrol engines: • 1.6...

Removal and installation of engine and gearbox
Attention! The engine can only be removed from the vehicle with the gearbox. Removal 1. Place the car on a flat horizontal surface, block the rear wheels, lift the front of the car and secure it on stands. Remove both...

Removal and installation of engines with automatic transmission
Attention! The engine is removed from the car only with the gearbox. Removal is carried out in the same way as removal of the engine with a manual transmission, except for the following differences. Removal 1. Using a...

Engine repair — general information
It is most convenient to carry out work on the engine if it is installed on a special frame. Before repairing the engine, it is necessary to remove the following: generator; thermostat and coolant outlet pipe (gasoline...

Removal and installation the cylinder head (2.1L engine)
Removal 1. Remove the camshaft and tappets. 2. Remove the intake and exhaust manifolds. 3. Remove the high pressure fuel pump pulley. 4. Remove the bolts and remove the engine mount from the front of the engine. 5....

Disassembling the cylinder head
1. Remove the cylinder head. 2. If not removed, remove the intake and exhaust manifolds. 3. Remove the camshaft, tappets and gaskets. 4. On diesel engines, remove the glow plugs. On 2.1 litre diesel engines, remove the...

Cleaning and inspection of the cylinder head
Caution! If the engine has been overheated, it is quite possible that the cylinder head is deformed. Therefore, it is necessary to carefully check it. Cleaning 1. Remove the remains of the old gasket from the cylinder...

Cylinder head assembly
1. Lubricate the valve stems with engine oil and insert them into their places. Install the valves in the places where they were ground. 2. Install the spring seat. Dip the valve stem seal into fresh engine oil and...

Removal pistons with connecting rods
1. Remove the cylinder head, oil pan and oil pump. 2. If there is carbon deposits on the top of the cylinder, remove them with a soft scraper. The presence of a step on the top of the cylinder indicates excessive wear...

Removal the crankshaft
1. Remove the crankshaft pulley and oil pump. 2. Remove the pistons and connecting rods. If the pistons and connecting rods are not going to be repaired, there is no need to remove the cylinder head. 3. Check the...

Cylinder block
Cleaning 1. Remove all parts and electrical sensors from the cylinder block. For complete cleaning, remove the process plugs. To remove the plugs, drill small holes in them and screw a self-tapping screw into the holes....

Pistons and connecting rods — check
Elements of the piston group Correct positioning of the piston relative to the connecting rod on diesel engines Examination 1. Before checking the pistons with connecting rods, remove the piston rings from the pistons...

Crankshaft — check
Checking the crankshaft axial play using a dial indicator Checking the crankshaft axial play 1. The crankshaft axial clearance is checked when it is installed in the engine cylinder block. 2. The axial play is checked...

Inspection of main and connecting rod bearings
Typical bearing defects 1. Even though the main and connecting rod bearings are subject to replacement during an engine overhaul, they should be carefully inspected as they can provide valuable information regarding the...

Sequence of engine assembly during major repairs
The engine assembly must be performed in the following order: crankshaft; pistons-connecting rods; oil pump; pallet; flywheel; cylinder head; timing belt tensioner and pulleys, as well as timing belt; hanging units.

Installing piston rings
The arrangement of piston rings on the piston 1. Oil scraper ring 2. Middle sealing ring 3. Upper sealing ring Before installing new piston rings, check the ring end gap. 1. Position the pistons and piston rings...

Selecting New Crankshaft Main Bearings
XU series engine Location of the plate on the cylinder block of the XU engine for the selection of main bearings A. Barcode (used in engine production) B. Designation signs On some engines, the top and bottom halves of...

Checking the working clearance of the crankshaft main bearings
XU series engine 1. On early engine models, new liners must be installed during a major overhaul. On later engine models, the running clearance check can be performed using the original liners. However, a new set is...

Installing the crankshaft (XU and XUD engines)
1. Using engine oil, install the upper thrust washers on each side of main bearing #2 with the oil grooves facing the crankshaft. 2. Install the bearing shells in their places. Lubricate the working surface of the shell...

Installing pistons
1. Check that the connecting rod bearings are installed correctly. If new bearings are installed, check that all traces of protective grease have been removed with a suitable solvent. Wipe the bearings and connecting...

Starting the engine after major repairs
1. With the engine installed in the vehicle's engine bay, check the engine oil and coolant levels. Check that all previously removed wires and hoses are in place. Petrol engines 2. Remove the spark plugs and disconnect...