Table of contents: Cleaning 🠇 Inspection 🠇
Cleaning
1. Remove all external components and electrical switches/sensors from the cylinder block. Ideally, smooth surfaces should also be removed for complete cleaning (rod) plugs (figure 12.1). Drill a small hole in the removable plug and screw a self-tapping screw into it.
Figure 12.1. Cylinder block rod plugs (marked with arrows)
Information copied from the resource PeugeotBook.ru
2. Pull the screw with pliers and remove the plug. You can also use an impact puller.
3. If applicable, remove the bolts and piston cooling oil jet tubes from the inside of the cylinder block.
4. Remove all traces of gasket material from the cylinder block/crankcase, being careful not to damage the mating/sealing surfaces.
5. Remove all oil channel plugs (if available). The plugs are usually very tightly fitted. They may need to be drilled out and the holes re-threaded. When reassembling the engine, use new plugs.
6. If any elements are heavily soiled, steam cleaning should be performed.
7. After this, clean all oil holes and oil channels again. Rinse all internal passages with warm water. You need to rinse until the water comes out clean. Dry thoroughly and apply a thin layer of oil to all mating surfaces to prevent rust. If you have access to compressed air, use it to speed up drying and blow out all grease holes and passages.
Caution! Wear eye protection when working with compressed air.
8. If the unit is not very dirty, you can use hot soapy water and a stiff brush to clean it. Take your time and work thoroughly. Regardless of the cleaning method used, clean all lubrication holes and passages very thoroughly and dry all components well. To prevent rust, take protective measures as described above.
9. Clean all threaded holes; this will ensure the required tightening torques during assembly. To clean the threads, tap each hole with a tap of the proper size. This will remove rust, corrosion products, thread sealant or sludge and restore damaged threads (figure 12.9). If possible, use compressed air to clear the holes of traces of previous cleaning.
Figure 12.9. Use a suitable tap to clean the threaded holes in the cylinder block
Caution! Wear eye protection when working with compressed air.
10. Apply appropriate sealant to the new oil passage plugs and insert the plugs into the holes in the block. Tighten them securely. Also apply a suitable sealant to the new smooth plugs and use a piece of pipe with machined ends or a socket head to insert the plug into the cylinder block.
11. On engines with piston cooling oil nozzles, clean the threads of the piston cooling oil nozzle mounting bolts and apply a drop of locking compound to the threads of these bolts. Install the oil pipes onto the cylinder block, screw in the bolts and tighten them to the specified torque.
12. If the engine is not to be reassembled immediately, cover it with a large plastic bag or just film to keep it clean. Protect all mating surfaces and cylinders as described above to prevent rust.
Inspection
13. Visually inspect the cylinder block for cracks, rust and corrosion. Inspect the threaded holes for stripped threads. If there has been an internal coolant leak, it may be helpful to take the engine block to an engine overhaul specialist to have it inspected using specialized equipment. If any defects are found, correct them if possible or replace the cylinder block.
14. Check each cylinder for scratches and burrs. Check for wear ridges in the upper area of the cylinder. This ridge indicates increased cylinder wear.
15. Accurate measurement of cylinder diameter requires special equipment and experience. It is recommended to have the measurement carried out by an engine repair specialist who can also provide the appropriate pistons (if possible), if the engine repair requires cylinder boring.
16. If the cylinder "mirrors" and pistons are in acceptably good condition and do not have excessive wear and the clearances between the pistons and cylinder walls are within the norm, only the piston rings will need to be replaced. If this is the case, the cylinders should be honed to allow the new rings to seat properly and ensure the best possible fit (as far as possible) compaction. An engine repair specialist will do this job for a reasonable price.
17. At the time of writing, it was not known whether repair-note size pistons were available for all models. For the latest piston availability information, please contact your Peugeot/Citroen dealer or engine repair specialist. If there are pistons of repair size (purchased either from a Peugeot/Citroen dealer or from another source), it is possible to bore out the cylinders and install pistons of a repair size. If oversize pistons are not available and the cylinders are worn, replacing the block is the only option.