Engine Removal And Overhaul Procedures - PEUGEOT 205 Manual

Chapter 2 Part D:

Engine removal and overhaul procedures

Contents
Crankshaft - refitting and main bearing running clearance check . . . 13
Crankshaft - removal and inspection . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cylinder block/crankcase - cleaning and inspection . . . . . . . . . . . . . 9
Cylinder head - dismantling, cleaning, inspection and reassembly . 6
Engine - initial start-up after overhaul . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine/automatic transmission - removal, separation, reconnection
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine/manual transmission - removal, separation, reconnection and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Degrees of difficulty
Easy, suitable for Fairly easy, suitable
1
novice with little for beginner with
experience some experience
Specifications
Note: At the time of writing, many specifications for certain engines were not available. Where the relevant specifications are not given here, refer
to your Peugeot dealer for further information.
Cylinder head
Maximum gasket face distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder head height::
XV, XW and XY series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XU series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TU series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves
Valve head diameter:
Inlet:
XV8 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XW7, XY7 and XY8 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XU5J engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
All other XU series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TU9 series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TU1 series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TU3, TU3A, TU3M and TU3S engines . . . . . . . . . . . . . . . . . . . . . .
TU3FM engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust:
XV8 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XW7, XY7 and XY8 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XU5J engines:
Early models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Later models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
All other XU series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TU9 series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TU1 series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TU3, TU3A, TU3M and TU3S engines . . . . . . . . . . . . . . . . . . . . . .
TU3FM engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve stem diameter:
Inlet:
XV, XW and XY series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XU51 and XU5M series engines . . . . . . . . . . . . . . . . . . . . . . . . . . .
All other XU series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TU series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine overhaul - preliminary information . . . . . . . . . . . . . . . . . . . . . 5
Engine overhaul - reassembly sequence . . . . . . . . . . . . . . . . . . . . . . 11
Engine/transmission removal - preparation and precautions . . . . . . 2
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Main and big-end bearings - inspection . . . . . . . . . . . . . . . . . . . . . . 10
Piston/connecting rod assembly - refitting and big-end bearing
running clearance check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Piston/connecting rod assembly - removal and inspection . . . . . . . 7
Piston rings - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fairly difficult,
2
3
suitable for competent
DIY mechanic
0.05 mm
Not available
141.0 ± 0.05 mm
111.2 ± 0.08 mm
34.8 mm
37.0 mm
40.0 mm
41.6 mm
34.8 mm
36.8 mm
36.8 mm
39.5 mm
27.8 mm
29.5 mm
32.0 mm
32.95 mm
34.5 mm
27.9 mm
29.4 mm
29.4 mm
31.4 mm
8.0 mm
7.30 mm
7.98 mm
6.99 mm
Difficult, suitable for Very difficult,
4
experienced DIY suitable for expert DIY
mechanic or professional
2D•1
5
2D