Peugeot 405 Manual

Engine and manual transmission - removal, separation and refitting
Engine removal and overhaul procedures / Engine and manual transmission - removal, separation and refitting


Note: Peugeot recommend that 8-valve XU engines are removed by lowering from the engine compartment, however in practise we found that on models not fitted with air conditioning, there is ample room to lift the engine upwards. Lowering the engine would involve raising the front of the vehicle onto axle stands approximately 21 inches high and also removing the engine subframe. On models fitted with air conditioning the engine may be lowered, or alternatively it can be lifted after removing the condenser and front panel (the refrigerant must first be evacuated by a qualified engineer if this method is used).

Removal
Note: The engine can be removed from the car only as a complete unit with the transmission; the two are then separated for overhaul.

1 Park the vehicle on firm, level ground.

Chock the rear wheels, then firmly apply the handbrake. Jack up the front of the vehicle, and securely support it on axle stands (see Jacking and Vehicle Support). Remove both front roadwheels.

2 Set the bonnet in the upright position, and remove the battery and tray as described in Chapter 5A.

3 On 8-valve XU engines remove the front cross panel with reference to Chapter 11 (see note at the beginning of this Section).

4 Remove the complete air cleaner housing and duct assembly, as described in the relevant Part of Chapter 4 (see illustration).

4.4 Inlet air duct connection to the front crossmember
4.4 Inlet air duct connection to the front crossmember

5 If the engine is to be dismantled, working as described in Chapter 1, first drain the oil and remove the oil filter. Clean and refit the drain plug, tightening it securely.

6 Drain the transmission oil as described in Chapter 7A. Refit the drain and filler plugs, and tighten them to their specified torque settings.

7 Remove the alternator as described in Chapter 5A.

8 Where applicable, remove the power steering pump as described in Chapter 10.

9 On models with air conditioning, unbolt the compressor, and position it clear of the engine. Support the weight of the compressor by tying it to the vehicle body, to prevent any excess strain being placed on the compressor lines whilst the engine is removed. Do not disconnect the refrigerant lines from the compressor (refer to the warnings given in Chapter 3).

10 Drain the cooling system as described in Chapter 1. Where necessary on 8-valve XU engines, remove the radiator (see Chapter 3).

11 On carburettor models, carry out the following operations, using the information given in Chapter 4A:
a) Disconnect the fuel feed hose from the anti-percolation chamber.

b) Disconnect the accelerator and choke cables from the carburettor.

c) Disconnect the braking system servo vacuum hose from the inlet manifold.

d) Remove the exhaust system front pipe.

12 On fuel injection models, carry out the following operations, using the information given in Chapter 4B or 4C (as applicable): a) Depressurise the fuel system, and disconnect the fuel feed and return hoses.

b) Disconnect the accelerator cable.

c) Disconnect the fuel system wiring connectors.

d) Disconnect the purge valve and/or braking system servo vacuum hoses from the inlet manifold (as applicable).

e) Remove the exhaust system front pipe.

13 Referring to Chapter 3, release the retaining clip and disconnect the heater matrix hoses from their connection on the engine compartment bulkhead.

14 Working as described in Chapter 6, disconnect the clutch cable from the transmission, and position it clear of the working area (see illustration).

4.14 Disconnecting the clutch cable
4.14 Disconnecting the clutch cable

15 Trace the wiring harness back from the engine to the wiring connector(s) in the engine compartment. Release the locking ring(s) by twisting them anti-clockwise and disconnect the connectors. Also trace the harness lead(s) back to the relay box, situated beside the battery. Unclip the wiring connector plate from the front of the relay box cover then undo the retaining nut and remove the cover.

Lift up the engine harness lead cover then undo the nut(s) and release the lead(s) from the relay box. Check that all the relevant connectors have been disconnected, and that the wiring is released from any relevant clips or ties, so that it is free to be removed with the engine/transmission.

16 From underneath the vehicle, slacken and remove the nuts and bolts securing the rear mounting link to the mounting assembly and subframe, and remove the link.

17 Remove both driveshafts as described in Chapter 8.

18 Carry out the following operations, using the information given in Chapter 7A: a) Disconnect the gearchange selector rod/link rods (as applicable) from the transmission.

b) Disconnect the speedometer cable from the speedometer drive.

c) Disconnect the wiring connector(s) from the reversing light switch and speedometer drive (as applicable).

19 Manoeuvre the engine hoist into position, and attach it to the lifting brackets bolted onto the cylinder head. Raise the hoist until it is supporting the weight of the engine.

20 Remove the right-hand engine mounting with reference to Chapter 2A.

Note: On certain models, if the right-hand engine mounting hydro-elastic unit is to be renewed because of wear/perishing, a special tool is needed to unscrew it from the wing panel, and for refitting and tightening to the specified torque (see illustration).

4.20 Special tool for removing and refitting right-hand engine mounting
4.20 Special tool for removing and refitting right-hand engine mounting hydro-elastic unit

21 Slacken and remove the centre nut and washer from the engine/transmission lefthand mounting. Undo the two nuts and washers securing the mounting to its bracket and remove the mounting from the engine compartment and recover the spacer (where fitted). To improve clearance, (where possible) undo the two retaining bolts and remove the bracket from the body.

22 Make a final check that any components which would prevent the removal of the engine/transmission from the car have been removed or disconnected. Ensure that components such as the gearchange selector rod are secured so that they cannot be damaged on removal.

23 Lift the engine/transmission out of the car, ensuring that nothing is trapped or damaged.

Enlist the help of an assistant during this procedure, as it will be necessary to tilt the assembly slightly to clear the body panels. On models equipped with anti-lock brakes, great care must be taken to ensure that the antilock braking system unit is not damaged during the removal procedure.

24 Once the engine is high enough, lift it out over the front of the body, and lower the unit to the ground.

Separation
25 With the engine/transmission assembly removed, support the assembly on suitable blocks of wood, on a workbench (or alternatively, on a clean area of the workshop floor).

26 Undo the retaining bolts, and remove the flywheel lower cover plate (where fitted) from the transmission.

27 On models with a pull-type clutch release mechanism (see Chapter 6 for further information), tap out the retaining pin or unscrew the retaining bolt (as applicable), and remove the clutch release lever from the top of the release fork shaft. This is necessary to allow the fork shaft to rotate freely, so that it disengages from the release bearing as the transmission is pulled away from the engine.

Make an alignment mark across the centre of the clutch release fork shaft, using a scriber, paint or similar, and mark its relative position on the transmission housing (see Chapter 7A for further information).

28 Slacken and remove the retaining bolts, and remove the starter motor from the transmission.

29 Ensure that both engine and transmission are adequately supported, then slacken and remove the remaining bolts securing the transmission housing to the engine. Note the correct fitted positions of each bolt (and the relevant brackets) as they are removed, to use as a reference on refitting.

30 Carefully withdraw the transmission from the engine, ensuring that the weight of the transmission is not allowed to hang on the input shaft while it is engaged with the clutch friction disc.

31 If they are loose, remove the locating dowels from the engine or transmission, and keep them in a safe place.

32 On models with a pull-type clutch, make a second alignment mark on the transmission housing, marking the relative position of the release fork mark after removal. This should indicate the angle at which the release fork is positioned. The mark can then be used to position the release fork prior to installation, to ensure that the fork correctly engages with the clutch release bearing as the transmission is installed.

Refitting
33 If the engine and transmission have been separated, perform the operations described below in paragraphs 34 to 42. If not, proceed as described from paragraph 43 onwards.

34 Apply a smear of high-melting-point grease (Peugeot recommend the use of Molykote BR2 plus - available from your Peugeot dealer) to the splines of the transmission input shaft. Do not apply too much, otherwise there is a possibility of the grease contaminating the clutch friction plate.

35 Ensure that the locating dowels are correctly positioned in the engine or transmission.

36 On models with a pull-type clutch, before refitting, position the clutch release bearing so that its arrow mark is pointing upwards (bearing fork slots facing towards the front of the engine), and align the release fork shaft mark with the second mark made on the transmission housing (release fork positioned at approximately 60 to clutch housing face).

This will ensure that the release fork and bearing will engage correctly as the transmission is refitted to the engine.

37 Carefully offer the transmission to the engine, until the locating dowels are engaged.

Ensure that the weight of the transmission is not allowed to hang on the input shaft as it is engaged with the clutch friction disc.

38 On models with a pull-type clutch, with the transmission fully engaged with the engine, check that the release fork and bearing are correctly engaged. If the release fork and bearing are correctly engaged, the mark on the release fork should be aligned with the original mark made on the transmission housing (see Chapter 7A for further information).

39 Refit the transmission housing-to-engine bolts, ensuring that all the necessary brackets are correctly positioned, and tighten them to the specified torque setting.

40 Refit the starter motor, and securely tighten its retaining bolts.

41 On models with a pull-type clutch release mechanism, refit the clutch release lever to the top of the release fork shaft, securing it in position with its retaining pin or bolt (as applicable).

42 Where necessary, refit the lower flywheel cover plate to the transmission, and securely tighten its retaining bolts.

43 Reconnect the hoist and lifting tackle to the engine lifting brackets. With the aid of an assistant, lift the assembly over the engine compartment.

44 The assembly should be tilted as necessary to clear the surrounding components, as during removal; lower the assembly into position in the engine compartment, manipulating the hoist and lifting tackle as necessary.

45 With the engine/transmission in position, refit the right-hand engine/transmission mounting bracket, tightening its retaining nuts and bolts (as applicable) by hand only at this stage.

46 Working on the left-hand mounting, refit the mounting bracket (where removed) to the body and tighten its retaining bolts to the specified torque. Refit the mounting rubber and refit the mounting retaining nuts and washers and the centre nut and washer, tightening them lightly only.

47 From underneath the vehicle, refit the rear mounting link and install both its bolts.

48 Rock the engine to settle it on its mountings then go around and tighten all the mounting nuts and bolts to their specified torque settings. Where necessary, once the right-hand mounting bracket nuts have been tightened, refit the rubber damper and curved retaining plate, tightening its retaining bolts to the specified torque. The hoist can then be detached from the engine and removed.

49 The remainder of the refitting procedure is a direct reversal of the removal sequence, noting the following points: a) Ensure that the wiring loom is correctly routed and retained by all the relevant retaining clips; all connectors should be correctly and securely reconnected.

b) Prior to refitting the driveshafts to the transmission, renew the driveshaft oil seals as described in Chapter 7A.

c) Ensure that all coolant hoses are correctly reconnected, and securely retained by their retaining clips.

d) Adjust the clutch cable as described in Chapter 6.

e) Adjust the choke cable and/or accelerator cable (as applicable) as described in the relevant Part of Chapter 4.

f) Refill the engine and transmission with correct quantity and type of lubricant, as described in Chapter 7A.

g) Refill the cooling system as described in Chapter 1.


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