Peugeot 405 Manual

Engine overhaul - dismantling sequence
Engine removal and overhaul procedures / Engine overhaul - dismantling sequence

1 It is much easier to dismantle and work on the engine if it is mounted on a portable engine stand. These stands can often be hired from a tool hire shop. Before the engine is mounted on a stand, the flywheel/driveplate should be removed, so that the stand bolts can be tightened into the end of the cylinder block/crankcase.

2 If a stand is not available, it is possible to dismantle the engine with it blocked up on a sturdy workbench, or on the floor. Be extracareful not to tip or drop the engine when working without a stand.

3 If you are going to obtain a reconditioned engine, all the external components must be removed first, to be transferred to the replacement engine (just as they will if you are doing a complete engine overhaul yourself).

These components include the following: a) Alternator mounting brackets.

b) Power steering pump and air conditioning compressor brackets (where fitted).

c) Thermostat and housing, and coolant outlet chamber/elbow (Chapter 3).

d) Dipstick tube.

e) Carburettor/fuel system components (Chapter 4).

f) All electrical switches and sensors.

g) Inlet and exhaust manifolds (Chapter 4).

h) Oil filter (Chapter 1).

i) Fuel pump - carburettor engines only (Chapter 4).

j) Flywheel/driveplate (Part A or B of this Chapter).

Note: When removing the external components from the engine, pay close attention to details that may be helpful or important during refitting. Note the fitted position of gaskets, seals, spacers, pins, washers, bolts, and other small items.

4 If you are obtaining a УshortФ engine (which consists of the engine cylinder block/ crankcase, crankshaft, pistons and connecting rods all assembled), then the cylinder head, sump, oil pump, and timing belt will have to be removed also.

5 If you are planning a complete overhaul, the engine can be dismantled, and the internal components removed, in the order given below, referring to Part A or B of this Chapter unless otherwise stated.

a) Inlet and exhaust manifolds (Chapter 4).

b) Timing belt, sprockets and tensioner(s).

c) Cylinder head.

d) Flywheel/driveplate.

e) Sump.

f) Oil pump.

g) Piston/connecting rod assemblies (Section 10).

h) Crankshaft (Section 11).

6 Before beginning the dismantling and overhaul procedures, make sure that you have all of the correct tools necessary. Refer to УTools and working facilitiesФ for further information.

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