Peugeot 405 Manual

Piston/connecting rod assembly - removal
Engine removal and overhaul procedures / Piston/connecting rod assembly - removal


1 Remove the cylinder head, sump and oil pump as described in Part A or B of this Chapter (as applicable).

2 If there is a pronounced wear ridge at the top of any bore, it may be necessary to remove it with a scraper or ridge reamer, to avoid piston damage during removal. Such a ridge indicates excessive wear of the cylinder bore.

3 Using a hammer and centre-punch, paint or similar, mark each connecting rod big-end bearing cap with its respective cylinder number on the flat machined surface provided; if the engine has been dismantled before, note carefully any identifying marks made previously (see illustration). Note that No 1 cylinder is at the transmission (flywheel) end of the engine.

10.3 Connecting rod and big-end bearing cap marked for identification (No 3
10.3 Connecting rod and big-end bearing cap marked for identification (No 3 cylinder shown)

4 Turn the crankshaft to bring pistons 1 and 4 to BDC (bottom dead centre).

5 Unscrew the nuts from No 1 piston big-end bearing cap. Take off the cap, and recover the bottom half bearing shell (see illustration). If the bearing shells are to be re-used, tape the cap and the shell together.

10.5 Removing a big-end bearing cap and shell
10.5 Removing a big-end bearing cap and shell

6 To prevent the possibility of damage to the crankshaft bearing journals, tape over the connecting rod stud threads (see illustration).

10.6 To protect the crankshaft journals, tape over the connecting rod stud
10.6 To protect the crankshaft journals, tape over the connecting rod stud threads prior to removal

7 Using a hammer handle, push the piston up through the bore, and remove it from the top of the cylinder block. Recover the bearing shell, and tape it to the connecting rod for safe-keeping.

8 Loosely refit the big-end cap to the connecting rod, and secure with the nuts - this will help to keep the components in their correct order.

9 Remove No 4 piston assembly in the same way.

10 Turn the crankshaft through 180° to bring pistons 2 and 3 to BDC (bottom dead centre), and remove them in the same way.


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