Peugeot 405 Manual

Crankshaft - removal
Engine removal and overhaul procedures / Crankshaft - removal


1 Remove the crankshaft sprocket and the oil pump as described in Part A or B of this Chapter (as applicable). Also unbolt and remove the timing belt rear cover noting the position of the special retaining studs (see illustration).

11.1 Timing belt rear cover special studs
11.1 Timing belt rear cover special studs

2 Remove the pistons and connecting rods, as described in Section 10. If no work is to be done on the pistons and connecting rods, there is no need to remove the cylinder head, or to push the pistons out of the cylinder bores. The pistons should just be pushed far enough up the bores that they are positioned clear of the crankshaft journals.

3 Check the crankshaft endfloat as described in Section 14, then proceed as follows.

TU series
aluminium block engines
4 Work around the outside of the cylinder block, and unscrew all the small (6 mm) bolts securing the main bearing ladder to the base of the cylinder block. Note the correct fitted depth of both the front and rear crankshaft oil seals in the cylinder block/main bearing ladder.

5 Working in a diagonal sequence, evenly and progressively slacken the ten large (11 mm) main bearing ladder retaining bolts by a turn at a time. Once all the bolts are loose, remove them from the ladder.

6 With all the retaining bolts removed, carefully lift the main bearing ladder casting away from the base of the cylinder block.

Recover the lower main bearing shells, and tape them to their respective locations in the casting. If the two locating dowels are a loose fit, remove them and store them with the casting for safe-keeping.

7 Lift out the crankshaft, and discard both the oil seals. Remove the oil pump drive chain from the end of the crankshaft. Where necessary, slide off the drive sprocket, and recover the Woodruff key.

8 Recover the upper main bearing shells, and store them along with the relevant lower bearing shell. Also recover the two thrustwashers (one fitted either side of No 2 main bearing) from the cylinder block.

TU series
cast-iron block engines
9 Unbolt and remove the crankshaft front and rear oil seal housings from each end of the cylinder block, noting the correct fitted locations of the locating dowels. If the locating dowels are a loose fit, remove them and store them with the housings for safekeeping.

10 Remove the oil pump drive chain, and slide the drive sprocket off the end of the crankshaft. Remove the Woodruff key, and store it with the sprocket for safe-keeping.

11 The main bearing caps should be numbered 1 to 5 from the transmission (flywheel) end of the engine. If not, mark them accordingly using a centre-punch or paint.

12 Unscrew and remove the main bearing cap bolts, and withdraw the caps. Recover the lower main bearing shells, and tape them to their respective caps for safe-keeping.

13 Carefully lift out the crankshaft, taking care not to displace the upper main bearing shell.

14 Recover the upper bearing shells from the cylinder block, and tape them to their respective caps for safe-keeping. Remove the thrustwasher halves from the side of No 2 main bearing, and store them with the bearing cap.

XU series engines
15 Slacken and remove the retaining bolts, and remove the oil seal carrier from the front (timing belt) end of the cylinder block, along with its gasket (where fitted) (see illustration).

11.15 Removing the oil seal carrier from the front of the cylinder block - XU
11.15 Removing the oil seal carrier from the front of the cylinder block - XU engine

16 Remove the oil pump drive chain, and slide the drive sprocket and spacer (where fitted) off the end of the crankshaft. Remove the Woodruff key, and store it with the sprocket for safe-keeping (see illustrations).

11.16a Remove the oil pump drive chain . . .
11.16a Remove the oil pump drive chain . . .

11.16b . . . then slide off the drive sprocket . . .
11.16b . . . then slide off the drive sprocket . . .

11.16c . . . and remove the Woodruff key from the crankshaft
11.16c . . . and remove the Woodruff key from the crankshaft

17 The main bearing caps should be numbered 1 to 5, starting from the transmission (flywheel/driveplate) end of the engine (see illustration). If not, mark them accordingly using a centre-punch. Also note the correct fitted depth of the rear crankshaft oil seal in the bearing cap.

11.17 Main bearing cap identification markings (arrowed)
11.17 Main bearing cap identification markings (arrowed)

18 On 1761 cc engines, undo the two bolts (one at the front of the block, and one at the rear) securing the centre main bearing cap to the block. Remove the bolts, along with their sealing washers.

19 On all engines, slacken and remove the main bearing cap retaining bolts/nuts, and lift off each bearing cap. Recover the lower bearing shells, and tape them to their respective caps for safe-keeping. Also recover the lower thrustwasher halves from the side of No 2 main bearing cap (see illustration). Remove the rubber sealing strips from the sides of No 1 main bearing cap, and discard them.

11.19 Removing No 2 main bearing cap. Note the thrustwasher (arrowed)
11.19 Removing No 2 main bearing cap. Note the thrustwasher (arrowed)

20 Lift out the crankshaft, and discard the rear oil seal (see illustration).

11.20 Lifting out the crankshaft - XU series engine
11.20 Lifting out the crankshaft - XU series engine

21 Recover the upper bearing shells from the cylinder block, and tape them to their respective caps for safe-keeping (see illustration). Remove the upper thrustwasher halves from the side of No 2 main bearing, and store them with the lower halves.

11.21 Remove the upper main bearing shells from the cylinder block/crankcase,
11.21 Remove the upper main bearing shells from the cylinder block/crankcase, and store them with their lower shells


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