Peugeot 205 - Manual (Page 81)

41 Fit the sump cover to the transmission
using a new gasket.
42 Tighten the tighten the cover bolts and
drain plug to the specified torque.
43 Fit the protective cover plate to the sump
cover.
44 Apply jointing compound to the mating
surfaces on the engine and transmission.
45 On the transmission, locate a new O-ring
seal and check that the locating dowels and
the studs are in position (see illustration).
46 Offer the transmission to the engine,
screw in the connecting bolts and nuts and
tighten to the specified torque.
47 With the fuel pump operating rod in place,
locate the timing chain cover using a new
gasket. The bolt nearest the coolant pump
pulley must be located in the cover before
offering it up, otherwise the pulley will prevent
the bolt entering its cover hole. Use the
crankshaft pulley to centralise the timing
chain cover and refit the remaining cover
bolts. Note that the coolant hose safety rod
must be fitted under its cover bolts. This rod
prevents the coolant hose being cut by the
rim of the coolant pump pulley should the
hose sag.
48 Tighten the timing chain cover bolts to the
specified torque and then trim the upper ends
of the gasket flush. Fit the rocker cover using
a new gasket. Do not overtighten the securing
bolts.
49 Tighten the crankshaft pulley nut to the
specified torque.
50 Refit the flywheel (Chapter 2A) and the
clutch and transfer gear assembly (Chapter 6).
51 If they were removed, bolt the engine
mountings to the flywheel housing.
52 Fit the starter motor. Tighten the bolts and
nuts in the following order:
a) Starter drive end flange to flywheel
housing
b) Brush end bracket to engine crankcase
c) Brush end bracket to starter motor
XU and TU series engines
53 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.
54 Ensure that the locating dowels are
correctly positioned in the engine or
transmission.
55 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.
56 Refit the transmission housing-to-engine
bolts, ensuring that all the necessary brackets
are correctly positioned, and tighten them
securely.
57 Refit the starter motor, and securely
tighten its retaining bolts.
58 Where necessary, refit the lower flywheel
cover plate to the transmission, and securely
tighten its retaining bolts.
Refitting
59 Reconnect the hoist and lifting tackle to
the engine lifting brackets. With the aid of an
assistant, lift the assembly over the engine
compartment.
60 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.
61 With the engine/transmission in position,
and centralised over its mountings, refit the
engine/transmission mountings using a
reverse of the removal operations, but only
tighten the mounting nuts/bolts finger tight at
this stage.
62 Where applicable, from underneath the
vehicle, refit the rear mounting link and install
both its bolts.
63 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. The hoist can then be
detached from the engine and removed.
64 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) Reconnect the clutch cable as described
in Chapter 6.
e) Adjust the choke cable and/or throttle
cable (as applicable) as described in the
relevant Part of Chapter 4.
f) Refill the engine and transmission with the
correct quantity and type of lubricant, as
described in Chapter 1 and 7A.
g) Refill the cooling system as described in
Chapter 1.
4 Engine/automatic transmission
- removal, separation,
reconnection and refitting 4
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 Carry out the operations described in
paragraphs 1 to 12 of Section 3, noting that
the transmission oil draining procedure is
given in Chapter 1.
2 Carry out the following operations, using
the information given in Chapter 7B:
a) Remove the transmission dipstick tube.
b) Disconnect the wiring from the starter
inhibitor/reversing light switch and the
speedometer drive housing. Release the
earth strap(s) from the top of the
transmission housing.
c) Disconnect the selector cable.
d) Release the power steering pipe from the
transmission.
e) Disconnect the speedometer cable.
3 Remove the engine/transmission as
described in paragraphs 15 to 21 of Section 3.
Separation
4 With the engine/transmission assembly
removed, support the assembly on suitable
blocks of wood, on a workbench (or failing
that, on a clean area of the workshop floor).
5 Detach the kickdown cable from the throttle
cam. Work back along the cable, freeing it
from any retaining clips, and noting its correct
routing.
6 Undo the retaining bolts and remove the
driveplate lower cover plate from the
transmission, to gain access to the torque
converter retaining bolts. Slacken and remove
the visible bolt. Rotate the crankshaft using a
socket and extension bar on the pulley bolt,
and undo the remaining bolts securing the
torque converter to the driveplate as they
become accessible.
7 Slacken and remove the retaining bolts,
and remove the starter motor from the
transmission.
8 To ensure that the torque converter does
not fall out as the transmission is removed,
secure it in position using a length of metal
strip bolted to one of the starter motor bolt
holes.
9 Ensure that both the 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 any relevant brackets) as they
are removed, to use as a reference on
refitting.
10 Carefully withdraw the transmission from
the engine. If the locating dowels are a loose
fit in the engine/transmission, remove them
and keep them in a safe place.
Engine removal and overhaul procedures 2D•7
2D
3.45 Locate a new O-ring oil seal on the
transmission casing