Peugeot 205 - Manual (Page 95)

53 Lower the crankshaft into position so that
Nos 2 and 3 cylinder crankpins are at TDC;
Nos 1 and 4 cylinder crankpins will be at BDC,
ready for fitting No 1 piston.
54 Lubricate the lower bearing shells in the
main bearing caps with clean engine oil. Make
sure that the locating lugs on the shells
engage with the corresponding recesses in
the caps.
55 Fit main bearing caps Nos 2 to 5 to their
correct locations, ensuring that they are fitted
the correct way round (the bearing shell tab
recesses in the block and caps must be on
the same side). Insert the bolts/nuts,
tightening them only loosely at this stage.
56 Apply a small amount of sealant to the No
1 main bearing cap mating face on the
cylinder block, around the sealing strip holes
(see illustration).
57 Locate the tab of each sealing strip over
the pins on the base of No 1 bearing cap, and
press the strips into the bearing cap grooves
(see illustration). It is now necessary to
obtain two thin metal strips, of 0.25 mm
thickness or less, in order to prevent the strips
moving when the cap is being fitted. Peugeot
garages use a special tool, which acts as a
clamp. Metal strips (such as old feeler blades)
can be used, provided all burrs which may
damage the sealing strips are first removed.
58 Where applicable, oil both sides of the
metal strips, and hold them on the sealing
strips. Fit the No 1 main bearing cap, insert
the bolts loosely, then carefully pull out the
metal strips in a horizontal direction, using a
pair of pliers if necessary (see illustration). 59 Tighten all the main bearing cap
bolts/nuts evenly to the specified torque.
Using a sharp knife, trim off the ends of the
No 1 bearing cap sealing strips, so that they
protrude above the cylinder block/crankcase
mating surface by approximately 1 mm
60 Refit the centre main bearing side
retaining bolts and sealing washers (one at the
front of the block, and one at the rear) and
tighten them both to the specified torque (see
illustration).
61 Fit a new crankshaft rear oil seal as
described in Part B of this Chapter.
62 Refit the piston/connecting rod
assemblies to the crankshaft as described in
Section 14.
63 Refit the Woodruff key, then slide on the
oil pump drive sprocket and spacer (where
fitted), and locate the drive chain on the
sprocket.
64 Ensure that the mating surfaces of the
front oil seal carrier and cylinder block are
clean and dry. Note the correct fitted depth of
the oil seal then, using a large flat-bladed
screwdriver, lever the old seal out of the
housing.
65 Apply a smear of suitable sealant to the oil
seal carrier mating surface. Ensure that the
locating dowels are in position, then slide the
carrier over the end of the crankshaft and into
position on the cylinder block. Tighten the
carrier retaining bolts to the specified torque.
66 Fit a new crankshaft front oil seal as
described in Part B of this Chapter.
67 Ensuring that the drive chain is correctly
located on the sprocket, refit the oil pump and
sump as described in Part B of this Chapter.
68 Where removed, refit the cylinder head as
described in Part B.
TU series aluminium block engines
69 Carefully lift the crankshaft out of the
cylinder block once more.
70 Using a little grease, stick the upper
thrustwashers to each side of the No 2 main
bearing upper location; ensure that the oilway
grooves on each thrustwasher face outwards
(away from the cylinder block) (see
illustration).
71 Place the bearing shells in their locations
as described earlier. If new shells are being
fitted, ensure that all traces of protective
grease are cleaned off using paraffin. Wipe
dry the shells and connecting rods with a lint-
free cloth. Liberally lubricate each bearing
shell in the cylinder block/crankcase with
clean engine oil (see illustration).
Engine removal and overhaul procedures 2D•21
2D
13.51 Fitting the thrustwasher upper
segments - XU series engines
13.56 Applying sealant to the cylinder
block No 1 main bearing cap mating face
13.57 Fitting a sealing strip to No 1 main
bearing cap
13.60 Refit and tighten the centre main
bearing side bolts
13.58 Using feeler blades to protect the
sealing strips as the cap is fitted
13.70 Refitting a crankshaft thrustwasher
- TU series aluminium block engine
13.71 Ensure each bearing shell tab (arrowed)
is correctly located and apply clean oil