Peugeot 406

since 1996 release

Repair and operation of the car



Peugeot 406
+ 1. Maintenance instruction
+ 2. Maintenance
- 3. Engine
   + 3.1. Petrol engines
   + 3.2. Diesel engines
   - 3.3. Repair of the engine
      3.3.1. Technical data
      3.3.2. Removal and installation of the engine and transmission
      3.3.3. Removal and installation of engines with the automatic transmission
      3.3.4. Repair of the engine
      3.3.5. Removal and installation of a head of the block of cylinders
      3.3.6. Dismantling of a head of the block of cylinders
      3.3.7. Cleaning and survey of a head of the block of cylinders
      3.3.8. Assembly of a head of the block of cylinders
      3.3.9. Removal of pistons with rods
      3.3.10. Removal of the crankshaft
      3.3.11. Block of cylinders
      3.3.12. Pistons and rods
      3.3.13. Crankshaft
      3.3.14. Survey of radical and conrod bearings
      3.3.15. Engine balance of assembly at capital repairs
      3.3.16. Installation of piston rings
      + 3.3.17. Installation of the crankshaft and check of working gaps of radical bearings
      + 3.3.18. Installation of pistons
      3.3.19. Start of the engine after capital repairs
+ 4. Cooling systems, heating and ventilation
+ 5. Fuel system
+ 6. System of ignition
+ 7. Coupling
+ 8. Transmissions
+ 9. Power shafts
+ 10. Brake system
+ 11. Suspension bracket and steering
+ 12. Body
+ 13. Electric equipment
+ 14. Main malfunctions


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3.3.11. Block of cylinders

Cleaning

PERFORMANCE ORDER
1. Remove all details and electric sensors from the block of cylinders. For full cleaning remove technological caps. For removal of caps drill in them small openings and in openings screw in the self-cutting screw. Having pulled for a screw head, remove a cap.
2. On blocks of the cylinders manufactured their aluminum remove steel sleeves of cylinders.
3. Where are established, unscrew bolts and remove a pipe of dispersion of oil in an internal part of the block of cylinders.
4. Remove all traces of laying from the interfaced surfaces of the block of cylinders of the engine.
5. Remove all caps of the oil highway. At installation use new caps.
6. The most polluted places clear the ferry.
7. Clear all lubricant openings and the oil highway. Wash out all internal channels a stream of warm water until water does not come out pure. It is necessary to drain completely the block of cylinders and to grease with a thin butter layer all interfaced surfaces for prevention of emergence of corrosion. On blocks of the cylinders manufactured of cast iron also grease engine cylinders. If there is a compressed air, use it to accelerate process of drying and to blow all lubricant openings and highways.
8. If the block of cylinders is not really polluted, it can be washed out warm soap water and a rigid brush.
9. Carefully clear all carving openings, using a tap with the corresponding carving then blow openings compressed air.
10. Install traffic jams to the oil highway in the block of cylinders of the engine and reliably fix them.
11. Clear and install a pipe of dispersion of oil in the block of cylinders and fix it by a bolt.
12. If the engine is not subject to immediate assembly, then close the block of cylinders a big plastic bag to protect it from pollution.

Check

PERFORMANCE ORDER
Pig-iron block of cylinders of the engine
1. Visually check the block of cylinders for existence of cracks and corrosion. Check integrity of a carving in carving openings.
2. Check diameter of cylinders of the engine for wear on existence of a step in the top part of the cylinder.
3. In the presence of the measuring tool measure diameter of a sleeve of each cylinder in the top part (under a wear step), in the center and at the basis parallel to a crankshaft axis.
4. Then perform the same measurements perpendicular to an axis of the crankshaft and compare them to specifications (see subsection 3.3).
The aluminum block of cylinders with damp sleeves
5. Remove fastening of a sleeve of the cylinder, then, using a firm wooden drift, beat out sleeves from an internal part of the block of cylinders. Take from the top part of the block of cylinders of a sleeve and mark them.
6. Remove from each sleeve a sealing ring (it is specified by an arrow) round section.
7. Check each sleeve for wear and damages.
8. In the presence of the measuring tool measure diameter of a sleeve in the top part (under a wear step), in the center and at the basis parallel to a crankshaft axis.
9. Then perform the same measurements perpendicular to an axis of the crankshaft and compare them to specifications (see subsection 3.3).
10. Repeat the procedure of measurement on other sleeves.
11. If wear of a sleeve exceeds admissible values or there are other damages, it is necessary to make replacement of sleeves.
12. New sleeves are delivered complete with pistons and piston rings.
13. Pistons and sleeves are divided into three groups of the sizes. The group of the sizes of each piston is designated by a symbol (A, B or C), put in the top part of the piston, and the group of the sizes of each sleeve is designated by cuts (from 1 to 3) at the top end face of a sleeve; one cut for group A, two cuts for group B, three cuts for group C. Check that each piston and the corresponding sleeve were the same group of the sizes. It is not allowed to use the piston of one group of the sizes and a sleeve of other group of the sizes.
14. Before installation of sleeves completely clear the interfaced sleeve surfaces in the block of cylinders and, using a fine-grained emery paper, a soshlifuyta all teases and sharp edges which can damage a sealing ring of round section. Clear sleeves and wipe them dry. Establish a new sealing ring of round section on a sleeve. To facilitate installation of a sealing ring, grease it and an external surface of a sleeve with engine oil.
15. If the sleeves which are earlier removed from the engine are established, establish them on the places according to earlier made marking. Insert each sleeve into the block of cylinders and press it a hand against the stop. Using the hammer and wooden whetstone, completely establish a sleeve into place.
16. After installation of all sleeves, using a ruler and the probe, check that the vystupaniye of each sleeve over the block of cylinders conforms to technical requirements (see subsection 3.3).
17. At installation of new sleeves change by their places is allowed to carry out to compliance a vystupaniye them from the block of cylinders of the engine.

18. If the vystupaniye of a sleeve does not conform to technical requirements, then it is necessary to address the specialist in repair of engines.

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