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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3.3.2. Removal and installation of the engine and transmission

GENERAL INFORMATION

Prevention

The engine can be removed from the car only with the transmission.


Removal

PERFORMANCE ORDER
1. Install the car on the flat horizontal platform, block back wheels, lift a forward part of the car and record on supports. Remove both forward wheels.
2. Open a cowl and fix it in vertical position.
3. Disconnect the negative plug of the accumulator.
4. Merge cooling liquid from the cooling system.
5. Remove both power shafts.
6. Remove the case of the air filter and system of inlet pipes. Unscrew bolts and remove an arm of support of the air filter.
7. On models with the diesel engine 2.1 liters remove the fuel ECU system and the control unit.
8. Disconnect an accelerator cable from the case of throttles or the fuel pump of high pressure.
9. Remove the case of throttles.
10. Remove wires, sockets and other components from the left forward end of a head of the block of cylinders.
11. Merge engine oil and remove an oil filter. Clear and establish a drain stopper, tightening it the required moment.
12. Merge oil from the transmission, establish drain and jellied traffic jams and tighten them the required moment.
13. Disconnect wires from the transmission.
14. Remove a cable of the drive of a speedometer or an electrical wiring of the converter from the transmission.
15. Using a screw-driver edge as the lever, disconnect the mechanism of the choice of transfers from the corresponding spherical hinged connections on the transmission.
16. Remove the sensor of position of the crankshaft.
17. Remove a coupling cable from the lever of switching off of coupling and disconnect it from a transmission case. On the 2.1 liters diesel engines remove the working cylinder of coupling.
18. Remove the pump of the amplifier of steering, without unscrewing from it hydraulic hoses. Using a soft wire, suspend the pump away from the engine.
19. Remove the generator.
20. On models with the conditioner unscrew a bolt of fastening of the compressor and, using a soft wire, fix it away from the engine.
21. On engines 2.1 liters unscrew a bolt of an additional suspension bracket from a forward part of the block of cylinders.
22. Remove a radiator.
23. On cars with petrol engines perform the following operations:
      – depressurize fuel system and disconnect the giving and returnable fuel hoses;
      – switch-off electric sockets of fuel system;
      – disconnect the ventilation valve from an inlet collector;
      – remove a reception exhaust pipe.
24. On models with diesel engines disconnect hoses of giving and return of fuel.
25. Release collars and remove heater hoses from an adapter on a partition of a motor compartment.
26. Track a plait of wires from the engine to the socket in a motor compartment. Switch-off sockets, take rings of fastening and remove sockets, previously having noted their arrangement (shooter). Check that all sockets are switched-off and the electrical wiring is taken from brackets and supports and will not prevent removal of the engine.
27. Hook on the load-lifting mechanism for suspension brackets on a head of the block of cylinders and lift until the weight of the engine is not perceived by the load-lifting mechanism.
28. Remove the right and left suspension brackets of the power unit.
29. From below the car unscrew nuts and bolts of fastening of limiters of the course to the lower frame and the engine and remove them.
30. Check that all elements interfering removal of the engine are removed or disconnected.
31. Lift the engine from a motor compartment up. On models with ABS it is necessary to show big care not to damage ABS in the course of removal of the engine.
32. After extraction of the engine from a motor compartment lower it on the earth ahead of the car.

Separation of the transmission from the engine

PERFORMANCE ORDER
1. Install the power unit on the corresponding bars.
2. Unscrew bolts of fastening and remove the lower protective plate of a flywheel from a transmission case.
3. On models with the hummock mechanism of switching off of coupling unscrew a bolt of fastening and remove the lever of switching off of coupling from the top part of a shaft. Put a tag of an arrangement of a shaft of switching off of coupling concerning a transmission case.
4. Unscrew bolts of fastening and remove a starter.
5. Check that the engine and the transmission are reliably fixed. Then unscrew the remained bolts of fastening of a case of the transmission to the engine.
6. Being careful, separate the transmission from the engine so that the weight of the transmission did not press an entrance shaft.
7. Remove the directing pins.
8. On models with the hummock drive of coupling make the second tag of relative provision of a fork after removal.

Installation

PERFORMANCE ORDER
1. Connect the transmission to the engine.
2. Check that the directing pins were installed in the engine or the transmission.
3. On models with the hummock drive of switching off of coupling before installation on the former place install the release bearing so that the tag on a shaft was combined with the second tag on a transmission case.
4. Install the transmission to the engine on the directing pins.
5. On models with the hummock drive of coupling check that the fork of switching off of coupling and the release bearing were correctly established, i.e. the tag on a fork was combined with the initial tag made on a transmission case.
6. Establish and tighten the required moment bolts of fastening of the transmission to the engine.
7. Establish a starter and screw bolts.
8. On models with the hummock mechanism of switching off of coupling install the lever of switching off of coupling on a shaft and fix it by bolts.
9. Establish the lower protective plate of a flywheel to a case of the transmission and fix by bolts.
10. Hook on the engine the load-lifting device and establish in a motor compartment.
11. At installation of the power unit, if necessary, incline and turn it so that it was established into place, without having done harm.
12. Establish the right suspension bracket of the power unit, tightening in this stage of a nut and bolts only a hand.
13. Establish the left suspension bracket of the power unit, tightening only them a hand.
14. From below the car install the course limiter.
15. Shake the engine in the parties that all elements of a suspension bracket fell into place then tighten them the required moment and unhook the load-lifting mechanism.
16. Further installation is made in the sequence, the return to removal.

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