Peugeot 205 Manual

Engine overhaul - preliminary information
Engine removal and overhaul procedures / Engine overhaul - preliminary information


It is much easier to dismantle and work on the engine if it is mounted on a portable engine stand. These stands can often be hired from a tool hire shop. Before the engine is mounted on a stand, the flywheel/driveplate should be removed so that the stand bolts can be tightened into the end of the cylinder block/crankcase.

If a stand is not available, it is possible to dismantle the engine with it suitably supported on a sturdy, workbench or on the floor. Be careful not to tip or drop the engine when working without a stand.

If you intend to obtain a reconditioned engine, all ancillaries must be removed first, to be transferred to the replacement engine (just as they will if you are doing a complete engine overhaul yourself). These components include the following:
a) Alternator mounting brackets.

b) Engine mountings and brackets (Part A, B or C of this Chapter).

c) The ignition system and HT components including all sensors, distributor cap and rotor arm, ignition module, HT leads and spark plugs (Chapters 1 and 5).

d) Power steering pump and air conditioning compressor brackets (where fitted).

e) Thermostat and housing, coolant pump, coolant outlet chamber/elbow (Chapter 3).

f) Dipstick tube.

g) Carburettor/fuel system components (Chapter 4).

h) All electrical switches and sensors.

i) Inlet and exhaust manifolds (Chapter 4).

j) Oil filter (Chapter 1).

k) Fuel pump - carburettor engines only (Chapter 4).

l) Flywheel/driveplate (Part A, B or C of this Chapter).

Note: When removing the external components from the engine, pay close attention to details that may be helpful or important during refitting. Note the fitting positions of gaskets, seals, washers, bolts and other small items.

If you are obtaining a УshortФ engine cylinder block/crankcase, crankshaft, pistons and connecting rods all assembled), then the cylinder head, timing chain/belt (together with tensioner, tensioner and idler pulleys and covers) sump and oil pump will have to be removed also.

If a complete overhaul is planned, the engine can be dismantled in the order given below, referring to Part A, B or C of this Chapter unless otherwise stated.

a) Inlet and exhaust manifolds (Chapter 4).

b) Timing chain, sprockets, tensioner and oil pump - XV, XW and XY series engines.

c) Timing belt, sprockets and tensioner - XU and TU series engines.

d) Cylinder head.

e) Flywheel/driveplate - XU and TU series engines.

f) Sump - XU and TU series engines.

g) Oil pump - XU and TU series engines.

h) Piston/connecting rod assemblies (Section 7).

i) Crankshaft (Section 8).


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