Peugeot 205 Manual

Engine overhaul - reassembly sequence
Engine removal and overhaul procedures / Engine overhaul - reassembly sequence

1 Before reassembly begins, ensure that all new parts have been obtained, and that all necessary tools are available. Read through the entire procedure to familiarise yourself with the work involved, and to ensure that all items necessary for reassembly of the engine are at hand. In addition to all normal tools and materials, thread-locking compound will be needed. A suitable tube of liquid sealant will also be required for the joint faces that are fitted without gaskets. It is recommended that Peugeot’s own product(s) are used, which are specially formulated for this purpose.

2 In order to save time and avoid problems, engine reassembly can be carried out in the following order:
a) Crankshaft (Section 13)*.

b) Piston/connecting rod assemblies (Section 14)*.

c) Oil pump - XU and TU series engines.

d) Sump - XU and TU series engines (See Part B or C as applicable).

e) Flywheel (See Part A, B or C as applicable).

f) Cylinder head (See Part A, B or C - as applicable).

g) Timing chain/belt, sprockets and tensioner (See Part A, B, or C as applicable).

h) Oil pump - XV, XW and XY series engines.

i) Engine external components.

*On XV XW and XY series engines the piston connecting rod assemblies must be fitted before the crankshaft due to the arrangement of the split crankcase.

3 At this stage, all engine components should be absolutely clean and dry, with all faults repaired. The components should be laid out (or in individual containers) on a completely clean work surface.

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