Peugeot 205. Manual - part 15

2D

Chapter 2  Part D:
Engine removal and overhaul procedures

Note: At the time of writing, many specifications for certain engines were not available. Where the relevant specifications are not given here, refer
to your Peugeot dealer for further information.

Cylinder head

Maximum gasket face distortion  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.05 mm

Cylinder head height::

XV, XW and XY series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not available

XU series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

141.0 ± 0.05 mm

TU series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

111.2 ± 0.08 mm

Valves

Valve head diameter:

Inlet:

XV8 engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34.8 mm

XW7, XY7 and XY8 engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37.0 mm

XU5J engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40.0 mm

All other XU series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41.6 mm

TU9 series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34.8 mm

TU1 series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36.8 mm

TU3, TU3A, TU3M and TU3S engines  . . . . . . . . . . . . . . . . . . . . . .

36.8 mm

TU3FM engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39.5 mm

Exhaust:

XV8 engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27.8 mm

XW7, XY7 and XY8 engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29.5 mm

XU5J engines:

Early models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32.0 mm

Later models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32.95 mm

All other XU series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34.5 mm

TU9 series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27.9 mm

TU1 series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29.4 mm

TU3, TU3A, TU3M and TU3S engines  . . . . . . . . . . . . . . . . . . . . . .

29.4 mm

TU3FM engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31.4 mm

Valve stem diameter:

Inlet:

XV, XW and XY series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.0 mm

XU51 and XU5M series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.30 mm

All other XU series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.98 mm

TU series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.99 mm

Crankshaft - refitting and main bearing running clearance check . . . 13
Crankshaft - removal and inspection . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cylinder block/crankcase - cleaning and inspection . . . . . . . . . . . . . 9
Cylinder head - dismantling, cleaning, inspection and reassembly  . 6
Engine - initial start-up after overhaul  . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine/automatic transmission - removal, separation, reconnection

and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Engine/manual transmission - removal, separation, reconnection and

refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Engine overhaul - preliminary information  . . . . . . . . . . . . . . . . . . . . . 5
Engine overhaul - reassembly sequence . . . . . . . . . . . . . . . . . . . . . . 11
Engine/transmission removal - preparation and precautions  . . . . . . 2
General information  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Main and big-end bearings - inspection  . . . . . . . . . . . . . . . . . . . . . . 10
Piston/connecting rod assembly - refitting and big-end bearing

running clearance check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Piston/connecting rod assembly - removal and inspection  . . . . . . . 7
Piston rings - refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2D•1

Specifications

Contents

Easy, suitable for
novice with little
experience

Fairly easy, suitable
for beginner with
some experience

Fairly difficult,
suitable for competent
DIY mechanic

Difficult, suitable for
experienced  DIY
mechanic

Very difficult,
suitable for expert DIY
or  professional

Degrees of difficulty

5

4

3

2

1

Valve stem diameter (continued):

Exhaust:

XV, XW and XY series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.0 mm

XU5J series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.96 mm

XU5JA and XU9J series engines . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.98 mm

XU51 and XU5M series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.30 mm

TU series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.97 mm

Overall length:

Inlet:

XV, XW and XY series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not available

XU series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109.29 mm

TU series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110.76 mm

Exhaust:

XV, XW and XY series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not available

XU series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

108.79 mm

TU series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110.60 mm

Cylinder block

Cylinder bore/liner diameter (nominal in three grades):

XV series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70.0 mm

XW series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72.0 mm

XY series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75.0 mm

XU5 series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83.0 mm

XU9 series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83.0 mm

TU9 series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70.0 mm

TU1 series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72.0 mm

TU3 series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75.0 mm

Maximum cylinder bore/liner taper*  . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.10 mm

Maximum cylinder bore/liner ovality*  . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.10 mm

Liner protrusion above block mating surface:

XV, XW and XY series engines:

With paper type base seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.11 to 0.18 mm

With O-ring type base seals  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.10 to 0.17 mm

XU series engines:

Pre-1987 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.08 to 0.15 mm

1987 models onward  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.03 to 0.10 mm

TU series (aluminium block) engines  . . . . . . . . . . . . . . . . . . . . . . . . .

0.03 to 0.10 mm

Maximum difference between any two liners:

XV, XW and XY series engines with paper type base seals  . . . . . . . .

0.04 mm

All other engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.05 mm

*These are suggested figures, typical for this type of engine - no exact values are stated by Peugeot.

Pistons

Piston to bore clearance:

XV, XW, and XY series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.07 to 0.09 mm

XU series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not available

TU series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.03 to 0.05 mm

Piston rings

End gaps*  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.3 to 0.5 mm

*These are suggested figures, typical for this type of engine - no exact values are stated by Peugeot.

Crankshaft

Endfloat:

XV, XW and XY series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.07 to 0.27 mm

All other engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.07 to 0.32 mm

Main bearing journal diameter:

XV, XW and XY series engines:

Standard  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49.965 to 49.981 mm

Undersize  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49.665 to 49.681 mm

XU series engines:

Standard  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59.981 to 60.000 mm

Undersize  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59.681 to 59.700 mm

TU series engines:

Standard  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49.965 to 49.981 mm

Undersize  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49.665 to 49.681 mm

2D•2 Engine removal and overhaul procedures

Big-end bearing journal diameter:

XV, XW and XY series engines:

Standard  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44.975 to 44.991 mm

Undersize  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44.675 to 44.691 mm

XU5 series engines:

Standard  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44.971 to 44.990 mm

Undersize  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44.671 to 44.690 mm

XU9 series engines:

Standard  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49.680 to 50.000 mm

Undersize  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49.380 to 49.700 mm

TU9 series engines:

Standard  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37.992 to 38.008 mm

Undersize  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37.692 to 37.708 mm

TU1 and TU3 series engines:

Standard  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44.975 to 44.991 mm

Undersize  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44.675 to 44.691 mm

Maximum bearing journal out-of-round (all models)  . . . . . . . . . . . . . . .

0.007 mm

Main bearing running clearance:

XV, XW and XY series engines*  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.023 to 0.048 mm

XU series engines:**

Models up to mid-1994 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.034 to 0.075 mm

Mid-1994 onwards models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.025 to 0.062 mm

TU series (aluminium block) engines:**

Models up to mid-1993 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.023 to 0.083 mm

Mid-1993 onwards models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.010 to 0.034 mm

TU series (cast-iron block) engines  . . . . . . . . . . . . . . . . . . . . . . . . . .

0.023 to 0.048 mm

Big-end bearing running clearance - all models*  . . . . . . . . . . . . . . . . . .

0.025 to 0.050 mm

*These are suggested figures, typical for this type of engine - no exact values are stated by Peugeot.
**On XU series engines and TU series (aluminium block) engines the bearing clearance was modified on later models - see text for further
information.

Torque wrench settings

Nm

lbf ft

XV, XW and XY series engines

Main bearing (crankcase housing) bolts:

Stage 1  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

27

Stage 2  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51

38

Big-end cap nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

27

Engine/transmission connecting bolts  . . . . . . . . . . . . . . . . . . . . . . . . . .

9

7

Engine mounting nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34

25

XU series engines

Main bearing cap nuts and bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49

36

Main bearing cap side bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

18

Big-end cap nuts:

Stage 1  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

30

Fully slacken all nuts, then tighten to:
Stage 2  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

15

Stage 3  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tighten through a further 70º

Oil seal carrier plate bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

11

Oil pressure switch  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

18

Engine-to-transmission bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

33

Engine mounting bracket bolts:

M8  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34

25

M10  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

33

Engine mountings:

RH nut  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

20

LH nut  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

26

Battery tray/bracket  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

13

Lower mounting centre bolt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34

25

Lower mounting to subframe  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

33

TU series engines

Big-end bearing cap  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37.5

28

Main bearing ladder casting - aluminium block engines (models with plain No 
5 main bearing half-shell fitted to cylinder block - see text):

11 mm bolts:

Stage 1  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

15

Stage 2  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tighten through a further 45º

6 mm bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

6

Engine removal and overhaul procedures  2D•3

2D

Torque wrench settings (continued)

Nm

lbf ft

Main bearing ladder casting - aluminium block engines (models with grooved
No 5 main bearing half-shell fitted to cylinder block - see text):

11 mm bolts:

Stage 1  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

15

Stage 2  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tighten through a further 55º

Fully slacken bolt, then tighten to:
Stage 3  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

15

Stage 4  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tighten through a further 45º

6 mm bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

6

Main bearing cap bolts (cast-iron block engine):

Stage 1  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

15

Stage 2  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tighten through a further 45º

Oil pressure switch  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

21

Engine-to-transmission bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

26

Engine/transmission left-hand mounting:

Mounting bracket-to-transmission nuts  . . . . . . . . . . . . . . . . . . . . . . .

20

15

Mounting bracket-to-body bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

18

Mounting rubber nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

15

Centre nut  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65

48

Engine/transmission rear mounting:

Mounting-to-cylinder block bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

30

Mounting link-to-mounting bolt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70

52

Mounting link-to-body bolt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50

37

Engine/transmission right-hand mounting bracket nuts  . . . . . . . . . . . .

45

33

2D•4 Engine removal and overhaul procedures

1

General information

Included in this Part of Chapter 2 are details

of removing the engine/transmission from the
car and general overhaul procedures for the
cylinder head, cylinder block/crankcase and
all other engine internal components.

The information given ranges from advice

concerning preparation for an overhaul and
the purchase of replacement parts, to detailed
step-by-step procedures covering removal,
inspection, renovation and refitting of engine
internal components.

After Section 5, all instructions are based

on the assumption that the engine has been
removed from the car. For information
concerning in-car engine repair, as well as the
removal and refitting of those external
components necessary for full overhaul, refer
to Part A, B or C of this Chapter (as
applicable) and to Section 5. Ignore any
preliminary dismantling operations described
in Part A, B or C that are no longer relevant
once the engine has been removed from the
car.

2

Engine/transmission
removal - preparation and
precautions

If you have decided that an engine must be

removed for overhaul or major repair work,
several preliminary steps should be taken.

Locating a suitable place to work is

extremely important. Adequate work space,
along with storage space for the car, will be
needed. If a workshop or garage is not

available, at the very least, a flat, level, clean
work surface is required.

If possible, clear some shelving close to the

work area and use it to store the engine
components and ancillaries as they are
removed and dismantled. In this manner the
components stand a better chance of staying
clean and undamaged during the overhaul.
Laying out components in groups together
with their fixing bolts, screws etc will save
time and avoid confusion when the engine is
refitted.

Clean the engine compartment and

engine/transmission before beginning the
removal procedure; this will help visibility and
help to keep tools clean.

The help of an assistant should be

available; there are certain instances when
one person cannot safely perform all of the
operations required to remove the engine
from the vehicle. Safety is of primary
importance, considering the potential hazards
involved in this kind of operation. A second
person should always be in attendance to
offer help in an emergency. If this is the first
time you have removed an engine, advice and
aid from someone more experienced would
also be beneficial.

Plan the operation ahead of time. Before

starting work, obtain (or arrange for the hire of)
all of the tools and equipment you will need.
Access to the following items will allow the task
of removing and refitting the
engine/transmission to be completed safely
and with relative ease: an engine hoist - rated
in excess of the combined weight of the
engine/transmission, a heavy-duty trolley jack,
complete sets of spanners and sockets as
described at the rear this manual, wooden
blocks, and plenty of rags and cleaning solvent
for mopping up spilled oil, coolant and fuel. A

selection of different sized plastic storage bins
will also prove useful for keeping dismantled
components grouped together. If any of the
equipment must be hired, make sure that you
arrange for it in advance, and perform all of the
operations possible without it beforehand; this
may save you time and money.

Plan on the vehicle being out of use for

quite a while, especially if you intend to carry
out an engine overhaul. Read through the
whole of this Section and work out a strategy
based on your own experience and the tools,
time and workspace available to you. Some of
the overhaul processes may have to be
carried out by a Peugeot dealer or an
engineering works - these establishments
often have busy schedules, so it would be
prudent to consult them before removing or
dismantling the engine, to get an idea of the
amount of time required to carry out the work.

When removing the engine from the vehicle,

be methodical about the disconnection of
external components. Labelling cables and
hoses as they removed will greatly assist the
refitting process.

Always be extremely careful when lifting the

engine/transmission assembly from the
engine bay. Serious injury can result from
careless actions. If help is required, it is better
to wait until it is available rather than risk
personal injury and/or damage to components
by continuing alone. By planning ahead and
taking your time, a job of this nature, although
major, can be accomplished successfully and
without incident.

On all models covered by this manual, the

engine and transmission are removed as a
complete assembly, upwards and out of the
engine bay. The engine and transmission are
then separated with the assembly on the
bench.