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Method for exchanging

(YUN .,'

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. .., l~fiERS AND PISTONS

on

PEUGEOT

•

Method for exchanging

CYLINDER LINERS AND PISTONS

on

PEUGEOT

LIST OF PARTS HECEUJ.RY

OPERA TIOH MeTHOO

Engin. ,.moY<l1

Oi.man.!;n\!

P •• ""rotion 01 fIG'"

R.b~ilding

Engine ,.inSlollo . ion

. PRACTICAL HIHTS

B,eooing_in

Oil con.~mp.ion

Eochan90 .y ... m

T""ling

CONTENTS

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7

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" " 16

17

LIST OF PARTS

Th. ,.,II_ ln; PO'U a,. n.c .. sa", .0 nchan;e <> $I ' 0' cr',"".,·lin .... <>nd pioto'" :

• 1 ~' " erli""., line,. and pillon. inclvdin; :

4 lin.,.

~ pl. lano, campi", ... ith ';n~. und .... i .. pin.

4 .ylind., lin ...... h ••.

·8 <",,",",,'ing .od. boll., .""pl"I" with nul und Bluefor w<>.h." .

. 1 oil fllI.r car.rld; •.

NOTE· To ."-i, _It H..e(it, ",poitv •• h""IJ U" ."ly guul". P EUG EOT ,. ... . TI, ••• ON .t';Clly .i ... i/o, ' 0 , ,,- ""i9i",,1 po,tl ami """ ve,,"h .. PE UG EOT .,e ... ... iII te •• ..,. .... ". _ri.,,,,"" ... ,Ine i t. 010"*'.1 ,,,,,,lille. ,

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OPERATI ON METH OO

ENGINE REMOVAL

3 · R.m ..... , ... ind.c,." .... he. ni pp les, hood, o •••• lnil h.nod le , ... ind ..... n "'o.h" bo", l, f ill., ' 0 co.· bur.nor ho.a , ignit ion coil, bo n . ry ond "'own· ' hoc' • • (on LHD •• hide.).

4 .0Iocom.c. choke and oc .. I.,o'", con'rol •• 0 .... 11 GO I •• d. on .h., __ ,., . wi'ch, ""'Vn • • ic fon ,I"","os .. i.ch, oil pr."",. con",c', genera'or ond . "', .... -r",.

S· R._ ... ,.di ... .. h .... , "-'.r h ..... and .",,,,",,.,,,,, hoo ... pipes .

6· R ........ ,odi •• ", and hea t .. '.'"'" h ... .

J. R.m"". bo,h OIorfQ' .... , .. to ciu.ch h"".inv fix. , ion Oct.,.. • .

13· Plac. hoi • • 2, n' &.0102 (po,," Ill. wi ,h hooko in .he hoi .. pr-.,...id.d for tho . put. po,. on .h. cylind..blod.

14. R_.,... •• nll'''' to fr .. " ."""",,, a.· ",ck_n' n,," .

15· Unboll engine from ,,"0.1>0. and '.mo .... englno, hcldi nll i. dl'IIonoliy in ",de. '0 cleo. it from tho cor.

16. Pu, .ngi .... on Cfoddl..

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8 • Re move pe trol pipe fr_ oil brO<r .h .. ,"Ia. g. Remo_ civ.ch " .... inll .... Iing plo .o.

10.0ioconn.cl uhoud p'pe fr __ nifold and fr_ po, bo ••

11 • Pia,," .u_t lack 1 n' 8.0103 Z ... i,k end 2 n' 8.0103 C ( . .. poge 17).

12 · Reme .. . h. 3 AII.n .c,ow. from c l .. ,.h housing, u.ing ..... nch 8.0202 (poge 17).

..... r .. 4 (no I "" !he flywh .. 1 "oIe).

7 _ R.m"". oann.c l'n; rod CGp ••

DIS4SSE ... L Y

I . R ......... cyllnd .. heod.

2 - Hold cylln", I'''' ' ' 10,.. _. 01 'C'.W' 1 .. " '.0104 D (~ 171.

4· Tum .~i ... UP"" d""", ond ......... G, I ._p. 5 - R.mo ... 011 Pu"", fiI"t, cl ... n ;1, c.,..~ ond

.".n ..... Uy t.ploc. " ... 1" .. (PN 1(1016.09).

6 _ MoB c ........ c li n; ,od. one! cops ,.ferenu, '" rhe ........... 1_2-3-<1, ... ltl.. Jr.. the

8 _ L.y ... , 1 ... an • .,. . Id. ond ........ If>ot .. ul .. , <"""o<:li .. , .od ... d ph''''' ' ; 0. . ... 1. tho c •••• poood , .. , ""p' , •• ,,,, clloll tho .. I ...... . .....

9 _ R ... "". IJUdil""" "'n •• I«lip. , u. ln; •• .,11 ... ; ......... ;udil""" pin • • nd c""".c' ;ng tod ••

10 _ Wrap . ,an.p'n. in oily PO"", In ",d ... to "''''oc. rho .. r. ........ nl""l ""och .. nd '0 "' ...... dl" It .... O*II ln'll Into .h ... 11 II .....

II _ R.mo .... crow. 8.0104 D .nd lIno ... n.. ... h .... ld n ... "",lIy co ... off .... lIy, by pull 01 hand; how."." .1,., ° lon, ~Iod .. I .'., dl"""ntllng ... , pr .... "''''' di lli cu lt and pull •• 2 n" O.OlOl .h .... ld be _ole, occ",din'll ' 0 ' •• 'ch 18.

13· R.""", •• 11 "PO"" in.lde ,he cylind.,bloc~ and cl •• n "...., < ... fu ll, 1.ln, loco .nd cyllnd •• llnors ""' •••

IMPORTAIIT NOTE· No .... ...... pI ' . loa ... tIoo Iittel. ,.1x!n.I ; ril rs w""W c/a-ap ",. ... "'ee " .. ,rr_n' .. ,.J ,1M ..." ... w""ld no ""'0-' IIcr". a __ , S.MC",,"'. iiI. .

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PARTS PREPARATION

T .... evlln",,, liM'S af. factary .... 'eh..r "ilh rh. "I .. on" cam~I ••• with f ;n~. and w,llI ~in. ond 11.1. ""eh . hould be , •• ,.cted.

TO. ""', • • A,B,C,E, on pis lons cor, •• pond , .. pee ll •• 11 wi,h ,h. 1, 2, 3 or 4 r.l.r." •• do, h .. an 'ho lin •••

Th. rin~ •• hould .... r be removed f,,,,,, th.l. pll1on, e~.n for daaning. H_e""r, .hould a ring br""k, tho n . ... one .. ill be li l l<ld wi th the ....... /acing upward,.

POllible do_go will be avaid.d by vn"rapping Ih. ",,'10 onl, a ' the m ........ rh..., a •• '-.:jui •• d.

CLEANING

Un a wooden block '0 dri"" p'"an. "'" a' I""i, lin., and i .... er .. one aft.r the ather each 11M. will. I .. pi" ... in'o .!.on ,.',01 . 0 .. a.h a.....,. .10 ...... , af ","' •• Ii"" "".nish. Whil. th. lin. reUI in the •• cip'''''' h .. ld the pill"" i_nd .. nd rao .... ,h •• ing .... ound in ...de, 10 fin.e "'" the gr""". ••

/.I,:"k •• "", tho, no "",ni.h hal ..... in.d in th. !If""V" and bt_ ,h. paris dry.

Aft., bl_ing, .h •• ' a""in the fr .. pla1 of rh. 'ing. in thei, g''''' •• ' : .h..., .hauld be 01 I, .. 01 ... , ill ring ••

Con .. e'ln, ,od,

A ... _"'" of lac', .. f,- ..... ori,inal 110'''_nl''9 and ~_.al .hau ... nd mil .. ope< .. , ion, a .on. ,od bah, .. hieh i. a .afery .... i. j .... 01, fOf 'n .... nu, a H .... . wh .. l .. vb ..... I., has _MOlly ""." .h.d ' 0 a e .. . oin . xlen •.

Shauld i, be used a""in, ,hi . .... uld prod"" ..... cond o".'ehing and, """'bly, .. ,ulb •• q .... ' broakago with,n .h .. ,.

Ther.I .... , i. ;1 hou'd .... a nd ."Ictl, p.ohlb lt.d , ......... a u .. d con. rod ba it , lor the eco­I'tOftIy i, ..... 01 po""",tlon .. i!h .h. damoi" i , _1 cou ...

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2. Ch. ok 011 lou, con .. cting ,ods 10, .!rolgh", ...

Should ooe 0' ... e,al connecting ,od. need ,e placement, make ,lire mal all lou, ",ngo within we igh l liMits nol nceeding 20 gtt. in diffe,ence.

C"",equont ly , 'he comod to ,oplace will be weighod ond 0 now ""0 wi ll boo .olected, 'he ",I",onco ma,k " 01 which, c""upond. ,,, Ihe de.i,ed weigh" occording to fabl. he, eunde,.

WEIGHT IN G~AM5 REfERENCE FIGUH PART N" . ~91to610 1 0601.59 611 1.630 , 0601.61 631 1.6~O , 0601.6] 6~1 ,.670 , 0601.6~

671 1.690 , Gli01.61 691 I. Ito • Gli01.6I

NOTE • The~e weigh •• a,e meant I", tho co.,oJ compie 'e, without bearing'" bu.h.

3. Ch.ck th.lreorln!il .h.lI . 10, condition

The <)OJ'. ' dia mele, of ' h beadng, i, c""""nt. Th. inne, di""", ,., con b. d.'.,mined by the thick · n . .. , o. meo ou,ed in ,h. middl e of Iho .hol1, with " pai' of campa .... '" a diolll""Ilo .

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CON. ROD BeA RINGS ID~HTlfICAT!OH

TM, ...... Di,. <too • • ; , p,,, N' ,I, DESCR IPTION .. I ,f 2 h.1f

.. , , 1- ~ .. M;"""", ~. , h.II,

Ck;I". ' .F,. 1.119 1,82~ ~9, 'H ~9.'/9I OWrl.09 h. U, d ... ' ,. 1 .~9 1,91$ ~9,61$ .9,691 Gli06. IO 2nd Und",;,. 1.069 2.0~ .9,~ 1~ .9.m WO<;. \ 1 ],' Und . .. I .. 1.219 1.nS .9.\71 .9,111 06G1i. Il

Th. unde .. ixu only oppl y wh en tho cranks""" has to bo .oc'ilied, which oporat ion i, beyond the .ubioc, of . ho p.o .... '""kl., .

•. Chock , .. 011 .nd buoh .. 10, condition

• 10 .

2. Fi l lho ci rclip. wi'" c.r ••

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REASSE".8LIHG

1. hlroc ' godg."" pinl if.", n.w pi.,,,,,., po irod with lino ••. Lubrico'e pin' and hand_drivo "'.m inro pil ' '''' and c""rod lmol l .nd. Mork AV with or •• w 2 "" 'OP 01 pili"". mUll poinl lowo,dl ,~. apo ' . 'o, . " h.n 011 . pili ing orllico 0" oon,od biG ond , i. 0" t~. I.ft .

Pill"'" ond gudgoon pin. oro krc .oty poi,...! loy ",".nt 01 hi"" p"oci . • 1"" .quipm.n •. Thi. _.<h il '0 be ,upoclod o' u .. mbly, ., on ow,tightoning would cou .. dill .. tl ......... ich _uld .flu' "' ...... ~ c.obl. lif. of lho ongin ••

3. Dilploy "" 0 troy 'h ouio. : c""rod and pili"" in Ike di.G .. ombling .oq .. nc. (6 pog. 8).

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5. Placo .ho .0" IIno .. , with .... ,..I .. onco do ..... 10 tho <o ... hol"i"", 0...1 ,ol~< . ing .... no<moi m,,,,,h Ii .... . _pi"an.

6. U •• 1<..,... 8.010.4 D 10 hold lin ... in politi .....

NOTE. Our of I •• el of linelS above rh. iaint lace of cylinJ.,hlack. should rang. be,w ........ 0,015 and 0,075.

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9. U.in~ . Ieeve 2, n' 0.0103, in,,<>duee ossie. pi . lon.eon,<>d hom Ihe .gp. Sleeve 0.0103 will be mode according.a , k.'eh PO!!" 18.

Th • • "ow, on piston 'O!' wi ll pain. towo.d. th o hont 01 eng ine.

RESPECT .he di,o .. o..,bly SEQUENCE of CONRODS (1.2 .3.4) (See poge 8, po,.6).

10. Assemble con ,<>ds with cor,,,ponding cop. " ve , c,,,nkpin' « on,od. "nd c"p. ",e mo,ked lor ,.f.,ence with the .0'" numbe, . The.e ,eferences mu, ' come on .he .ome ,id...

II. In",,11 no ... Slod", washe" and no ... nulS un ."'~ ..... w,onch to tighton to 30'035 ft. lb • .

12. R.l it oil pump fil "" on oil . u",p and ,olit sump wi .h "","'" cork'lI"s ke •.

\3. Turn engine up on crodle .

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U . I~.,.,II 'Opp.'I.

IS. It __ ql ..... Ii_ hold ln, la.wl _01 '""011 ••• eyl ,"d ....... d 00 ..... , _ ...... d .i'" cooked I ' ~"'" oil, w i ........ otl. ·0 ...... · hocl"g..p.

Locete .... eolk •• by _I of cyl,nM ... d gvi<le le ... w' e' • 0115, .. ,,""", fining ."d. { ... ~II" In ....... ..1 In holel a ",d 12.

16. R.fi. cyll"d.mood, .oe'." pu.h,od. Gnd ,oek •• 0"" Ihohl .

11. F'~ cyli"d ... head, .c •• wl~g fi .. . . c •• w. n' 3 and , i" Old .. to loca ...... OOlk •• ",_Iy, .... d fit rock ... """ .... tI.

II. R_ .. ",id •• a 0115, ~Ii", ...... "',.,chobl • ..... ... pull ... _ OU ' ...... eplace by u ..... potIdi"g OC'_'. TIGHTENING SEQUENCE

19. TI ...... ,he \0 cyli"cl..heocl .c ..... , I" !h. Mqu....:e ._n "" .k ... c" h .. _~ •• U ....... ,... ... end, ..... pooc ..... in , __ ... Ion. -

Fifl.,;p, ..... " : 30 I. loS h .I ~1 2 enfinite to.qu. : 5\ '0 sa h.I.. ,,~~---'-/"'-/"---"'-'-' (Se . .... 1""0Ii ... "".,ly ' ollo ... d)

20. Tip, '«ling to"l~. ho, ... ek ....... nutl :

l' to 18 It . lb.

,.-(,· f,· t, · f.­/' . /' . r. _ 10 . _ ........ • = ==

®

....... '-1 .. .. I ....

1.11 _ ...

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CD

"[:...Ii;:.' . ... _. • •

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21. P.oCNd with .oek ... cI.",,,,,,,. adi~'_ '. following .... abo ................ leh II die,., •• d by ... . pa •• ic~lo. choroctetill'co of .... " .....

• 13 -

23. Reploc .. oil filt., cO'I.i4~.

1"1. 1 :. ISmm

E.ho .. 1 : .30 ...

24. Inlloll fon belt : on flo. becl., d,ow I"",,,,,,.k. dl.lon l 100 mm. It"", ... ch olhe •. T.",ionlMrlt"nllf mo.ks a •• 103 mm. "","" mo-I •• ,". N.v •• sl •• ICh ov ••• holll.lI.

EN GI NE REINSTALLATION

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1. I!dng engine dioll"",,olly, in Ih •• 0_ po.ilion OS for ,.moval.

2. Shih f""' lh geo., in "' ... 10 ..,1.. e_elion of .ngin" ,.; ,h g .. "bo. easi ...

3. lineup engin. with gea.b ... , "" Iii cluleh hOlJ.1niil beG .. ",".,,",.I y agoin.1 cylinde,bl",,!. ioinl fac e, fill ing II,. clo.ing plar .. In """" .....

4. Fi. "'lIine .... I .. Iron . ,uPP<><'" "'i"ln.

5. Refi l all "eceo.",ie, and fill liP wi th .iI and " 0'.'.

6. ReC"""K I boll • ." and PilI .I.e dock ,,·go;ng.

7. Rood .e.1 1M cot. AfTef I .. , •• elight." .he cylinde,h ... d on .ng;ne COLO (01 I"",u 6 ho ..... nol nmningl and odiull ,ock., eI ... ,anee ogoin ", .15 "n" .30 Mm •

PRACTICAL HINT S

· u .. th. oil ro,co ...... nc!ed by tho IIIonuloClu,.r. ,

ESse EXTRA MOTOR OIL 20 W/30/40 011 tho Y"" ,,,,,nd 0' ESse MOTOR OIL SAE 40 in tummer tim.

ESse MOTOR OIL SA E 20 du'lnV lonv "" •• period.

• All. 600 .. iI .. , chong. oil ond r •• ighten tho cylirwlerh.od, ENGINE COLO, ""d "ju.t rock. d."",nu.

Inl., : : 10_ E,«"" • • I I 2.5 ••

· !.ho.ld the .... V;,;. o~.,~.al, ••• 1. coolin9 "1".'"

BREAKING IN

Th .... gin . ...... oYert.oulod, ..... . be bro~.n·in just in the ...... woy OS 0 n.'" .... gin • .

Hig!. ,.~ • . • r. of 11 .. 1. i"'1>o"o"c., pto. i"-d th.y 0,. no' being ... 101 ..... l0nt.

Fo. mo •• horm .. ill be don. by ,h. 0l»'0 ' i .... 0' 10 .. ,n', ""der full lood, I. • . o' full o.,.n lng 01 tho t\o,ollie ""I~. 0' .10'" .pud (porticulor ly In t\ol,d ond 'op lI"0r). N .... he.ilote 1<1 change 11""" In .,d.r '0 ,educe .h •• ff.rt. r.qui,.d from the .ngin., a. 1.0", during tho Ii ... 600 ",II ...

Anywoy, .ho following .peed •• h""ld no. be .. c.od.d :

1 .. , ., '" .. 11 .. ph

" ." H_ph SS",ph

OIL COtUU MPTIOH

All er>gin •• IOU" cono ..... om. o;1. A....d .... .." In. "' .... ;nll o. SOOOrpn one! c ....... ;n9 .... oil o' 011 1. Iou. 0 dongerou. ill •• i .... .

U~ 1<1 3 ~i nt. of oil .... y 1000 ",it ..... y be ...... id.red 0 """"01 c"" ..... p.i"".

Exit. lubrko tl"" .h,ough oil in 110 • .,..rol .. oy be odmi". d du.ing .1.. fin. 600 mil .. on 0 n.'" a. o .... h""l.d ""lIino, bu. io "" ic l.y p.ohibi •• d oft., tho t "."iod. Additionol ond unlul c •• bon .;.poilu I .... od by .h. u •• of .hil .. Iro oil would .0nC.nlt.,. on the .01 ••• '.ml , cou ll ng 110 ... 1<1 •• i .. In lIo.i, guid •• and 1<1 Iou'n in 0 lhot. ' i ... .

• 1 S •

EXCH.vICE SYSTEM

WII ... ,II. lIftl.ral .. oar of .11 .... gino doe. no 10n9'" pormi , ' 0 .. ,..,d Ito •• ",iceabl. lif. by "",.Iy ,eplacing 1\,. cylinder lin'" ond pillan., In .. all on excllal9" engine Ito., 1\, •• pecial recondi· tioning lin. a ' Peugeo"" Til ... u,lIalli' "'vinn carty ,h. 00." .. o"on'y a. a nO" "'gin'.

jf prer..".d, one Can in .. all a ,,"" '"'!lIn., and .h. P"'II"" C_P""Y .. III I<ad . in 1\,. old one in .i.h .. co ...

No cio i .. will be 9",nl..l c ..... id .. o, ... n if 1\,. abo_ ,..::_d,nlo ... ha_ "'" beer. folio""!,

• 16 .

PEUGEOT SPECIAL TOOLS

Thes. lOolin~s will b. o,dered ftom:

T.U .P.A.C. 18, Boulevard HelianQl. La c;.. ... nne· S.ine

FEHWICK a, Rue de RaeO"Oy . PARIS l (lo

801031 ,

Engi ne and g ... 'box suppo" jook, logether ",ilh:

A . Filling .... d for suppo" poinl undo< engine cronkeo ...

a _ Filling end for suppo rl poinl under cluloh housing 203 . 404 and A .. ocio . • eo'types.

C· Filling end fOf suppo" point under clutch hou sing _ 404

80202

Wren ch for clutch hou.ing sere'" 404

,al!m::]I]I==:::C~ ~

·n

80102 _ 801028

Hoi .. fa, 404 engine

80102

Seam

80102 B

2 Symelricol eno .. ,

80104 D

2 Se ... w. fo, holding 404 cylinderl'ner. in pooi'ion.

80115

Set of two 404 cylinderheod guide SCrew'.

TOOLS TO MANUFACTURE ON THE SPOT

0-0101

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0.0103

• • 0

Pistons ins'olio , j"" .Ieev<! . . to .. '*. f __ ... old cylind.<l in •• j -.

• 18 .

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•

P · .- -' In France ron"",

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5,000 - 5-62 _ tII0 •