TU3 engine disassembly (Peugeot 405)

Cylinder Block Assembly

Crank mechanism

1. Remove starter.

2. Disconnect gearbox from engine.

3. Drain the oil from the engine oil system by unscrewing the drain plug in the oil pan.


4. Remove V-belt and alternator.

5. Attach the motor to the mounting frame.

6. Remove the valve cover, remove the two spacers and the sheet casing (oil reflector).

7. Unscrew the oil filter located on the side at the bottom of the cylinder block on the left side (viewed from the flywheel).

8. Unscrew the oil pressure sensor located at the top of the cylinder block above the oil filter stand and remove the crankshaft pulley.

9. Remove the oil level gauge tube.

10. Remove the ignition index plate above the flywheel by unscrewing the two bolts from the rear wall at the top of the cylinder block.

11. Extract (if present) crankshaft position sensor (TDC sensor), and also unscrew the bolt of the sensor holder in the rear wall of the cylinder block opposite the flywheel.

12. Fix the flywheel with a special tool Peugeot (fixture 0132).

13. Unscrew the mounting bolts and remove the three-piece toothed belt guard.

14. Unscrew the three bolts securing the pulleys (crankshaft, camshaft and tension roller), remove the toothed belt and tension roller.

15. Unscrew the cylinder head bolts in several stages in order from the middle outwards.

16. Remove all five valve lever axle brackets with levers and axle.

17. Tilt the cylinder head with the two curved ends around one of the bottom long edges of the head to separate it from the cylinder block.

18. Carefully remove the cylinder head gasket.

19. Attach the cylinder liners to the cylinder block with two special Peugeot plates (tool 0132 A1Z), screwing each plate with two M10 bolts 40 mm long.


20. Remove the two cylinder head dowels from the holes in the top surface of the cylinder block.

21. Remove the four coolant pump mounting bolts from the cylinder block.

22. Unscrew the six bolts securing the clutch drive to the flywheel in several steps to avoid bending the drive.

23. Unscrew the flywheel from the crankshaft.

24. Unscrew the upper and lower bolts connecting both parts of the cylinder block.

25. Unscrew the two screw plugs of the main oil passage located in the front and rear walls of the upper part of the cylinder block.

26. Turn the engine upside down and remove the oil pan by unscrewing the appropriate bolts.

27. Unscrew the three bolts securing the oil pump and remove it, leaving the chain in the cylinder block.

28. Unscrew and remove the 10 crankshaft main bearing bolts, remove the lower part of the cylinder block.

29. Mark the relative position of the connecting rods and their caps by making marks from the side of the oil filter stand, unscrew the bolts of the connecting rod caps and remove them together with the liners.

30. Remove the crankshaft together with the oil pump drive chain from the cylinder block.

31. Remove main bearings from cylinder block seat.

32. Place the cylinder block on the front wall (from the side of the gas distribution drive) and remove two special Peugeot plates (holding cylinder liners) from the top of the cylinder block.

33. Pull out the cylinder liners together with the corresponding pistons and connecting rods towards the cylinder head.

34. Remove the piston with connecting rod from each cylinder liner.

35. The pistons should only be separated from the connecting rods if the piston is damaged. It is necessary to squeeze the piston pin out of the piston on a hydraulic press using a special Peugeot nozzle (fixture 0139). The removed connecting rod can be reused, while the piston must be replaced.

36. Remove piston rings with special pliers.