Remove : (page 4 of 7)

Prepare the flywheel

Replace the fly wheel bearing (if necessary).

Replace the starter ring gear (if necessary). Drive off the starter ring gear with a drift. Clean the ring gear locating area.

Heat the new ring gear with a torch whilst continually moving it round to ensure that it expands evenly (heat it to between 200 and 250°C, that is to say until it is a light straw colour).

Fit the ring gear with the unmachined face against the shoulder on the flywheel. Carry out this operation quickly. Drive the ring gear fully into place with a drift if necessary.

Check the ring gear run-out (max. 0.3 mm).

Prepare the oil pump : Fig. I and II. Coat the edge of the oil pump body “a” with PEUGEOT jointing compound : Fit the following to the oil pump body :

• the drive shaft,
• the two oil pump gears,
• the cover (2) tightening the bolts (→).
• the seal (1) coated with grease.

Prepare the pressure relief valve : Fig. III Fit in the valve body (3) :

• the piston (5),
• the spring (6),
• the washer (7),
• the circlip (8).

Fit the O-ring seal (4).

Fit the pistons to the connecting rods : Fig. IV. Position the connecting rod so that the oil hole “b” is on the same side as the recess “c” on the piston.

Fit a circlip

Fit a gudgeon pin (9).

Fit the other circlip.

Whenever replacing a piston, ensure that the new piston fitted is of the same class as the cylinder diameter.

Fit the accessory components to the cylinder block : as shown in Fig. V.

Fit the cylinder block water circulation plates :

Fit :

• the pressure relief valve body (10).
• tighten the cone ended grub screw and nut (11).
• The dipstick guide (with the dipstick parallel to the block and pointing towards the fly-wheel).

Fit the crankshaft : Fig. V.

Lubricate the various components parts with engine oil just before each is fitted.

Fit :

• the bearing half shells to the cylinder block and the main bearing caps, LUBRICATING them as they are fitted,
• the crankshaft,
• the upper half thrust washers (12) on either side of the centre main bearing, to obtain an end float of : 0.07 to 0.17 mm : Fig. VII.

The lower thrust washers (13) which are fitted to the centre main bearing cap and which have a locating stud “d” : Fig. VI.

The two thrust washers placed on one SIDE of the bearing MUST BE the same tickness. The thrust washers fitted to one side of the bearing may BE OF A DIFFERENT THICKNESS to those fitted on the other side. The white metal face and the lubrication grooves “e” on the washers must be against the crankshaft : see Fig. VI.