Remove : (page 5 of 7)

Fit the main bearing caps : Fig. I and II.

REMARK : Before fitting the main bearing cap on the flywheel side coat the face shown shaded and identified as “a”, on Fig. I, with PEUGEOT jointing compound.

The main bearing cap numbers appear on the camshaft side. No. 1 bearing is at the flywheel end.

IMPORTANT - The main bearing cap bolts are to be replaced by new ones whenever they are removed.

Fit the lower thrust washers at “b” and fit the main bearing caps.

Tighten the bolts (→) to a torque of 9.5 m.daN (95 Nm, 70 lbf ft).

Fit seal (1) into the groove on the No. 1 main bearing cap (at the fly wheel end).

Before fitting seal (2) (which is red in colour), check that it is fact the correct type for the engine to which it is to be fitted. The arrow should be in the same direction as the rotation of the engine (to the left as seen from the fly wheel end).

Oil the lip on the seal and assembly sleeve 8.0110 AB.

Fit the seal to sleeve AB.

Place the assembly in front of the seal location, place fitting plate AC over the entire arrangement and tighten 2 of the flywheel securing bolts as far as they will go.

Take off the fitting sleeve AB by turning it.

Fit a new seal (3) to the camshaft aperture. Ensure that the lubrication gallery plugs (4) are fitted.

Fit the connecting rod-piston assemblies.

Fit the bearing shells to the connecting rod big-ends and big-end caps. Oil them.

The upper haft shell has a lubrication groove and hole in it.

Place the connecting rod-piston assembly in the cylinder block when the crank pin is at TDC.

The piston protrusion, which is dependent on the nominal diameter is as follows :

(dial indicator 8.01504 and support 8.0110 H : Fig. V.

If it does not, reface the piston crown to obtain the correct height.

Fit the piston rings to the piston with the gap in the expander ring (6) set at 180° to the gap in the ring itself (5) : Fig. VI.

NOTE - There is an inscription mark on one face of each piston ring near the gap. When they are fitted, this inscription must be towards the crown of the piston.

Stagger the gaps.

Fit each connecting rod-piston assembly when its crank pin is at TDC, with the clover leaf saped recess in the piston crown on the camshaft side.

Use a piston assembly sleeve.

IMPORTANT - The big-end bolts are to be replaced by new ones each they are removed.

Tighten the big-end nuts to a torque of 7.6 m.daN (76 Nm, 56 lbf ft).

The connecting rod side float should be between 0.04 and 0.25 mm (it is not adjustable).