Peugeot405
1. The maintenance instruction
2. Maintenance service
3. Engines
    3.1. Petrol engines
    3.2. Diesel engines
    3.3. The petrol engine 1,4 дм3
      3.3.1. A technical characteristics
      3.3.2. Check and adjustment of a backlash of valves
      3.3.3. Check and adjustment of a corner of an advancing of ignition
      3.3.4. Carburettor adjustment
      3.3.5. Removal of the air filter
      3.3.6. Removal of a head of the block of cylinders
      3.3.7. Installation of a head of the block of cylinders
      3.3.8. Removal and installation of the power unit from the petrol engine 1,4 дм3
      3.3.9. Features of dismantling of the petrol engine 1,4 дм3
      3.3.10. Engine TU3 dismantling
      3.3.11. Dismantling of a head of the block of cylinders
      3.3.12. Assemblage of a head of the block of cylinders
      3.3.13. Definition of the size of loose leaves
      3.3.14. Engine TU3 assemblage
      3.3.15. Removal of the oil pump
      3.3.16. Dismantling of the oil pump
      3.3.17. Removal of the pump of a cooling liquid
      3.3.18. Service and repair of a transmission of type МА
      3.3.19. Removal and installation of a transmission of type МА
      3.3.20. Transmission dismantling
      3.3.21. Dismantling of a secondary shaft
      3.3.22. Dismantling of a primary shaft
      3.3.23. Differential dismantling
      3.3.24. Dismantling of knot of plugs with their axes
      3.3.25. Dismantling of the plug of synchronizers
      3.3.26. Verification of parts of a transmission
      3.3.27. Assemblage of the plug of synchronizers
      3.3.28. Assemblage of knot of plugs with their axes
      3.3.29. Differential assemblage
      3.3.30. Assemblage of a primary shaft
      3.3.31. Assemblage of a secondary shaft
      3.3.32. Transmission assemblage
    3.4. Ignition system
4. Fuel system
5. Systems of greasing, cooling
6. Release system
7. Coupling
8. Transmissions
9. Power shafts
10. A steering
11. Suspension brackets
12. Brake system
13. A body
14. An electric equipment





3.3.14. Engine TU3 assemblage
PERFORMANCE ORDER
1. To establish piston rings in flutes of pistons, paying attention to a corresponding order of installation and an inscription on rings which should be visible from above, and also on correct installation of locks of rings on each piston through everyone 120 .
2. Plentifully to grease with engine oil pistons and sleeves of cylinders.
3. To compress piston rings a special tightening bandage so that rings have completely entered into flutes of the piston and cautiously to insert knot of the piston with a rod into an aperture of each sleeve.
4. To put on a sleeve of each cylinder a new sealing ring, paying attention to its correct arrangement (the ring on the plug cannot be braided).
5. To insert into the top part of the block of cylinders of a sleeve of cylinders together with corresponding pistons and rods.
6. Pistons to establish in position in which arrows on their bottoms will be directed towards a drive timing.
7. To attach sleeves of cylinders to the block of cylinders special plates Peugeot (the adaptation 0132 А1Z), screwing each plate two bolts М10 the in length of 40 mm.
8. To insert radical loose leaves (dry) into nests of the top part of the block of cylinders and to grease their surfaces of sliding with engine oil.
9. Cautiously to establish a cranked shaft in nests of radical bearings of the block of cylinders.
10. To insert persistent half rings of a cranked shaft the flutes directed towards a shaft.
11. To measure by the indicator of hour type longitudinal backlash a cranked shaft (correct size of 0,1-0,3 mm), putting the indicator to the shaft end from outside a drive timing. On the basis of measurements, in case of need, to replace persistent half rings with rings of a corresponding thickness (identical from both
The parties).
12. To insert шатунные loose leaves (dry) into nests of rods and to grease their surfaces of sliding with engine oil.
13. To put on covers of rods together with loose leaves, remembering their adjustment to corresponding rods, and to tighten nuts of bolts the moment of 40 Nanometers.
14. On a pin of the forward end of a cranked shaft to dress an asterisk of a drive of the oil pump, to insert шпонку into a flute of a pin and to put on a gear wheel a chain.
15. To insert radical loose leaves (dry) into nests of the bottom part of the block of cylinders and to grease their surfaces of sliding with engine oil, remembering their correct installation (radical loose leaves of the second and fourth bearings have flutes).
16. To degrease both surfaces of connection of two parts of the block of cylinders and to grease with their thin layer герметизирующей weights (for example, "Loctite Autojoint").
17. Cautiously to establish the bottom part of the block of cylinders, extending приводную a chain of the oil pump over this part of the block of cylinders.
18. To insert ten bolts of fastening of radical bearings of a cranked shaft and to tighten them in two stages: at first the moment of 20 Nanometers, and then on a corner 45 .
19. To check up, whether rods with шатунными necks of a cranked shaft are correctly connected, paying attention to their movings to the parties.
20. To put on приводную a chain an asterisk of the oil pump and to establish the pump on the block of cylinders, paying attention to position of the aligning plug of the oil pump placed in the bottom part of the block of cylinders.
21. To tighten three bolts of fastening of the oil pump the moment of 8 Nanometers.
22. To turn some times a cranked shaft, checking smoothness and freedom of its rotation.
23. To degrease both surfaces of connection of the oil pallet with the bottom part of the block of cylinders, to grease with their thin layer герметизирующей weights (for example, "Loctite Autojoint") to establish the oil pallet on the block of cylinders and to screw bolts of the oil pallet the moment of 8 Nanometers.
24. To screw in two bolts, uniters the top and bottom parts of the block of cylinders on a forward wall (from outside a drive timing) and to tighten their moment of 8 Nanometers.
25. To screw in two заглушки with a carving of the main oil channel, being in forward and back walls of the top part of the block of cylinders, tightening their moment of 30 Nanometers.
26. To establish the block of cylinders the oil pallet downwards.
27. To screw in other bolts of fastening of both parts of the block of cylinders and to tighten their moment of 8 Nanometers.
28. To grease with engine oil an edge of a back sealing ring of a cranked shaft and to press the sealing ring directed by an edge in the engine, into a back nest of the block of cylinders (from outside a flywheel) by means of the corresponding assembly adaptation.
29. To press (against the stop) into a forward nest of the block of cylinders (from outside a drive) a forward sealing ring of a cranked shaft by means of the corresponding assembly adaptation.
30. To establish on the forward end of a cranked shaft a remote ring and a pulley of a cranked shaft; to screw in a hand a bolt of fastening of a pulley of a cranked shaft.
31. To establish on the back end of a cranked shaft a flywheel and temporarily to fix its bolts.
32. To fix a flywheel by means of the special adaptation.
33. To grease bolts of fastening of a flywheel with means "Loctite Frenetanch" and to tighten their moment of 65 Nanometers.
34. To tighten a bolt of fastening of a pulley of a cranked shaft the moment of 110 Nanometers.
35. To insert into an aperture of the block of cylinders a sealing ring of the pump of a cooling liquid (in the right wall of the block of cylinders in the top forward part) and also to adjust the case of the pump of a cooling liquid to the block of cylinders by means of two aligning plugs and to tighten four bolts of fastening of the pump to the block of cylinders: two bolts М6 the moment of 30 Nanometers and two bolts М8 the moment of 50 Nanometers.
36. To remove two special plates Peugeot (the adaptation 0132 А1Z) fastenings of plugs of cylinders, having unscrewed their bolts of fastening.
37. To degrease surfaces of connection of the block of cylinders and a head of the block of cylinders with a head lining.
38. To insert two aligning plugs of a head of the block of cylinders into apertures in the top part of a surface of the block of cylinders from outside the pump of a cooling liquid.
39. To put on a camshaft a pulley and a hand to screw in a bolt of its fastening.
40. Into an aperture for fixation of a pulley of a camshaft to insert an adjusting core and to fix a camshaft.
41. To establish on the top surface of the block of cylinders a new lining of a head of the block of cylinders and to establish on it a head.
42. To establish on a head of the block of cylinders all five arms of an axis of the lever of valves with levers and their axis, paying attention to correct installation of intermediate fingers of each arm of an axis of the lever of valves in their apertures in a head of the block of cylinders.
43. To grease with a small amount of means Molykote G Rapi12 Plus a carving of bolts of a head of the block of cylinders. These bolts at first to screw in a hand, and then to tighten them in two stages: at first the moment of 20 Nanometers, and then on a corner 240 , one after another from the middle outside, moving on a spiral.
44. To establish a tension roller and to screw in a hand its bolt.
45. To check up, whether distributive and cranked shaft are correctly established.
46. To put on a gear belt at first a pulley of a cranked shaft, and then on a camshaft pulley. To pull with small force a gear belt by means of a tension roller.
47. To clean adjusting cores of distributive and cranked shaft, and into a tension roller to insert special adaptation Peugeot (the adaptation 0132) for a tension of a gear belt or accordingly adjusted core in length of 10 sm, the forming unilateral lever with cargo is powerful 1,5 kg, hanging on the end of a shoulder of the lever.
48. To weaken a bolt of a tension roller of a gear belt and to tighten its moment of 23 Nanometers.
49. To tighten a pulley of a camshaft the moment of 80 Nanometers.
50. Slowly to turn a cranked shaft in a direction of working rotation on two turns, rotating for a bolt of fastening of a pulley of a cranked shaft, and then to fix a flywheel an adjusting core.
51. To weaken a bolt of a tension roller and it is easy to press a belt so that the roller has turned. In this position the adjusting core of a camshaft should not be inserted.
52. To tighten a bolt of a tension roller the moment of 23 Nanometers, to take an adjusting core from a flywheel, repeatedly slowly to turn a cranked shaft in a direction of working rotation on two turns and again to fix a flywheel an adjusting core.
53. Slowly to weaken a bolt of a tension roller so that adaptation weight has caused a tension of a gear belt then to tighten a bolt of a tension roller the moment of 23 Nanometers and to check up, whether the adjusting core of a camshaft is inserted in this position. If yes to take both adjusting cores (distributive and cranked shaft).
54. With the help щупа to adjust backlashes of valves (a backlash of inlet valves of 0,2 mm, final – 0,4 mm).
55. To establish a three-element casing of a gear belt and to tighten bolts of fastening by the moment of 6 Nanometers.
56. To insert into a head of the block of cylinders a sheet casing (an oil reflector) and two remote plugs, and also to establish a new lining of a cover of valves and a cover, tightening its bolts of fastening by the moment of 16 Nanometers.
57. To grease the end of a tube of the index of level of oil with means "Loctite Frenetanch" and to insert it into the cleared nest, and then to tighten fastening of a tube by the moment of 15 Nanometers.
58. To fix the gauge of pressure of oil in the top part of the block of cylinders over a support of the oil filter the moment of 27,5 Nanometers.
59. To screw a hand the oil filter together with a lining greased with engine oil, on a support of the oil filter.
60. To insert into a flywheel special the mandrel for a coupling centering. To insert a disk of coupling and a leading part of coupling. To screw in six bolts of fastening of a leading part of coupling to a flywheel, tightening them in some stages – the final moment of a tightening of bolts makes 10 Nanometers – and to take the mandrel for a coupling centering.
61. To establish a plate with divisions for ignition installation over a flywheel, having screwed two bolts on a back wall of the block of cylinders.
62. To establish (if there is) a gauge of position of a cranked shaft (gauge VMT) at a back wall of the block of cylinders and cautiously to press it against the stop about a flywheel surface. To screw a bolt of a holder of the gauge and to designate this position of the gauge. Cautiously to weaken a bolt of a holder and to submit the gauge a little back approximately on 1 mm; to tighten in this position a bolt of a holder of the gauge.
63. To establish the piston of 1st cylinder (considering from a flywheel) in position ВМТ and to turn the distributor case in such position that the electrode of 1st cylinder was in a cover under a distributor rotor. To fix the distributor in this position.