406 TD Engine Overhaul

[jv6cdx]

Note - Pics are using photobucket, so may not display if you're at work, etc.

Anyway I thought I'd post up my pics in the event anyone's interested!

A while ago I bought a Peugeot 406 Turbo Diesel, basically as an economical runaround, for camping trips with the dogs, so on.

I bought it as a "project" as the engine was very poorly - overheating, belching nasty smoke, making horrible noises, misfiring... it was basically a nail under the bonnet! The clutch was also slipping, and the head-gasket was causing the coolant to over pressurise.

So - first job, was to extract the lump for a decent overhaul!!

Draining fluids in preparation:




This is where a nice new hydraulic engine crane from Machine Mart proved very handy:




Equally as handy, was the engine stand, to mount the engine on for maintenance:





As you can see above, cylinder head now removed, timing belt kit and water pump removed, incl associated covers. The manifolds and Turbo were also obviously taken off at this point.


The underview of the engine, with the sump off. Strainer etc was all lovely and clear - and the crankshaft, main bearings etc all showing no signs of wear:




Bores all looking nice and clean, and not too coked up. Linings were fine, and leakdown test showed no sign of piston ring trouble:



Here is the old crank seal - the one that sits behind the flywheel. This was leaking oil into the clutch, which caused it to fail - so it was good to identify (and fix) the culprit for that:



The clutch release fork did NOT want to come off. Nothing a blowtorch and good pair of grips can't sort, though



Will it EVER run again???






Here is the cylinder head on the Bench, before I overhauld it by re-grinding in the valves, and fitting new valve stem oil seals:




And finally, a slightly less taxing job - fit my dog guards!!





Cost wise, I spent around £300 on parts, renewing Clutch kit, head gasket, cambelt kit, water pump, auxiliary belt, and all the various seals etc.

She ran sweet as anything once all done - the main issues being the head gasket, and the fact the indirect diesel injection pump was timed up wrong!

I obviously can't get enough of it - because I have now purchased a 406 HDi Estate, the newer type, with the commonrail diesel injection engine in it...... wondering what fun I Can have with that, using my big boys toys...

[mjb]

What a first post!

Welcome!

[jv6cdx]

Thanks

I was quite happy to do all this on the XUD lump... but I'm nervous about doing the cambelt kit on the new HDi

[mjb]

I've done a couple of clutch changes on my V6 (within months of each other ) and it took me about 3 weeks of weekends+evenings the first time and the second time I could have had it done in a day...

How long did it take you to do this? It looks like you managed to avoid removing the subframe and gearbox - how did you do that?

[mandelbug]

Impressive first post, I thought you were one of the ol' regulars on here nice work

[maglite1]

seconded excelent post , real shame you never done step by step write up would have been fantastic but im sure you now have the knowlage to post on further problems with these engines nice 1 .

[jv6cdx]

The subframe stayed in the car.

The engine and box are best to come in and out together, as 1, from the top. Learnt that the hard way

I would be more than happy to write up step by step what I did..... I can still remember most of it.
I have also done a simelar job on a 1.8 16v LX Petrol 406.

There are certain "tips" around driveshaft removal, (Centre bearing/mount!) and balljoints etc that make the job much easier....

I'll cut you a deal - I'll happily do a write up on this - if someone can point me in the direction of a guide for changing a HDi cambelt..... I didn't mind with these cars, I could do it with "trial and error" - but the HDi I have to get right

[jasper5]

Well done so far

Here is a good how-to on the HDi cambelt...viewtopic.php?f=10&t=8229

I have done more than 50 HDi timing belt jobs, so, if you are not sure about anything just ask.

[mjb]

There are certain "tips" around driveshaft removal, (Centre bearing/mount!)

Haha yeah that's a b**ch when you don't know how it's held in. On the V6 I can actually free it off much faster (by well over an hour!) by dropping the subframe Damn exhaust manifold and big hands...

[BruceT]

Is that the Barjo dog gaurd?

We have one in the estate also, interesting how you mounted it.

Can you supply some more pics of how its fitted?

I bolted the bottom into the boot carpet holding brackets and just screwed into the D pillars with a self tapper.

I see you have screwed into the metal tailgate shiny thing which is nice as it gives about 6 inches more space...

Piccies please, think ill have to redo mine lol

[TopDonkey]

Thats a very nice workshop you have there, undercover and dry !, i could get so much done in a place like that instead of working out on my driveway in between the rain, i am very envious !

[Doggy]

Excellent post there

Wouldn't say the HDI's too daunting - after all you only have to get the crank / camshaft timing correct, the HP pump doesn't matter.