406 1.9 Diesel Cylinder Head

[GGG]

I have a p reg 406 1.9 TD with a snapped timing belt. I have just got a head from a breakers. Had a look and it looks a bit tight to get the old one off. Can anyone offer any advice on the easiest way to fit it, I take it you have to remove the manifolds , turbo etc before getting to the head bolts

Thanks

[jameslxdt]

your better off throwing an engine in it as its more than likely cracked the pistons, or the swirl chamber will have dropped out of the head and popped a hole in one of the pistons (common)
take the glow plugs out and see if they are intact

[GGG]

Thanks James,

I have a full engine from a 306 td, The engine looks the same just pipework a bit different, Will that fit and how easy are they to change, Do you split it from the gearbox and take it out the top or drop the whole lot out the bottom.

[jameslxdt]

the 306 enign will go in, you need to swap fuel pump and injectors though, there was a huge post on here somewhere about swapping the 1.9 engines, though it may have been lost when we got hacked, ill do a search

[GGG]

Thanks again james, Its appreciated

[jameslxdt]

here we go viewtopic.php?t=2852

[GGG]

Magic, Thanks James

[mcrobbie123]

Yay! Thats my topic! Yeh the stupid engine angle means an engine swap is alot easier than changing the head. I removed the engine and gearbox as one basically because I couldn't be arsed with faffing about trying to join them up with the gearbox in situ. It will all come out as one if you remove all the trim around the engine, battery tray, ecu box, intercooler and radiator. Just leave the air con stuff plumbed in and rest the compressor on an axel stand. Take lot's of pics of what you do and change timing belt, tensioners, waterpump, glowplugs while it's all out and easy to get to

I recommend these guy's for the waterpump and timing belt kit ... http://www.buypartby.co.uk

Think the timing belt kti was about £30 which is ludicrously cheap and made by continental so ok brand.

All I can say is don't get put off by the swap as it's ok once you get going, just you become VERY good friends with your Peugeot parts man for all the bit's you need. ALso may I suggest getting an exhaust fitting kit when it comes to refitting. It's about £14 from peugeot and has nice new bolts, nuts and the spacers that go on the downpipe. Saves trying to do this with rusty 10 year old bit's! Also do all the exhaust reattachment and turbo pipework before re-fitting the driveshafts as you get more room to fiddle

Oh and the hardest part is getting the new engine to marry up to the engine mounts. I ahd 3 assistants and a jack as well as the engine hoist to get them in ok but the extra 20 minutes doing this was better than dismantling the front of the car and getting it out that way. I also suggest leaving off the alternator/ P/S pump/ a/c bracket and oil filter until the engine is in as these are esy to get on with the engine in and give you a great deal of waggling space!

Good luck!

P.S: My name was robbie123 but my account was eaten when the forum got hacked!

PPS: Hi james, Hows it going mate? Hope you haven't lost too much hair with your peugeots...I hear you bought a D9... I sold teh 406 and bought a Saab 9000 which I love but I'm missing the 50mpg so may eb returning to diesel...not sure if I can face the trials and tribulations of a Peugeot again...

[stoneysaxo1982]

I agree I did the head gasket on a 306 1.9 td recently and it was an absolute pig its a cose of both inlet and exaust manifold off top engine mount etc.. it would have been much easier to swap the engine.

main block and head are the same in 306, 405, 406 and xantia 1905 TD the piping will be different and in some cases the fuel pump, but if you just swap all the ancilaries off your old lump you'l be fine.

[GGG]

Finally got the 306 engine swapped for a complete 406 engine. It is now in the car but wont start. There is no fuel getting to the injectors.

The car used to start without touching any imobilizer. Will the new pump have a cut off fitted and if so how do you by pass it.

Any ideas appreciated

[darrenwall]

it sounds like the immobiliser is working and the stop solenoid isnt allowing fuel thro i think that each pump is coded to the keypad and will only work with the original pump unless u get them coded to each other ( im not 100% on that but im sure others on here will put be able to tell you for sure ) . there is a way around it and i think that involves rewiring the solenoid but the solenoid is hidden under a protective cover which needs to be drilled out . do a search on here and you should find a few topics on it . hope that helps

[GGG]

Thanks Darren.

Just checked and the old pump looks to have been tampered with. The shear bolts have been removed. The new pump which came with the engine hasnt. Looks like i will have to swap the pumps over