Peugeot 405 Manual

Cylinder head cover - removal and refitting
XU petrol engine in-car repair procedures / Cylinder head cover - removal and refitting


Removal
1 Disconnect the battery negative lead.

1580 cc and 1905 cc (8-valve) models 2 On 1580 cc models, remove the air cleanerto- throttle body duct, and the air cleaner housing, as described in Chapter 4.

3 On 1905 cc models, remove the air cleaner housing as described in Chapter 4, and position the inlet duct clear of the cylinder head cover.

4 On all models, slacken the retaining clip and disconnect the breather hose from the top of the cylinder head cover. Where the original crimped-type hose clip is still fitted, cut it off and discard it. Replace it with a standard worm-drive hose clip on refitting.

5 Undo the two nuts/bolts securing the HT lead retaining bracket to the cylinder head, and position the bracket clear of the head cover (see illustration).

4.5 On 1580 cc and 1905 cc models, undo the retaining
4.5 On 1580 cc and 1905 cc models, undo the retaining bolts/nuts and move the HT lead retaining clips clear of the head cover

6 Slacken and remove the two remaining cylinder head cover retaining bolts, along with their sealing washers.

7 Lift off the cylinder head cover, and remove it along with its rubber seal. Examine the seal for signs of damage and deterioration, and if necessary, renew it. Also examine the retaining bolt sealing washers for signs of damage, and renew if required.

1761 cc and 1998 cc (8-valve) models 8 Slacken the retaining clips, and disconnect the breather hoses from the front right-hand end of the cover. Where the original crimpedtype hose clips are still fitted, cut them off and discard them; use standard worm-drive hose clips on refitting.

9 Slacken the retaining clip, and disconnect the air cleaner-to-throttle housing duct from the front of the cylinder head cover. Also remove the inlet duct from the left-hand side of the head cover.

10 Release the two retaining clips, then undo the two retaining screws located at the front, and remove the air cleaner element cover from the cylinder head cover. Remove the air cleaner element, and store it with the cover.

11 Slacken and remove the ten cylinder head cover retaining nuts, lift off the cylinder head cover, and remove it along with its rubber seal (see illustration).

4.11 Cylinder head cover retaining nuts (arrowed) -
4.11 Cylinder head cover retaining nuts (arrowed) - 1761 cc and 1998 cc (8-valve) models

Examine the seal for signs of damage and deterioration, and if necessary, renew it.

16-valve models
12 Refer to the information given in Chapter 4 on depressurising the fuel system.

Slacken the retaining clips, and disconnect the fuel feed and return hoses from their unions at the front of the head cover. Where the original crimped-type hose clips are still fitted, cut them off and discard them; use standard worm-drive hose clips on refitting.

Plug both the hose and fuel rail ends, to prevent the possible entry of dirt into the fuel system. Mop up any spilt fuel.

13 Undo the retaining nut and bolt securing the fuel hose retaining clips to the top of the cylinder head cover, and remove both clips.

Position both fuel hoses clear of the head cover, so that they do not hinder the removal procedure.

14 Slacken and remove the remaining seven retaining bolts, and lift the spark plug access cover off the cylinder head cover.

15 Pull each ignition HT coil off its spark plug. Trace the coil wiring back to its connector on the left-hand end of the cylinder head. Rotate the locking ring anti-clockwise, disconnect it from the main wiring loom, and remove the wiring and coils as an assembly.

16 Disconnect the breather hose from the left-hand end of the cylinder head. Any original crimped-type hose clips can be discarded, as already mentioned.

17 Slacken and remove the twelve cylinder head cover retaining bolts, noting the correct fitted positions of any brackets or clips. Note that the bolts are of four different lengths, and it is important that each is refitted in the correct position. To avoid confusion on refitting, remove each bolt in turn, and store it in its correct fitted position by pushing it through a clearly-marked cardboard template.

18 Lift off the cylinder head cover, and remove it along with its rubber seal. Recover the four spark plug hole sealing rings from the cylinder head. Examine all seals for damage and deterioration, and renew as necessary.

Refitting
1580 cc and 1905 cc models 19 Carefully clean the cylinder head and cover mating surfaces, and remove all traces of oil.

20 Fit the rubber seal over the edge of the cylinder head cover, ensuring that it is correctly located along its entire length.

21 Carefully refit the cylinder head cover to the engine, taking great care not to displace the rubber seal.

22 Check that the seal is correctly located, then refit the cover retaining bolts and sealing washers (not forgetting to position the HT lead bracket under the centre bolt head), and tighten them to the specified torque.

23 Refit the remaining HT lead bracket retaining bolt, and tighten it securely.

24 Reconnect the breather hose to the cylinder head cover, and securely tighten its retaining clip.

25 Refit the air cleaner housing and duct as described in Chapter 4, and reconnect the battery negative terminal.

1761 cc and 1998 cc 8-valve models 26 Clean the cylinder head and cover mating surfaces, and remove all traces of oil.

27 Locate the rubber seal in the cover groove, ensuring that it is correctly located along its entire length.

28 Carefully refit the cylinder head cover to the engine, taking great care not to displace the rubber seal.

29 Check that the seal is correctly located, then refit the cover retaining nuts, and tighten them evenly and progressively to the specified torque in the order shown (see illustration).

4.29 On 1761 cc and 1998 cc 8-valve models tighten the
4.29 On 1761 cc and 1998 cc 8-valve models tighten the cylinder cover retaining nuts in the sequence shown

30 Refit the air cleaner element, and install the element cover. Securely tighten the cover retaining screws, and secure it in position with the retaining clips.

31 Reconnect the breather hoses, inlet duct and throttle housing duct to the cover, tightening their retaining clips securely.

Reconnect the battery.

16-valve models
32 Carry out the operations described in paragraphs 26 to 28. Fit the four spark plug hole seals to the recesses in the cylinder head (see illustration).

4.32 Fitting a spark plug hole oil seal
4.32 Fitting a spark plug hole oil seal

33 Check that the seal is correctly located, then refit the cover retaining bolts. Ensure that each bolt is refitted in its correct location, and that all retaining clips/brackets are correctly positioned. Tighten the cylinder head cover retaining bolts evenly and progressively to the specified torque.

34 Reconnect the breather hose to the end of the cover, and securely tighten its clip.

35 Connect the HT coil wiring loom to its wiring connector, and secure it in position by rotating the locking ring. Ensuring that the wiring is correctly routed, reconnect the HT coils to the tops of the spark plugs.

36 Refit the spark plug access cover to the head cover, and refit its retaining bolts (not forgetting the fuel hose retaining clip). Ensure that the HT coil wiring is correctly located in the cover cutout, and that the fuel hoses are positioned under the retaining clip, then securely tighten the retaining bolts.

37 Fit the rear fuel hose retaining clip, and securely tighten its retaining nut.

38 Reconnect the feed and return hoses to their respective fuel rail unions, ensuring that their retaining clips are securely tightened.

39 Reconnect the battery negative terminal.

On completion, start the engine and check the fuel hose unions for signs of leakage.

40 Note: From early 1992 a modified camshaft cover gasket has been fitted in production to 1905 cc models. The later type of gasket can be identified from its grey colour (the earlier type of gasket was coloured black). The later type gasket can be fitted to earlier engines, but the following procedure must be followed when fitting the later type gasket to any engine.

a) Apply silicon sealant to the corners of Nos 1 and 5 camshaft bearing caps, then after refitting the cover tighten the securing bolts to the Stage 1 torque wrench setting in the order shown (see illustrations).

4.40a Spark plug hole oil seal (2). Apply silicon
4.40a Spark plug hole oil seal (2). Apply silicon sealant to the areas arrowed (3) - XU9J4 engine

4.40b Cylinder head cover bolt stage 1 tightening
4.40b Cylinder head cover bolt stage 1 tightening sequence - XU9J4 engines with later type camshaft cover gasket

b) Start the engine, and run it at idle speed for 10 minutes with the bonnet closed.

c) Open the bonnet and check for leaks. If evident, do not tighten the bolts further, but remove the cover to establish the cause, then repeat the fitting operations.

d) Allow the engine to cool for 4 hours, then tighten the ten outer cover bolts to the Stage 2 torque wrench setting in the order shown (see illustration).

4.40c Cylinder head cover bolt stage 2 tightening
4.40c Cylinder head cover bolt stage 2 tightening sequence - XU9J4 engines with later type camshaft cover gasket

This procedure allows for the settling of the gasket, which takes place due to the heat produced by the engine.


© 2018 www.peugeot405.ru. All Rights Reserved.