Peugeot 405 Manual

Camshaft and followers - removal, inspection and refitting
XU petrol engine in-car repair procedures / Camshaft and followers - removal, inspection and refitting


Removal
1 Remove the battery and its mounting tray as described in Chapter 5A.

2 Remove the cylinder head cover and gasket as described in Section 4.

1905 cc 16-valve models
3 Unbolt the plastic cover from over the power steering pump drive pulley.

4 Disconnect the drivebelt from the power steering drive pulley with reference to Chapter 1.

5 Unscrew the bolt and remove the pulley from the end of the exhaust camshaft.

6 Remove both camshaft sprockets as described in Section 8.

7 Remove the distributor cap and rotor arm with reference to Chapter 5A.

8 Unbolt and remove the rotor arm support and the sealing disc.

9 Unbolt the inner timing belt cover from the side of the cylinder head.

10 Carefully ease the oil supply pipe out from the top of the camshaft bearing caps, and remove it. Note the O-ring seals fitted to each of the pipe unions.

11 Turn each camshaft so that the sprocket key grooves are approximately at the 3 oclock position.

12 Evenly and progressively slacken the camshaft bearing cap retaining screws by one turn at a time. This will relieve the valve spring pressure on the bearing caps gradually and evenly. Once the pressure has been relieved, the bolts can be fully unscrewed and removed.

13 Lift off the bearing caps, noting the correct fitted location of the locating dowels.

If the dowels are a loose fit, remove them and store them with the bearing caps for safekeeping.

14 Lift the camshafts out of the cylinder head, and slide the oil seals off the camshaft ends. Identify each camshaft for position - on early models the inlet camshaft is identified by the distributor drive keyway.

15 Obtain sixteen small, clean plastic containers, and number them 1 to 16. Using a rubber sucker, withdraw each cam follower in turn, invert it to prevent oil loss, and place it in its respective container. The container should then be filled with clean engine oil. Do not interchange the cam followers, or the rate of wear will be much-increased. Do not allow them to lose oil, or the hydraulic tappet mechanism will take a long time to refill with oil on restarting the engine, resulting in incorrect valve clearances.

1998 cc 16-valve models
16 Remove both camshaft sprockets as described in Section 8. Where necessary also remove the vacuum pump from the left-hand end of the cylinder head.

17 Undo the six bolts securing the inner timing belt cover to the side of the cylinder head, and remove the cover from the engine.

18 Carefully ease the oil supply pipe out from the top of the camshaft bearing caps, and remove it. Note the O-ring seals fitted to each of the pipe unions.

19 The camshaft bearing caps should be numbered 1 to 5, number 1 being at the transmission end of the engine. If not, make identification marks on the caps, using white paint or a suitable marker pen.

20 Working in the reverse of the sequence shown in illustration 10.54, evenly and progressively slacken the camshaft bearing cap retaining screws by one turn at a time.

This will relieve the valve spring pressure on the bearing caps gradually and evenly. Once the pressure has been relieved, the bolts can be fully unscrewed and removed.

21 Lift off the bearing caps, noting the correct fitted location of the locating dowels.

If the dowels are a loose fit, remove them and store them with the bearing caps for safekeeping.

22 Lift the camshafts out of the cylinder head, and slide the oil seals off the camshaft ends. The inlet camshaft can be identified by the braking system vacuum pump drive slot in its left-hand end; therefore, there is no need to mark the camshafts for identification.

23 Obtain sixteen small, clean plastic containers, and number them 1 to 16. Using a rubber sucker, withdraw each cam follower in turn, invert it to prevent oil loss, and place it in its respective container. The container should then be filled with clean engine oil. Do not interchange the cam followers, or the rate of wear will be much-increased. Do not allow them to lose oil, or the hydraulic tappet mechanism will take a long time to refill with oil on restarting the engine, resulting in incorrect valve clearances.

All other models
24 Remove the camshaft sprocket as described in Section 8.

25 On models with a distributor, remove the distributor as described in Chapter 5. Make sure the recessed socket-headed screw is removed from the distributor housing.

26 On models with a carburettor, remove the fuel pump as described in Chapter 4.

27 On models with a static (distributorless) ignition system, remove the ignition HT coil as described in Chapter 5.

28 With the distributor or coil removed (as applicable), slacken the upper bolt securing the thermostat housing to the left-hand end of the cylinder head. Remove the bolt, along with its sealing washer. This is necessary since the bolt screws into the left-hand (No 1) camshaft bearing cap.

29 Carefully ease the oil supply pipe out from the top of the camshaft bearing caps, and remove it. Note the O-ring seals fitted to each of the pipe unions on later models.

30 The camshaft bearing caps should be numbered 1 to 5, number 1 being at the transmission end of the engine. If not, make identification marks on the caps, using white paint or a suitable marker pen. Also mark each cap in some way to indicate its correct fitted orientation. This will avoid the possibility of installing the caps the wrong way around on refitting.

31 Evenly and progressively slacken the camshaft bearing cap retaining nuts by one turn at a time. This will relieve the valve spring pressure on the bearing caps gradually and evenly. Once the pressure has been relieved, the nuts can be fully unscrewed and removed (see illustration).

10.31 Working as described in the text, unscrew the retaining nuts . . .
10.31 Working as described in the text, unscrew the retaining nuts . . .

32 Note the correct fitted orientation of the bearing caps, then remove them from cylinder head (see illustration).

10.32 . . . and remove the camshaft bearing caps . . .
10.32 . . . and remove the camshaft bearing caps . . .

33 Lift the camshaft away from the cylinder head, and slide the oil seal off the camshaft end (see illustration).

10.33 . . . then lift the camshaft away from the cylinder head
10.33 . . . then lift the camshaft away from the cylinder head

34 Obtain eight small, clean plastic containers, and number them 1 to 8; alternatively, divide a larger container into eight compartments. Using a rubber sucker, withdraw each follower in turn, and place it in its respective container. Do not interchange the cam followers, or the rate of wear will be much-increased. If necessary, also remove the shim from the top of the valve stem, and store it with its respective follower. Note that the shim may stick to the inside of the follower as it is withdrawn. If this happens, take care not to allow it to drop out as the follower is removed.

Inspection
35 Examine the camshaft bearing surfaces and cam lobes for signs of wear ridges and scoring. Renew the camshaft if any of these conditions are apparent. Examine the condition of the bearing surfaces, both on the camshaft journals and in the cylinder head/bearing caps. If the head bearing surfaces are worn excessively, the cylinder head will need to be renewed. If suitable measuring equipment is available, camshaft bearing journal wear can be checked by direct measurement (where the necessary specifications have been quoted by Peugeot), noting that No 1 journal is at the transmission end of the head.

36 Examine the cam follower bearing surfaces which contact the camshaft lobes for wear ridges and scoring. Renew any follower on which these conditions are apparent. If a follower bearing surface is badly scored, also examine the corresponding lobe on the camshaft for wear, as it is likely that both will be worn. Renew worn components as necessary.

37 On 16-valve models, if the engines valve clearances have sounded noisy, particularly if the noise persists after initial start-up from cold, there is reason to suspect a faulty hydraulic tappet mechanism. Only a good mechanic experienced in these engines can tell whether the noise level is typical, or if renewal of one or more of the tappets is warranted. If a faulty hydraulic tappet is diagnosed and the engines service history is unknown, it is always worth trying the effect of renewing the engine oil and filter before going to the expense of renewing any of the cam followers. Use only good-quality engine oil of the recommended viscosity and specification (Chapter 1). It is not possible to overhaul the hydraulic tappet mechanism, so if any tappets operation is faulty, it must be renewed.

38 On earlier 1580 cc and 1905 cc models, inspect the camshaft thrust fork (fitted to the side of No 5 camshaft bearing cap) for signs of wear or scoring, and if necessary renew it (see illustrations).

10.38a On early 1580 cc and 1905 cc models, slacken the retaining bolt . . .
10.38a On early 1580 cc and 1905 cc models, slacken the retaining bolt . . .

10.38b . . . and remove the camshaft thrust fork from the bearing cap
10.38b . . . and remove the camshaft thrust fork from the bearing cap

The fork is retained by a single bolt; on refitting, ensure that the bolt is securely tightened. On later models, the thrust fork is no longer fitted, and the camshaft endfloat is controlled by the camshaft bearing cap.

Refitting
1905 cc 16-valve models
39 Liberally oil the cylinder head cam follower bores and the followers. Note that, if new followers are being fitted, they must be charged with oil before installation by placing them in a bath of clean engine oil and working them. Carefully refit the followers to the cylinder head, ensuring that each follower is refitted to its original bore, where applicable. Some care will be required to enter the followers squarely into their bores.

40 Liberally oil the camshaft bearings and lobes, then refit the camshafts to the cylinder head. Temporarily refit the Woodruff keys and sprockets to the end of each camshaft. Set each camshaft so that the sprocket key grooves are approximately at the 3 oclock position. Also ensure that the crankshaft is still locked in position (see Section 3).

41 Ensure that the bearing cap locating dowels are pressed firmly into their recesses.

Check that the mating surfaces are completely clean, unmarked and free from oil then apply jointing compound to the contact surfaces of Nos 1 and 5 caps.. Refit the bearing caps, using the identification marks noted on removal to ensure that each is installed correctly and in its original location.

42 Working in the sequence shown, progressively tighten the camshaft bearing cap bolts by one turn at a time, until the caps touch the cylinder head evenly. Go round again, working in the same sequence, and tighten all the bolts to the specified torque setting. Work only as described, to impose the pressure of the valve springs gradually and evenly on the bearing caps.

43 Examine the oil supply pipe union O-rings for signs of damage or deterioration, and renew as necessary. Check that the supply pipe oil spray holes are clear, unblocking them with a pin if necessary. Apply a smear of clean engine oil to the O-rings. Ease the pipe assembly into position in the top of the bearing caps, taking great care not to displace the O-rings.

44 Refit the inner timing belt cover to the side of the cylinder head, and tighten its retaining bolts to the specified torque.

45 Fit two new camshaft oil seals using the information given in Section 7.

46 Where applicable, refit the distributor rotor arm support and sealing disc, rotor arm and distributor cap - refer to Chapter 5A.

47 Refit the camshaft sprockets as described in Section 8.

48 Refit the power steering pulley to the end of the exhaust camshaft and tighten the retaining bolt, then refit the drivebelt with reference to Chapter 1.

49 Refit the plastic cover over the power steering pump drive pulley.

50 Refit the cylinder head cover as described in Section 4, and the battery and mounting tray as described in Chapter 5A.

1998 cc 16-valve models
51 Liberally oil the cylinder head cam follower bores and the followers. Note that, if new followers are being fitted, they must be charged with oil before installation by placing them in a bath of clean engine oil and working them. Carefully refit the followers to the cylinder head, ensuring that each follower is refitted to its original bore, where applicable. Some care will be required to enter the followers squarely into their bores.

52 Liberally oil the camshaft bearings and lobes, then refit the camshafts to the cylinder head. Temporarily refit the Woodruff keys and sprockets to the end of each camshaft. Set each camshaft so that its sprocket timing hole is aligned with the corresponding cutout in the cylinder head. Also ensure that the crankshaft is still locked in position (see Section 3).

53 Ensure that the bearing cap locating dowels are pressed firmly into their recesses.

Check that the mating surfaces are completely clean, unmarked and free from oil.

Refit the bearing caps, using the identification marks noted on removal to ensure that each is installed correctly and in its original location.

54 Working in the sequence shown, progressively tighten the camshaft bearing cap bolts by one turn at a time, until the caps touch the cylinder head evenly. Go round again, working in the same sequence, and tighten all the bolts to the specified torque setting (see illustration).

10.54 Camshaft bearing cap bolt tightening sequence - 1998 cc 16-valve models
10.54 Camshaft bearing cap bolt tightening sequence - 1998 cc 16-valve models

Work only as
described, to impose the pressure of the valve springs gradually and evenly on the bearing caps.

55 Examine the oil supply pipe union O-rings for signs of damage or deterioration, and renew as necessary. Check that the supply pipe oil spray holes are clear, unblocking them with a pin if necessary. Apply a smear of clean engine oil to the O-rings. Ease the pipe assembly into position in the top of the bearing caps, taking great care not to displace the O-rings (see illustration).

10.55 Take care not to displace the O-rings when refitting the oil supply
10.55 Take care not to displace the O-rings when refitting the oil supply pipe to the camshaft bearing caps

56 Refit the inner timing belt cover to the side of the cylinder head, and tighten its retaining bolts to the specified torque.

57 Fit two new camshaft oil seals using the information given in Section 7, then refit the camshaft sprockets as described in Section 8.

Where necessary refit the vacuum pump to the left-hand end of the cylinder head.

58 Refit the cylinder head cover as described in Section 4, and reconnect the battery negative terminal.

All other models
59 Where removed, refit each shim to the top of its original valve stem. Do not interchange the shims, as this will upset the valve clearances (see Section 11).

60 Liberally oil the cylinder head cam follower bores and the followers. Carefully refit the followers to the cylinder head, ensuring that each follower is refitted to its original bore. Some care will be required to enter the followers squarely into their bores.

61 Liberally oil the camshaft bearings and lobes, then refit the camshaft to the cylinder head. Temporarily refit the sprocket to the end of the shaft, and position it so that the sprocket timing hole is aligned with the corresponding cutout in the cylinder head.

Also ensure that the crankshaft is still locked in position (see Section 3).

62 Ensure that the bearing cap and head mating surfaces are completely clean, unmarked, and free from oil. Refit the bearing caps, using the identification marks noted on removal to ensure that each is installed correctly and in its original location.

63 Evenly and progressively tighten the camshaft bearing cap nuts by one turn at a time until the caps touch the cylinder head.

Then go round again and tighten all the nuts to the specified torque setting. Work only as described, to impose the pressure of the valve springs gradually and evenly on the bearing caps.

64 Refit the oil supply pipe to the top of the bearing caps. Note that there are no seals fitted to the pipe fittings on early models, however later versions are fitted with seals.

Where applicable, examine the oil supply pipe union O-rings for signs of damage or deterioration, and renew as necessary. Apply a smear of clean engine oil to the O-rings before refitting the pipe (see illustration).

10.64 Early supply pipe (A) without seals and later pipe (B) with seals
10.64 Early supply pipe (A) without seals and later pipe (B) with seals

65 Examine the sealing washer for signs of damage or deterioration, and renew it if necessary. Refit the upper retaining bolt to the thermostat housing, tightening it to the specified torque setting.

66 On models with a distributor, refit the distributor as described in Chapter 5.

67 On models with a static (distributorless) ignition system, refit the ignition HT coil as described in Chapter 5.

68 On models with a carburettor, refit the fuel pump with reference to Chapter 4.

69 Fit a new camshaft oil seal, using the information given in Section 9, then refit the camshaft sprocket as described in Section 8.

70 Refit the cylinder head cover as described in Section 4, then refit the battery and mounting tray with reference to Chapter 5A.


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