Replacement of camshafts (diesel engines) (Peugeot 207)

Removal

Remove:

• turbocharger inlet and outlet air ducts (see the corresponding operation);
• air supply system (see the corresponding operation);
• diesel injectors (see the corresponding operation).

Remove:

• fuel filter (2) (see the corresponding operation);
• fuel filter bracket (1);
• vacuum pump (3) (see the corresponding operation).

Take it off (see related operations):

• accessory drive belt;
• accessory drive belt.

Visually inspect the condition of the timing belt.

Caution: If the belt has cracks or oil stains, it must be replaced.

Take it off (see related operations):

• accessory drive belt;
• accessory drive belt.

Visually inspect the condition of the timing belt.

Caution: Lock the camshaft pulley (5) using tool 1.

Remove:

• bolt (4);
• camshaft pulley (5);
• timing drive housing (6).

Note: Follow the tightening sequence specified (order from 1 to 24).

Remove:

• bolts (order from 1 to 16);
• hairpins (order from 17 to 24).

Separate the camshaft bearing cap housing and remove it.

Note: Mark the location of the camshaft bearing caps (9).

Unscrew the camshaft support cover screws one by one.

Remove:

• gland (11);
• camshaft bearing caps (9);
• timing chain tensioner (7);
• camshafts (8) and (10).

Mark the position of the rocker arms (12) and pushers.

Examination

Note: Check the condition of the rocker arm tips (16) and hydraulic tappets (17) and the condition of the camshaft support caps.

Caution. Clean the surfaces to be joined with a metal residue remover. Do not use abrasives or scratching tools on the surfaces to be joined; they must not have any impact marks or cracks.

Note: Mark the position of the rocker arms (16) and hydraulic tappets (17).

Make sure the hydraulic lifters move freely.

Before installing the camshaft bearing cap housing, check the operation of the rocker arms and hydraulic lifters (bearing rotation, surface condition).

Check the condition of the camshaft surfaces of the intake and exhaust valves.

Check the condition of the chain tensioner (freedom of displacement tension state of surfaces).

Check the condition of the drive chain. Replace faulty parts.

Attention: During installation, all previously removed sealing gaskets must be replaced with new ones.

Install the retaining springs (16a) onto the rocker arms (16).

Note: Springs (16a) are supplied in the repair kit.

Position of the locking spring (16a): "b" - side without protrusion; "c" - side with a protrusion.

Caution: Before installation, make sure that the retaining springs are not deformed.

Step "A": Place the spring (16a) with the "b" side on the inner edge of the rocker arm roller.

Step "B": Snap the spring "c" side onto the outer edge of the rocker arm.

Step "C": Check the correct installation.

Lubricate the hydraulic tappet housings (17) and rocker arms (16) with engine oil.

Install hydraulic tappets (17) (respecting the initial location) and rocker arms (16) assembled with locking springs (16a) (respecting the initial location).

Caution: Check that the rocker arms and valve lifters are functioning properly before installing the camshaft bearing cap housing.

Installation

Apply bead "a" sealant to the crankshaft bearing housing flange "Autojoint Noir".

Caution: Do not seal the channels through which oil is supplied to the hydraulic tensioners of the timing chain (in area "a") with sealant.

Install the chain (13) on the camshaft sprockets (8) and (10).



Lubricate the camshaft bearing caps (9).

Install:

• chain (13) together with chain tensioner (7) and camshafts (8) and (10);
• camshaft support covers (9).

Caution: Make sure that the links marked "b" and "e" are opposite the teeth marked "c" and "d" of the camshaft sprockets. Otherwise, start the camshaft installation operation over again.

Install and then tighten the mounting screws in sequence from 1 to 16 in the order shown.

Install the camshaft seal (11) using tools 3a and 3b.

Lubricate the tappet housings and the bearing surfaces of the camshafts (8) and (10).



Check that the tappets rotate freely in the head. Install the rocker arms (12) (respecting the initial location). Install the rocker arm retainer on the pushrod hinge.

Caution: Check that the rocker arms and valve lifters are functioning properly before installing the camshaft bearing cap housing.

Timing chain fixation

Install the camshaft pulley (5) and bolt (4).

Lock the camshaft pulley using tool 2.

Remove device 2.

Perform 40 camshaft revolutions.

Note: Make sure that the chain links marked "b" and "e" are opposite the teeth marked "c" and "b" of the camshaft sprockets. Otherwise, start the installation operation over again.

Remove the bolt (4) and camshaft pulley (5).

Install fixture 4.

Install the camshaft bearing cap housing onto the cylinder head using tools 4.

Note: Follow the tightening sequence (order from 1 to 24).

Install:

• hairpins (1 to 8);
• bolts (from 9 to 24).

Remove tool 4.

Install the timing case, camshaft pulley and bolt.

Turn the camshaft toothed pulley (5) clockwise using tool 1.

Note: If the pulley is turned too far, return it a quarter turn toward the mounting hole (counterclockwise direction).

Adjusting the camshaft position sensor

Note: When installing the camshaft position sensor, maintain the required air gap between the sensor and the target.

Unscrew the bolt (14).

Move the camshaft position sensor (15) into the depth of the slots.

Tighten the screw (14) a few turns.

Adjust the air gap (1.2 mm) of the camshaft position sensor (15).



New camshaft position sensor: Engage the camshaft position sensor protrusion with the "target" on the camshaft drive pulley (5).

Reusing the camshaft position sensor: Position the drill (f) (diameter 9.5 mm) between the camshaft position sensor (15) and the timing case (6).

Tighten the bolt (14).

Install the remaining parts in reverse order.

Connect the positive and negative terminals of the battery.

Replacing the camshaft seal

Lock the camshaft pulley using the tool (see description above).



Remove the camshaft pulley and timing case (remove the inserts).

Drill a 3.5 mm diameter hole in area "a" of the seal (4).

Screw the bolt of device 3 into the hole in "a".

Remove the oil seal assembly using pliers.

Caution: Do not lubricate the outside of the new seal.

Use the cone to place the seal (4) into tool 2a.



Install the seal using the tool.

Install the remaining parts in reverse order.