Installing the cylinder head (Peugeot 405)

Cylinder Head Gasket Identification

Position of the cylinder head installation guide pin

Cylinder Head Bolt Tightening Sequence and Valve Positioning

1. Clean the connection surface with the product "Decaploc 82". Do not use abrasives or sharp instruments.

2. Make sure that the connection surface is free of scratches and impact marks.

3. Check the flatness of the surface where the cylinder head meets the cylinder block. If necessary, this surface can be re-ground.

4. Using a dial indicator, measure the piston protrusion above the cylinder block surface.

5. Using a dial indicator, measure the center setting of each piston. The maximum allowable difference between the two pistons is 0.12 mm. The largest measurement determines the thickness of the cylinder head gasket that should be used. Cylinder head gaskets are marked with special cutouts.

6. Select the thickness of the cylinder head gasket.

7. Check if the camshaft is in the locked position so that the valves of cylinder block No.1 and No.4 are completely closed (install the camshaft timing pulley and tighten the locking screw).

8. Degrease (remove all traces of grease) and dry the cylinder head bolt holes.

9. The engine must be blocked. Use a tap M12x150 to clean the threads in the engine cylinder block holes and clean them with a jet of air.

10. Install the guide pin on the engine block mating surface.

11. Install the cylinder head gasket (only one position).

12. Install the cylinder head.

13. Lubricate the cylinder head mounting bolts (under heads and on threads) means "Molykote G Rapid", insert new gaskets with the convex surface facing up. Install the cylinder head mounting bolts.



14. Tighten the cylinder head bolts according to the following instructions:

• first screw in the sequence (see figure Cylinder head bolt tightening sequence and valve placement) torque 30 Nm;
• tighten in sequence to 70 Nm;
• tighten according to the sequence to an angle of 120°.

15. If necessary, adjust the valve clearance and replace the camshaft sealing ring.

16. Screw in the bolts (2) and (3) of the tension roller and engine bracket.

17. At the end of the camshaft, install the toothed pulley together with the key and tighten the locking bolt (it should be screwed in by hand).

18. Tighten the toothed pulley mounting bolt to a torque of 35–40 Nm.

19. Install the camshaft timing belt.

20. Install the left engine lift bracket.

Original can be viewed at PeugeotBook

21. Connect the exhaust pipe.

22. In the XUD 7TE engine, install the intake manifold and right bracket.

23. Connect the coolant, fuel and electrical hoses. Connect the high speed idle linkage to the pump.

24. Install the power steering servo pump belt (depending on equipment) and pull it tight.

25. Turn the engine crankshaft and, if necessary, top up the coolant to the required level.

26. Adjust idle speed with increased RPM.

Piston protrusion (mm)	Designation (b) (see figure Cylinder Head Gasket Identification)
0,54 – 0,77	2 cutouts
0,77 – 0,82	3 cutouts