Caution: Do not use sharp-edged tools to clean the cylinder head to avoid damaging the aluminum parts of the cylinder block and the surface of the cylinder head gasket.
51. Clean the holes A of the cylinder head mounting bolts (see illustration).
4.51 Clean the holes A of the cylinder head mounting bolts
52. Inspect the mating surfaces of the cylinder head and block. They should not have any dents, deep scratches or other damage. Minor defects can be eliminated by mechanical treatment. In case of significant defects, the parts must be replaced.
53. Clean the threads of the cylinder head bolts. There should be no oil or other contaminants in the bolt holes. If necessary, blow out the holes with compressed air or clean them with a screwdriver wrapped in a rag to absorb the liquid. Oil can be collected from the holes with a grease gun. If this is not done, excess pressure will be created in the holes when the bolts are screwed in, which can lead to a rupture of the cylinder block or to an incorrect tightening torque of the bolts.
54. Check the cylinder head for deformation and warpage using a standard steel ruler, placing the ruler along the measurement lines (see illustration)warpage within 0.05 mm is allowed.
4.54 Check the cylinder head for deformation and warpage using a reference steel ruler, placing the ruler along the measurement lines
55. Measure the length of the cylinder head mounting bolts. The length of their rods X, measured from the lower surface of the bolt head, should not exceed 122 mm, or 124.5 mm for vehicles with the XU102TE engine, or 11.2 mm for vehicles with the XU10J4R engine (see illustration). Otherwise, the bolts should be replaced with new ones.
4.55 Measure the length X of the cylinder head bolts
56. Check for the presence of the mounting pins 1 (see illustration).
4.56 Check for the presence of the dowel pins 1
57. Install a new cylinder head gasket. The B projection on the gasket should be on the clutch side (see illustration 4.56).
58. Lock the camshaft by installing a suitable thrust roller or stop "a" in the appropriate hole (see illustrations 4.58 and 4.58a). Install the cylinder head into its seat.
4.58 Lock the camshaft gear a by installing a suitable thrust roller or stop "a" 0153-DA in the appropriate hole. Cars with engine XU10J2TE
4.58a Lock the camshaft gears by installing suitable thrust rollers or stops "a" 0153-AB in the appropriate holes. Vehicles with engine XU10J4R
59. Lubricate the threads of the cylinder head mounting bolts with MOLYKOTE G RAPID PLUS sealant (see arrows in illustration 4.59) and tighten the bolts in the sequence shown in Illustration 4.59a, in several passes:
- 1st pass - tighten the bolts to 35 Nm;
- 2nd pass - tighten the bolts to 70 Nm;
- 3rd pass - tighten the bolts by 160°.
4.59 Lubricate the threads of the cylinder head mounting bolts with MOLYKOTE G RAPID PLUS sealant (see arrows)
4.59a Cylinder head bolt tightening sequence
Next, the installation of the dismantled components is carried out in the reverse order of removal, taking into account the following:
60. Vehicles with XU10J2TE engine. Apply sealant I SILICONE CATEGORIE 2 to areas A (see illustration).
4.60 Apply SILICONE CATEGORIE 2 sealant to areas A. Vehicles with XU10J2TE engine
61. The intake manifold gasket must be replaced.
62. Cars with XU10J4R engine. Tightening torque of nuts 2 for fastening the right engine mount is 45 Nm, bolts 3 — 60 Nm (see illustration).
4.62 The tightening torque of nuts 2 for fastening the right engine mount is 45 Nm, bolts 3 - 60 Nm. Cars with XU10J4R engine
63. Cars with XU1OJ4R engine. Install the intake manifold and tighten bolts 4 and nuts 5 of its fastening with a force of 20 Nm, bolt 6 with a force of 10 Nm (see illustration).
4.63 Install the intake manifold and tighten bolts 4 and nuts 5 of its fastening with a force of 20 Nm, bolt 6 with a force of 10 Nm. Cars with engine XU10J4R
64. Cars with engine XU1OJ4R. Install covers 7 of the cylinder head (see illustration 4.63).
Attention! Cylinder head cover gaskets are composite; minor damage to the gasket can be repaired by applying SILICONE CATEGORIE 2 sealant.
65. Vehicles with XU10J4R engine. Tighten the cylinder head cover bolts to 10 Nm in the sequence shown in the illustration.
4.65 Tighten the cylinder head cover bolts to 10 Nm in the sequence shown. Vehicles with XU10J4R engine
66. Cars with XU10J2TE engine. The tightening torque of nuts 8 and bolts 9 securing the right engine mount is 45 Nm, bolt 10 - 55 Nm, bolt 11 - 60 Nm (see illustration).
4.66 The tightening torque of nuts 8 and bolts 9 securing the right engine mount is 45 Nm, bolt 10 - 55 Nm, bolt 11 - 60 Nm. Cars with XU10J2TE engine
67. After completing the work, remove air from the cooling system.
View the original on the website peugeotbook.ru