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Replacing the cylinder head gasket on a Peugeot 205

Written By: hrmuller t (and one other contributor)
  • Comments: 12
  • Favorites: 2
  • Completions: 11

Difficulty

Very difficult

Steps

46

Time Required

04:00:00

Sections

1

Flags

1

Ce tutoriel a été créé par la communauté

Ce tutoriel a été créé par la communauté

User contributed

Introduction

Tutorial made on Peugeot 205 petrol (1.4i - TU3M)

  1. First, drain the cooling circuit. To do this, open the various drain plugs/screws. Open the coolant reservoir Open the radiator cap

    • First, drain the cooling circuit. To do this, open the various drain plugs/screws.

    • Open the coolant reservoir

    • Open the radiator cap

    Edit

  2. Open the heating circuit bleed screw Open the bleed screw on the thermostat housing.

    • Open the heating circuit bleed screw

    • Open the bleed screw on the thermostat housing.

    Edit

  3. Place a basin under the lower radiator hose, then disconnect it. Once all the liquid has been drained, close the various purges/plugs and reconnect the lower hose

    • Place a basin under the lower radiator hose, then disconnect it.

    • Once all the liquid has been drained, close the various purges/plugs and reconnect the lower hose

    Edit

  4. Unscrew the 2 fixing screws of the timing case Unscrew the 2 fixing screws of the timing case Unscrew the 2 fixing screws of the timing case

    • Unscrew the 2 fixing screws of the timing case

    Edit

  5. Remove the housing by simply pulling it upwards

    • Remove the housing by simply pulling it upwards

    Edit

  6. Detach the electrical sheath from the housing Unscrew the 3 fixing screws of the lower timing case Unscrew the 3 fixing screws of the lower timing case

    • Detach the electrical sheath from the housing

    • Unscrew the 3 fixing screws of the lower timing case

    Edit

  7. Roughly align the hole in the camshaft pulley (red) to the pin hole in the cylinder head (green) (stay a little short) To do this, turn the engine by hand using a wrench on the crankshaft pulley fixing nut by "tightening" the nut, the engine will turn.

    • Roughly align the hole in the camshaft pulley (red) to the pin hole in the cylinder head (green) (stay a little short)

    • To do this, turn the engine by hand using a wrench on the crankshaft pulley fixing nut by "tightening" the nut, the engine will turn.

    Edit

  8. Once the 2 holes are almost aligned, pre-engage the pin in the flywheel hole (here a ø6mm screw) While continuing to try to push the pin in, slowly crank the engine until the pin goes in and the engine is locked. While continuing to try to push the pin in, slowly crank the engine until the pin goes in and the engine is locked.

    • Once the 2 holes are almost aligned, pre-engage the pin in the flywheel hole (here a ø6mm screw)

    • While continuing to try to push the pin in, slowly crank the engine until the pin goes in and the engine is locked.

    Edit

  9. Once the flywheel is locked, the pin holes of the camshaft pulley must be aligned, also put the pin in place (ø8mm drill here)

    • Once the flywheel is locked, the pin holes of the camshaft pulley must be aligned, also put the pin in place (ø8mm drill here)

    • You can also mark the belt/pulley in case your pin comes off

    Edit

  10. Unscrew and remove the tensioner roller (Already removed in the photo) Remove the belt

    • Unscrew and remove the tensioner roller (Already removed in the photo)

    • Remove the belt

    Edit

  11. Remove the throttle cable by tilting the throttle (as if you were pressing the pedal) and simply sliding it out of its housing Then pull on the sheath to release it from the support Then pull on the sheath to release it from the support

    • Remove the throttle cable by tilting the throttle (as if you were pressing the pedal) and simply sliding it out of its housing

    • Then pull on the sheath to release it from the support

    Edit

  12. Turn the plastic screw a quarter turn and release it from its housing Turn the plastic screw a quarter turn and release it from its housing Turn the plastic screw a quarter turn and release it from its housing

    • Turn the plastic screw a quarter turn and release it from its housing

    Edit

  13. Open the 2 fixing clamps and detach the air intake box Open the 2 fixing clamps and detach the air intake box Open the 2 fixing clamps and detach the air intake box

    • Open the 2 fixing clamps and detach the air intake box

    Edit

  14. Disconnect the 4 hoses arriving at the box

    • Disconnect the 4 hoses arriving at the box

    Edit

  15. Disconnect the connectors from the injection box To disconnect the electrical plugs, press the metal tab and then pull the plug To disconnect the electrical plugs, press the metal tab and then pull the plug

    • Disconnect the connectors from the injection box

    • To disconnect the electrical plugs, press the metal tab and then pull the plug

    Edit

  16. Disconnect the various probes going to the thermostat box Disconnect the various probes going to the thermostat box

    • Disconnect the various probes going to the thermostat box

    Edit

  17. Disconnect the connector from the ignition box Disconnect the spark plug wires and remove the spark plug wire clamp rail. Disconnect the spark plug wires and remove the spark plug wire clamp rail.

    • Disconnect the connector from the ignition box

    • Disconnect the spark plug wires and remove the spark plug wire clamp rail.

    Edit

  18. Disconnect the 2 fuel hoses going to the injection box Plug them with screws Also disconnect the electrical connector

    • Disconnect the 2 fuel hoses going to the injection box

    • Plug them with screws

    • Also disconnect the electrical connector

    Edit

  19. Release the radiator hose at the thermostat housing Release the radiator hose at the thermostat housing

    • Release the radiator hose at the thermostat housing

    Edit

  20. Also remove the heater hose at the thermostat housing.

    • Also remove the heater hose at the thermostat housing.

    Edit

  21. Open the 3 nuts securing the exhaust line. 3rd photo after unscrewing to help you identify the positions of the 3 nuts more easily 3rd photo after unscrewing to help you identify the positions of the 3 nuts more easily

    • Open the 3 nuts securing the exhaust line.

    • 3rd photo after unscrewing to help you identify the positions of the 3 nuts more easily

    Edit

  22. Unscrew the 2 nuts securing the rocker cover Remove the rocker cover Unscrew the cylinder head screws in a spiral pattern (Red circle => orange => yellow => green => sky blue => dark blue => pink => black => red square => orange square

    • Unscrew the 2 nuts securing the rocker cover

    • Remove the rocker cover

    • Unscrew the cylinder head screws in a spiral pattern (Red circle => orange => yellow => green => sky blue => dark blue => pink => black => red square => orange square

    Edit

  23. Remove the screws Tilt the cylinder head slightly, check that nothing has been forgotten (harness/mechanical element) and lift it to remove it. Then lay it flat, paying attention to the gasket plane Tilt the cylinder head slightly, check that nothing has been forgotten (harness/mechanical element) and lift it to remove it. Then lay it flat, paying attention to the gasket plane

    • Remove the screws

    • Tilt the cylinder head slightly, check that nothing has been forgotten (harness/mechanical element) and lift it to remove it. Then lay it flat, paying attention to the gasket plane

    Edit

  24. Unscrew the 2 screws fixing the heat shield and remove it Unscrew the 2 screws fixing the heat shield and remove it

    • Unscrew the 2 screws fixing the heat shield and remove it

    Edit

  25. Unscrew the exhaust manifold mounting nuts Unscrew the exhaust manifold mounting nuts Unscrew the exhaust manifold mounting nuts

    • Unscrew the exhaust manifold mounting nuts

    Edit

  26. Remove the manifold and old gaskets Remove the manifold and old gaskets Remove the manifold and old gaskets

    • Remove the manifold and old gaskets

    Edit

  27. Put down the turntable Put down the turntable

    • Put down the turntable

    Edit

  28. Unscrew the 3 fixing screws Remove the case Remove the case

    • Unscrew the 3 fixing screws

    • Remove the case

    Edit

  29. Unscrew the ignition module mounting screws Remove the ignition module Also unscrew the cylinder head temperature sensor

    • Unscrew the ignition module mounting screws

    • Remove the ignition module

    • Also unscrew the cylinder head temperature sensor

    • Clean the joint faces

    Edit

  30. Unscrew the intake pipe fixing nuts Unscrew the intake pipe fixing nuts Unscrew the intake pipe fixing nuts

    • Unscrew the intake pipe fixing nuts

    Edit

  31. Unscrew the intake pipe fixing nuts Remove the intake pipe and clean the gasket surface Also unscrew and remove the 4 spark plugs

    • Unscrew the intake pipe fixing nuts

    • Remove the intake pipe and clean the gasket surface

    • Also unscrew and remove the 4 spark plugs

    Edit

  32. Remove the rocker arm ramp and mark its assembly direction (using a piece of cardboard for example) The cylinder head is now bare, you can take it to the rectifier (STRONGLY recommended to have it rectified + tested)

    • Remove the rocker arm ramp and mark its assembly direction (using a piece of cardboard for example)

    • The cylinder head is now bare, you can take it to the rectifier (STRONGLY recommended to have it rectified + tested)

    Edit

  33. Unscrew the camshaft pulley screw, remove the pin and remove the pulley Remove the old seal using a screwdriver. Compare the new gasket with the old one

    • Unscrew the camshaft pulley screw, remove the pin and remove the pulley

    • Remove the old seal using a screwdriver.

    • Compare the new gasket with the old one

    Edit

  34. Insert the new gasket by pushing it in by hand as far as possible Place the old gasket in front and tap with a rubber mallet to fully seat the new gasket. Place the old gasket in front and tap with a rubber mallet to fully seat the new gasket.

    • Insert the new gasket by pushing it in by hand as far as possible

    • Place the old gasket in front and tap with a rubber mallet to fully seat the new gasket.

    Edit

  35. Reassemble the camshaft pulley and replace the pin.

    • Reassemble the camshaft pulley and replace the pin.

    Edit

  36. Install the new gaskets Install the intake pipe (Injection module removed, but this is not mandatory) Tighten (gradually) the fixing nuts

    • Install the new gaskets

    • Install the intake pipe (Injection module removed, but this is not mandatory)

    • Tighten (gradually) the fixing nuts

    Edit

  37. Tighten (gradually) the intake pipe nuts

    • Tighten (gradually) the intake pipe nuts

    Edit

  38. Replace the spark plugs, tighten by hand first, then finish with a quarter turn with the ratchet Take the opportunity to install new spark plugs Take the opportunity to install new spark plugs

    • Replace the spark plugs, tighten by hand first, then finish with a quarter turn with the ratchet

    • Take the opportunity to install new spark plugs

    Edit

  39. Install the new gaskets Place the exhaust manifold in place and gradually tighten the fixing nuts.

    • Install the new gaskets

    • Place the exhaust manifold in place and gradually tighten the fixing nuts.

    Edit

  40. Clean the joint faces Put gasket paste on the ignition module Gradually tighten the fixing screws

    • Clean the joint faces

    • Put gasket paste on the ignition module

    • Gradually tighten the fixing screws

    Edit

  41. Clean the joint faces Put some gasket paste on the thermostat housing Gradually tighten the fixing screws

    • Clean the joint faces

    • Put some gasket paste on the thermostat housing

    • Gradually tighten the fixing screws

    Edit

  42. Also tighten the cylinder head temperature sensor

    • Also tighten the cylinder head temperature sensor

    Edit

  43. Remove the old gasket Clean the joint surface well, there should be no residue left! Put the new seal in place (making sure that the 2 centering devices are present!)

    • Remove the old gasket

    • Clean the joint surface well, there should be no residue left!

    • Put the new seal in place (making sure that the 2 centering devices are present!)

    Edit

  44. Position the cylinder head Replace the rocker arm ramp

    • Position the cylinder head

    • Replace the rocker arm ramp

    • Place the cylinder head screws

    Edit

  45. Tightening order for all following steps (snail tightening): Red circle => orange => yellow => green => light blue => dark blue => pink => black => red square => orange square Perform an initial tightening to 20Nm Perform a second tightening at 120°

    • Tightening order for all following steps (snail tightening): Red circle => orange => yellow => green => light blue => dark blue => pink => black => red square => orange square

    • Perform an initial tightening to 20Nm

    • Perform a second tightening at 120°

    • Use a CD with 120° markings if you don't have an angle key

    • Perform a third tightening at 120°

    Edit

    • Proceed to reassemble the various elements and reconnect the various connectors.

    • Refer to steps 22 to 11

    • Perform an oil change on the vehicle, including replacement of the oil filter

    • Fill again, and purge the cooling circuit

    • It is recommended to perform a rocker arm clearance adjustment following this operation.

    • Once the engine has warmed up for the first time, I advise you to remove the rocker cover and clean it again (a little mayonnaise is present)

    • I also recommend a new oil change + purge of the cooling circuit after approximately 500 km in order to properly clean the circuit.

    Edit
Finish Line

11 other people completed this guide.

Author

with 1 other contributor

hrmuller t

Member since: 09/04/2017

3,352 Reputation

67 Guides authored

9 Comments

Good morning,

Is it normal that the cylinder head gasket is different from the original one? There are missing water passage holes on the ignition side

thieldamien - Reply

Many thanks to the author of this tutorial. It is a great help to us!

You just need to add the tightening torques, and specify that when removing the cylinder head you need to tilt it front to back, and not lift the cylinder head upwards at the risk of damaging the cylinder liners.

enzo.gilbin - Reply

Thank you very much, this tutorial is very well done and was very useful to me, maybe add all the tightening torques, external pulley, but frankly it's very good work.

Best regards,

philippe lebon - Reply

Good morning,

Thank you for this very detailed tutorial.

I would just like to ask if there is not a SPY seal on the ignition side? I don't see it at all and I wonder what is supposed to make that side watertight? Just the O-ring in the distributor?

Thank you for your reply.

Mohamed Najdat BEN BELGACEM - Reply

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