Peugeot 205 - Manual (Page 46)

26 Remove the head bolts and lift off the
rocker shaft assembly (see illustration). It
may be necessary to leave one or two bolts in
the assembly if they foul the bulkhead due to
insufficient engine height.
27 Loosen the camshaft thrust plate bolt, pull
out the plate and temporarily retighten the
bolt (see illustration).
28 The camshaft sprocket must now be
supported in its normal position while the cylinder head is removed. If it is allowed to
drop it will not be possible to lift it again
without releasing the timing chain tensioner
which will necessitate removal of the timing
cover. Peugeot dealers use a special mandrel,
tool number 70132, but as this is unlikely to
be available to the home mechanic it is
suggested that a plate and bolt are used,
together with the access plate (see Tool Tip).
29 Slide the camshaft from the fuel pump
eccentric and camshaft sprocket and let it
rest in the cylinder head (see illustration).
30 Before removing the cylinder head the
following must be noted. The cylinder head is
positioned during assembly by means of two
dowels. When removing the cylinder head it is
most important not to lift it directly from the
cylinder block; it must be twisted slightly. This
action prevents the cylinder liners from
sticking to the cylinder head face and being
lifted with it, thus breaking their bottom seals.
Before the cylinder head can be twisted, the
dowel at the flywheel end must be tapped
down flush with the top of the cylinder block,
using a drift (see illustration). 31 Remove the four timing cover-to-cylinder
head bolts then move the flywheel end of the
cylinder head sideways slightly to release the
gasket.
32 Lift the cylinder head from the block and
remove the gasket without disturbing the
liners. Do not turn the engine over as this also
will break the liner bottom seals. If further
work is to be carried out on the engine, such
as cleaning the tops of the cylinder liners, they
should be clamped in position using two
cylinder head bolts, metal tubing, and large
washers (see illustration).
Preparation for refitting
Note: As mentioned at the beginning of this
Section, the camshaft sprocket must be
supported in such a way that it will be allowed
to rotate as the crankshaft is turned to clean
the pistons. The Peugeot special tool locates
through the sprocket retaining bolt hole and is
bolted to the front of the timing cover. If this
tool cannot be obtained, a suitable alternative
can be easily fabricated.
33 With the camshaft sprocket supported so
as to allow rotation, commence the cleaning
operation as follows.
34 The mating faces of the cylinder head and
cylinder block/crankcase must be perfectly
clean before refitting the head. Use a hard
2A•8 XV, XW and XY series engine in-car repair procedures
7.29 Slide the camshaft from the fuel
pump eccentric (arrowed)
7.30 Driving the cylinder head dowel down
flush with the block face
7.26 Removing the rocker shaft assembly 7.27 Loosening the camshaft thrust plate bolt
In the absence of the Peugeot tool, a
nut and bolt used together with the
access plate can be used as shown to
prevent the camshaft sprocket from
dropping.
7.32 Using washers, tubing and the cylinder
head bolts to clamp the liners in position