Engine - Modifications
83peugeot01Bulletin No. 115
Date: April, 1983
Subject: 505 XN6 ENGINE MODIFICATIONS (FUEL INJECTION MODELS)
During the 1983 model year the 505 XN6 engine has been revised in two stages.
1) New Cylinder Head Gasket (P.N. 0209.04)
Starting with V.I.N. 0331834, the 1983 505 fuel injection models are equipped with a cylinder head gasket incorporating a 0.2 mm (0.008") zinc plated steel insert sandwiched between the outer layers of the gasket.
^ Previous gasket thickness : 1.1 to 1.3 mm.
^ New gasket thickness : 1.3 to 1.5 mm.
Interchangeability:
The new gasket, P.N. 0209.04, can be used for repair purposes on 504 XN1, XNA, XNAC, and 505 XN6 engines originally equipped with the earlier type gasket.
The retorquing requirements after a gasket replacement on these engines remain the same, namely:
a) after the first rise to operating temperature, and
b) after 1000 to 1500 miles of operation.
2) Elimination of Cylinder Head Retorque Requirement at 1000 - 1500 Mile Inspection
Starting with V.I.N. 0334057, modifications to the components indicated below have made it possible to eliminate the requirement for retorquing the cylinder head and adjusting the valves at the 1000 - 1500 mile inspection.
- Cylinder Head Part Number: 0201.24
Elimination of 52 mm diameter hole on the water pump side of the cylinder head.
Increased reinforcement around mounting area for rocker assembly supports.
- Rocker Assembly Supports Part Numbers:
^ Front : 0924.30
^ Intermediate : 0925.17
^ Center : 0925.18
^ Rear : 0926.16
Exhaust side ends with a 29 mm diameter instead of 24 mm.
- Sleeve Seals Part Number: 0112.80 (complete set)
Plated alloy seals instead of paper and synthetic fiber.
Three thicknesses available: 0.10 mm. 0.12 mm. 0.15 mm.
Interchangeability:
The new plated alloy sleeve seals can be used for repair purposes on all 504 and 505 vehicles originally equipped with the previous type sleeve seals. These sleeve seals must only be used with the new head gasket, P.N. 0209.04.
- Piston Part Numbers:
^ Paired piston and sleeve : 0111.43
^ Complete piston and sleeve kit : 0114.80
Piston dome height increased by 0.34 mm.
Cylinder Head Tightening Procedure on All Gas Engine Vehicles (After Cylinder Head or Gasket Replacement)
- Apply a thin coat of "Molykote G Rapid" (P.N. 9730.08) or equivalent under bolt head and on the threads.
- Pretighten to 5 daN-m (36.25 ft.lbs.) one bolt at a time in the numbered sequence.
- Fully loosen Bolt No. 1.
- Using Tool 8.0129, retighten to 2 daN-m (14.5 ft.lbs.).
- While maintaining tension at 2 daN-m, place pointer on tool 0~ notch and continue torquing to 90~ +/- 2~.
- Repeat procedure at other bolts, following numbered sequence.
- Adjust valve clearance to : Intake : 0.10 mm (0.004")
Exhaust : 0.25 mm (0.010")
- Run the engine at 2000 RPM until the declutchable cooling fan engages. Shut off engine and allow to cool for 6 hours.
IMPORTANT: It is essential to allow time for the engine to cool down. A retorque operation on an insufficiently cooled engine will cause insufficient tension of the cylinder head bolts.
- Fully loosen Bolt No. 1.
^ Using Tool 8.0129, retighten to 2 daN-m (14.5 ft.lbs.).
^ While maintaining tension at 2 daN-m, place pointer on tool 0~ notch and continue torquing to 90~ +/- 2~.
- Repeat above procedure at other bolts, following numbered sequence.
- Adjust valve clearance to : Intake : 0.10 mm (0.004")
Exhaust : 0.25 mm (0.010")
Cylinder Head Retorque After 1000 - 1500 Miles of Operation
Not required as of 505 V.I.N. 0334057.
505's prior to V.I.N. 0334057 and all 504's with XN engines must be cold for a minimum of 6 hours.
- Fully loosen Bolt No. 1.
^ Using Tool 8.0129, retighten to 2 daN-m (14.5 ft.lbs.).
^ While maintaining tension at 2 daN-m, place pointer on tool 0~ notch and continue torquing to 90~ +/- 2~.
- Repeat above procedure at other bolts, following numbered sequence.
- Adjust valve clearance to : Intake : 0.10 mm (0.004")
Exhaust : 0.25 mm (0.010")