02/02/2024, 20:32 EP6 Engine Head Gasket Replacement

EP6 PSA - N13 BMW - N18 Mini (Prince) engine

head gasket replacement

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OVERALL DIFFICULTY INDEX: 8/10

IF YOU HAVE NO TOOLS YOU SPEND $ 300 TO GET THEM FOR THIS JOB
IF YOU HAVE NO EXPERIENCE YOU SPEND 3 DAYS TO CARRY OUT THIS JOB*
RISK OF SKIN IRRITATION FROM CONTACT WITH USED MOTOR OIL OR EYE INJURY
DUE TO SOLVENT USE.​​

BEFORE YOU START

This pictorial is PART 3 of a set of 5 pictorials:
1. Cylinder head removal
2. Timing chain removal
3. Head gasket replacement
4. Cylinder head refitting
5. Timing chain refitting and setting
The suggested required time covers the 5 pictorials.

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The below works concerned a Peugeot 5008 equipped with a turbo-charged EP6 engine (156 HP
version).
Same or similar engine can be found on Peugeot 207, 208, 308, 508, 3008, 5008 and Citroen C4, C4
Sedan, DS3, DS4, DS5 also the Mini Cooper S.

DISCLAIMER:
Our pictorials are of informative nature and do illustrate works carried out by ourselves at our own
premises for our own use and satisfaction.
Readers who envisage to carry out similar works inspired by the below method shall do this at their
own risks and liability.

BACK TO PART 2: TIMING CHAIN REMOVAL PAGE

Controlling the cylinder head flatness

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Use a thick metal ruler to make sure the cylinder head is not excessively distorted.
Try it while the cylinder head is vertical and horizontal having light behind the ruler.
If needed, use an inspection lamp behind the ruler.

You should make sure that:

Any distortion found at the middle cylinders No 2 and 3 is far less than the thickness of the
used head gasket you removed
There are no cracks in the cylinder head around valves
Injectors tips are clean and along with the valves, they all have the same appearance in all
cylinders.

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Minimum cleaning of the cylinder head

If you do not intend to dismantle the camshafts, valves, injectors, etc to thoroughly clean the cylinder
head, then you should observe a minimal cleaning consisting of:
1. Brushing with a rigid plastic brush the camshafts, hydraulic lifters, etc. to remove partially
carbonized engine oil. See our page for cylinder head sludge removal for more details.
2. Cleaning the hydraulic valve lifters with carb spray. Later, and after refitting the cylinder head,
new engine oil will be poured over the lifters.
3. Blow with compressed air whatever particles that are left after the cleaning operation.

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Complete the cylinder head cleaning by using WD-40 or equivalent to clean the cylinder head
surface where the head gasket will be in contact.

Cylinder head bolts cleaning and greasing

You should replace your cylinder head bolts.
If you do not find new bolts, thoroughly clean with carb spray the bolts, washers and nuts and apply a
thick coat of high temperature grease to the whole the threaded part of the bolt.
Grease with graphite contents are well suited for the job and widely available.

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Engine block top surface cleaning

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Use a P1000 sand paper to clean the engine cylinder block top surface. Make sure to:
remove whatever deposits.
use only P1000 (one thousand) or higher grit sand paper, NEVER LESS.
inspect the cylinder liners tops to make sure all are aligned with the engine block body. Use a
metallic ruler like for he cylinder head.

Use WD-40 r equivalent to complete the cleaning process then wipe-out and dry well with a cotton
cloth:

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Pegging the EP6 engine

Turn the engine by hand clockwise using a combination spanner on the crank pulley bolt (left) and
while making sure the timing belt is attached to the hood.

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With any stick like an Allen key make sure to bring your pistons to mid-travel by measuring the height
to surface of 2 adjacent cylinders like 4 and 3 as shown here. Mid-travel occurs twice at every engine
turn, you should do so with pistons 1 and 4 moving up.

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Never turn the engine anti-clockwise during this operation. Turn it gain clockwise by a complete turn
if you pass the mid-travel position.

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In order to facilitate the positioning of the engine peg, make sure your mid-travel alignment is quite
accurate using calipers.

Now fit the EP6 engine peg (left) into its place located between the exhaust and flywheel.

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DO NOT FORCE IT into its seat especially this depends on how accurate you were able to put the
pistons at mid-travel.

If the peg hole is passed (even slightly by a fraction of a millimeter, turn the engine again clockwise
and repeat your attempt. Do not turn the engine anti-clockwise at all.

CONTINUE TO PART 4: CYLINDER HEAD REFITTING

Spares in relation with this pictorial from our partners' store:

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JUMP TO PART 5: TIMING CHAIN REFITTING

SEE ALL EP6 ENGINE REPAIR TIPS

BACK TO CAR MAINTENANCE & REPAIR

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