Attention! Correct tensioning of the toothed belt requires the use of a special electronic tool (SEEM C105.5). If the belt is tensioned without this tool, do not travel long distances and operate the engine at high speeds. Have the belt tension adjusted at the Peugeot station as soon as possible.
The timing belt drives the camshaft and coolant pump and is driven by a pulley located at the front end of the crankshaft. If the belt breaks while the engine is running, the pistons can hit the valves, resulting in serious engine damage.
The toothed belt must be replaced after a certain mileage, or earlier if it has been exposed to oil or uneven wear.
If the toothed belt is removed, it is necessary to check the condition of the coolant pump and its tightness.
Removing
1.6 liter engine models
1. Disconnect the negative terminal from the battery.
2. Raise the front of the car and remove the right front wheel. Unscrew the mudguard mounting bolt.
3. Remove the auxiliary drive belt. Unscrew the bolt and remove the drive belt tensioner.
4. Unscrew a bolt and remove the top casing of a gear belt.
5. Turn the crankshaft until the alignment holes in the camshaft and crankshaft pulleys are aligned and fix them in this position with the rods.
6. Remove the auxiliary drive belt pulley from the crankshaft.
7. Remove the central and lower casings of a gear belt.
8. Loosen the toothed belt tensioner pulley bolt. Using an appropriate square wrench in the hole in the pulley hub, turn the pulley clockwise and retighten the mounting bolt.
9. If the timing belt is to be reused, mark the direction of rotation with paint or chalk. Remove the belt from the pulleys.
Attention! After removing the belt, the rotation of the crankshaft is not allowed.
10. Check the toothed belt for uneven wear, splitting or oil contamination. Pay special attention to the condition at the base of the belt teeth. If the engine is overhauled after the belt has run more than 60,000 km, replace the belt regardless of its condition. If traces of oil are found on the belt, the source of the oil leak must be found and repaired.
1.8 and 2.0 liter engine models
11. Disconnect the negative terminal from the battery.
12. Turning the crankshaft, align the mounting holes on the camshaft and crankshaft pulleys and fix the pulleys with rods.
13. Remove the upper outer and lower toothed belt covers.
14. For free access to the toothed belt, if necessary, disconnect the electrical connectors and remove the wiring harness from the clamps and supports. When disconnecting connectors, be sure to mark them for proper installation in their original place.
15. Support the engine with a jack and remove the right engine mount.
16. Loosen the timing belt tensioner pulley bolt and turn the pulley clockwise using an appropriate square wrench installed in the pulley hub. Then re-tighten the mounting bolt.
17. Check that the camshaft pulley locking pins are in place, then remove and check the condition of the toothed belt.
Installation
1.6 liter engine models
1. Check and clean the toothed belt drive pulleys. Also check the condition and freedom of rotation of the tensioner pulley.
2. Check for the presence of the camshaft locking pins. Temporarily install the pulley on the crankshaft and insert the setting rod into it to check the position of the crankshaft.
3. Remove pulley from crankshaft. Install the toothed belt, observing the direction of rotation. When installing the belt, ensure the maximum tension of the front branch of the belt, the slack in the belt should be on the rear branch. Check that the toothed belt teeth are properly seated on the pulleys.
4. Temporarily install the auxiliary drive belt pulley and moderately tighten the mounting bolt. Then install the fixing rod.
Attention! The tension of the toothed belt is carried out with the casing removed.
5. Loosen the tensioner pulley bolt. Using a square wrench, turn the pulley counterclockwise until the belt is tensioned.
6. In the presence of special measuring equipment, install it on the front branch of the toothed belt and set the initial belt tension equal to 30±2 units.
7. Remove the dowel pins and turn the crankshaft two full turns clockwise. Reinstall the fixing rods. If the rods are inserted easily, then the timing drive mechanism is installed correctly. Remove the lock bars.
8. If the pulley fixing pins are not installed in the hole, it is necessary to remove the belt and align the mounting holes.
9. If the belt tension is being done without a special tool, the belt tension can be checked by applying moderate force of the thumb in the middle of the front branch of the belt and turning the belt 90°. If the belt is tensioned without this tool, do not travel long distances and operate the engine at high speeds. Have the belt tension adjusted at the Peugeot station as soon as possible.
10. When using special measuring tools, turn the crankshaft two turns, install the crankshaft lock rod and check the tension of the front branch of the belt, which should be 44±2 units.
11. After accurately tensioning the belt, remove the camshaft lock rod, then remove the auxiliary drive belt pulley from the crankshaft and install the covers.
12. Install the auxiliary belt pulley on the crankshaft, lubricate the bolt threads with an anti-loose agent and screw in the pulley mounting bolt.
13. Install the auxiliary drive belt tensioner and tension the auxiliary drive belt.
14. Install mudguard and front right wheel. Lower the car.
15. Connect the negative terminal to the battery.
1.8 and 2.0 liter engine models
16. Check and clean the toothed belt drive pulleys. Also check the condition and freedom of rotation of the tensioner pulley.
17. Check that the dowel pin is in the camshaft pulley. Temporarily install the crankshaft pulley and insert the locking rod into it to ensure proper crankshaft installation.
18. Remove the crankshaft pulley. Install the toothed belt on the crankshaft pulley, observing the direction of its rotation.
19. Install the lower belt cover and auxiliary belt pulley to the crankshaft.
20. Install the locking rod into the crankshaft pulley.
21. Without removing the locking rods, loosen the six bolts securing the camshaft pulleys. Check that both pulleys rotate freely within a small range.
22. Tighten the six camshaft pulley bolts. Then unscrew them by 60°each.
23. Rotate each pulley clockwise and tighten additional bolts.
24. Pull the front branch of the toothed belt from the crankshaft pulley, through the idler pulley and onto the intake camshaft pulley.
25. Pulling the front branch of the belt, install it on the camshaft pulley that controls the exhaust valves.
26. While tensioning the belt, install it on the rear tensioner pulley and around the coolant pump pulley.
27. Tension the toothed belt.
28. In the presence of special measuring equipment, install it on the front branch of the toothed belt. By turning the tensioner pulley counterclockwise, set the belt tension to 45 units and tighten the tensioner mounting bolt.
29. Unscrew the mounting bolts from the camshaft pulleys and check that the bolt holes in the pulleys are not in the extreme position with respect to the mounting bolts. If everything is satisfactory, unscrew the two additional bolts and tighten the six bolts securing the pulleys.
30. Remove the locating rods, turn the crankshaft clockwise two full turns, and install the locating rod into the crankshaft pulley. Loosen the six camshaft mounting bolts, re-tighten and back off 60°.
31. Install the dowel pins into the camshaft pulleys. Then loosen the tensioner pulley bolt. Install the measuring equipment on the front branch of the belt and turn the tensioner pulley until the belt pretension is set to 26 units. Tighten the tensioner bolt.
32. Retighten the six camshaft pulley bolts to the correct torque.
33. Remove the lock rods, rotate the crankshaft two full turns clockwise and install the lock rod into the crankshaft pulley.
34. Loosen the six camshaft mounting bolts, re-tighten and back off 60°.
35. Install the dowel pins into the camshaft pulleys. Then loosen the tensioner pulley bolt. Install the measuring equipment on the front branch of the belt and turn the tensioner pulley until the final belt tension is set to 32-40 units. Tighten the tensioner bolt.
36. Retighten the six camshaft pulley bolts to the correct torque.
37. If the belt is tensioned without special measuring equipment, turn the belt tensioner pulley counterclockwise until the sagging of the rear branch of the belt is eliminated and, in this position, tighten the bolt of the tensioner pulley.
38. Unscrew the mounting bolts from the camshaft pulleys and check that the bolt holes in the pulleys are not in the extreme position with respect to the mounting bolts. If everything is satisfactory, unscrew the two additional bolts and tighten the six bolts securing the pulleys.
39. Remove the locating rods, turn the crankshaft clockwise two full turns, and install the locating rod into the crankshaft pulley.
40. Loosen the six camshaft mounting bolts, re-tighten and back off 60°.
41. Install the dowel pins into the camshaft pulleys. Rotate the tensioner pulley so that, with moderate force, the belt can be rotated 45°midway between the intake camshaft pulleys and the idler pulley, and tighten the tensioner mounting bolt.
42. Retighten the six camshaft pulley bolts to the correct torque.
43. Install the timing belt guards and connect the negative terminal to the battery.