Peugeot 405 Manual

Auxiliary drivebelt check and renewal (6000 Mile (10 000 km) / 6 Month Service)
Routine maintenance and servicing / Auxiliary drivebelt check and renewal (6000 Mile (10 000 km) / 6 Month Service)


Note: On models from 1994, the makers specified interval for this procedure is 18 000 miles (30 000 km).

Note: Peugeot specify the use of a special electronic tool (SEEM C.TRONIC type 105 belt tensioning measuring tool) to correctly set the auxiliary drivebelt tension. If access to this equipment cannot be obtained, an approximate setting can be achieved using the method described below. If the method described is used, the tension should be checked using the special electronic tool at the earliest opportunity.

1 Except for XU9J4 16-valve engines, all models are fitted with one auxiliary drivebelt driven from the crankshaft pulley on the righthand side of the engine. On non-air conditioning models the belt drives the alternator and power steering pump and its tension is adjusted manually. On models fitted with air conditioning it drives the alternator, power steering pump and the air conditioning compressor. On XU9J4 models a separate drivebelt drives the power steering pump from a pulley on the end of the camshaft.

Checking the
auxiliary drivebelt condition Except XU9J4 16-valve
power steering drivebelt 2 Apply the handbrake, then jack up the front of the car and support it on axle stands (see Jacking and Vehicle Support). Remove the right-hand front roadwheel.

3 Remove the engine undercover and wheelarch cover as applicable.

4 Using a suitable socket and extension bar fitted to the crankshaft sprocket/pulley bolt, rotate the crankshaft so that the entire length of the drivebelt can be examined. Examine the drivebelt for cracks, splitting, fraying or damage. Check also for signs of glazing (shiny patches) and for separation of the belt plies.

Renew the belt if worn or damaged.

5 If the condition of the belt is satisfactory, on models where the belt is adjusted manually, check the drivebelt tension as described below. On models with an automatic springloaded tensioner, there is no need to check the drivebelt tension.

XU9J4 16-valve
power steering drivebelt 6 The power steering drivebelt is positioned on the left-hand end of the cylinder head.

Examine the full length of the drivebelt for cracks, splitting, fraying or damage. If necessary turn the engine with a spanner on the crankshaft pulley or by engaging 4th gear and pushing the car (for safety, the car must be on level ground). Check also for signs of glazing (shiny patches) and for separation of the belt plies.

7 If the condition of the belt is satisfactory, check the drivebelt tension as described later in this Section.

Auxiliary drivebelt
(early models) - removal, refitting and tensioning Removal
8 Loosen the alternator pivot and link bolts, then unscrew the adjuster bolt to release the drivebelt tension (see illustration).

5.8 Loosening the alternator adjustment bolts (early models)
5.8 Loosening the alternator adjustment bolts (early models)

9 Remove the drivebelt from the alternator, crankshaft and where necessary the power steering pulleys.

Refitting and tensioning 10 Locate the drivebelt on the pulleys making sure it is correctly engaged with the grooves.

11 The belt tension must be adjusted so that with moderate thumb pressure applied midway along the belts longest run, it can be deflected by approximately 6.0 mm. Turn the adjuster bolt in or out to obtain the correct tension, then tighten the pivot and link bolts (see illustration).

5.11 Alternator drivebelt deflection (A)
5.11 Alternator drivebelt deflection (A)

Auxiliary drivebelt
(models with a manuallyadjusted tensioning pulley) -
removal, refitting and tensioning Removal
12 If not already done, proceed as described in paragraphs 2 and 3.

13 Disconnect the battery negative lead.

14 Slacken the tensioner pulley bracket adjustment/mounting bolts (one located in the middle of the pulley and the other located below on the bracket (see illustration).

5.14 Tensioner pulley bracket lower mounting bolt (arrowed)
5.14 Tensioner pulley bracket lower mounting bolt (arrowed)

15 Fully tighten the adjustment bolt to its stop, then slip the drivebelt from the pulleys (see illustration).

5.15 Auxiliary drivebelt tension adjustment bolt (arrowed)
5.15 Auxiliary drivebelt tension adjustment bolt (arrowed)

Refitting
16 If the belt is being renewed, ensure that the correct type is used. Fit the belt around the pulleys, and take up the slack in the belt by tightening the adjuster bolt. Ensure that the ribs on the belt are correctly engaged with the grooves in the pulleys.

17 Tension the drivebelt as described in the following paragraphs.

Tensioning
18 If not already done, proceed as described in paragraphs 2 and 3.

19 Correct tensioning of the drivebelt will ensure that it has a long life. A belt which is too slack will slip and perhaps squeal.

Beware, however, of overtightening, as this can cause wear in the alternator bearings.

20 The belt should be tensioned so that, under firm thumb pressure, there is approximately 5.0 mm of free movement at the midpoint between the pulleys on the longest belt run (see the note at the start of this Section).

21 To adjust, unscrew the adjustment bolt until the tension is correct, then rotate the crankshaft a couple of times, and recheck the tension. Securely tighten the tensioner pulley bracket adjustment/mounting bolts.

22 Reconnect the battery negative lead.

23 Refit the engine undercover and wheelarch cover. Refit the roadwheel, and lower the vehicle to the ground.

Auxiliary drivebelt
(models with an automatic spring-loaded tensioner pulley) - removal, refitting and tensioning Removal
24 If not already done, proceed as described in paragraphs 2 and 3.

25 Disconnect the battery negative lead.

26 Using a square drive key in the square hole in the bottom of the automatic adjuster bracket, turn the bracket anticlockwise to release the tension on the belt. Hold the bracket in this position by inserting a 4.0 mm Allen key through the special hole and tightening the peg.

27 Unscrew the mounting bolts and remove the tensioner roller, then slip the auxiliary drivebelt from the pulleys.

28 Check that the tensioner pulleys turn freely without any sign of roughness.

Refitting and tensioning 29 If the belt is being renewed, ensure that the correct type is used. Fit the belt around the pulleys making sure that it is engaged with the correct grooves in the pulleys.

30 Refit the tensioner roller and tighten the mounting bolts.

31 Using the square drive key hold the automatic adjuster, then release the peg and slowly allow the tensioner to tighten the belt.

Check again that the belt is correctly located in the pulley grooves.

32 Reconnect the battery negative lead.

33 Refit the engine undercover and wheelarch cover. Refit the roadwheel, and lower the vehicle to the ground.

Power steering pump drivebelt (XU9J4 16-valve) models
Removal
34 Drain the hydraulic fluid from the system as described in Chapter 10.

35 Loosen the pump mounting bolts and remove the drivebelt.

36 Disconnect the high and low pressure unions on the pump.

37 Remove the bolts and lift off the pump.

Refitting and tensioning 38 Refit in reverse order, then tension the belt by applying a torque of 55 Nm for a new belt and 30 Nm for a used belt by using the square of a torque wrench in the square cutout in the pump bracket, tightening the mounting bolts while the torque tension is maintained (see illustration).

39 Fill and bleed the system (see Chapter 10).


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