Peugeot 405 Manual

Engine assembly/valve timing holes - general information and usage
XU petrol engine in-car repair procedures / Engine assembly/valve timing holes - general information and usage


Note: Do not attempt to rotate the engine whilst the crankshaft/camshaft are locked in position. If the engine is to be left in this state for a long period of time, it is a good idea to place suitable warning notices inside the vehicle, and in the engine compartment. This will reduce the possibility of the engine being accidentally cranked on the starter motor, which is likely to cause damage with the locking pins in place.

1 On all models, timing holes are drilled in the camshaft sprocket(s) and crankshaft pulley.

The holes are used to align the crankshaft and camshaft(s), to prevent the possibility of the valves contacting the pistons when refitting the cylinder head, or when refitting the timing belt. When the holes are aligned with their corresponding holes in the cylinder head and cylinder block (as appropriate), suitable diameter pins can be inserted to lock both the camshaft and crankshaft in position, preventing them rotating unnecessarily.

Proceed as follows.

2 Remove the timing belt upper cover as described in Section 6.

3 Apply the handbrake, jack up the front of the car and support it on axle stands (see Jacking and Vehicle Support). Remove the right-hand front roadwheel.

4 From underneath the front of the car, prise out the two retaining clips and remove the plastic cover from the wing valance, to gain access to the crankshaft pulley bolt. Where necessary, unclip the coolant hoses from the bracket, to improve access further. The crankshaft can then be turned using a suitable socket and extension bar fitted to the pulley bolt. Note that the crankshaft must always be turned in a clockwise direction (viewed from the right-hand side of vehicle).

16-valve models
5 Rotate the crankshaft pulley until the timing holes in both camshafts are aligned with their corresponding holes in the cylinder head. The holes are aligned when the inlet camshaft sprocket hole is in the 8 oclock position, and the exhaust camshaft sprocket is in the 6 oclock position, when viewed from the righthand end of the engine.

6 With the camshaft sprocket holes correctly positioned, insert a 6 mm diameter bolt (or a drill of suitable size), through the timing hole in the crankshaft pulley, and locate it in the corresponding hole in the end of the cylinder block. Note that it may be necessary to rotate the crankshaft slightly, to get the holes to align.

7 With the crankshaft pulley locked in position, insert a 6 mm diameter bolt (or a drill) through the timing hole in each camshaft sprocket, and locate it in the cylinder head.

Note that the special Peugeot locking pins are actually 8 mm in diameter, with only their ends stepped down to 6 mm to locate in the cylinder head (see illustration).

3.7 Camshaft sprocket locking pins in position
3.7 Camshaft sprocket locking pins in position (arrowed) - 1998 cc 16-valve models

To simulate
this, wrap insulation tape around the outer end of the bolt or drill, to build it up until it is a snug fit in the camshaft hole.

8 The crankshaft and camshafts are now locked in position, preventing unnecessary rotation.

All other models
9 Rotate the crankshaft pulley until the timing hole in the camshaft sprocket is aligned with its corresponding hole in the cylinder head.

Note that the hole is aligned when the sprocket hole is in the 8 oclock position, when viewed from the right-hand end of the engine.

10 On early 1580 cc and 1905 cc models having a semi-automatic timing belt tensioner, a 10 mm diameter bolt (or a drill of suitable size) will be required to lock the crankshaft pulley in position.

11 On later 1580 cc and 1905 cc models, and all 1761 and 1998 cc 8-valve models (which have a manually-adjusted timing belt tensioner pulley) the pulley can be locked in position with an 8 mm diameter bolt or drill.

The special Peugeot locking pin is actually 10 mm in diameter, with only its end stepped down to 8 mm to locate in the cylinder block.

To simulate this, wrap insulation tape around the outer end of the bolt/drill, to build it up until it is a snug fit in the pulley hole.

12 With the camshaft sprocket holes correctly positioned, insert the required bolt or drill through the timing hole in the crankshaft pulley, and locate it in the corresponding hole in the end of the cylinder block. Note that it may be necessary to rotate the crankshaft slightly, to get the holes to align.

13 With the crankshaft pulley locked in position, insert the appropriate bolt or drill through the timing hole in the camshaft sprocket and locate it in the cylinder head (see illustration).

3.13 Camshaft sprocket and crankshaft pulley locking
3.13 Camshaft sprocket and crankshaft pulley locking pins in position (1580 cc model shown)

14 The crankshaft and camshaft are now locked in position, preventing rotation.


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