Peugeot 405 Manual

Timing belt covers - removal and refitting
XU petrol engine in-car repair procedures / Timing belt covers - removal and refitting


1580 cc and
1905 cc 8-valve models
Upper cover
1 Release the retaining clips, and free the fuel hoses from the top of the cover.

2 Undo the two cover retaining bolts (situated at the base of the cover), and remove the cover from the engine compartment.

Centre cover - early (pre-1992) models with a semi-automatic belt tensioner
3 Slacken and remove the four cover retaining nuts and bolts (two directly below the mounting bracket, and two at the base of the cover), then manoeuvre the cover upwards out of the engine compartment.

Centre cover - later (1992-on) models with a manually-adjusted belt tensioner pulley
4 Slacken and remove the two cover retaining bolts (located directly beneath the mounting bracket). Move the cover upwards to free it from the two locating pins situated at the base of the cover, and remove it from the engine compartment.

Lower cover
5 Remove the crankshaft pulley as described in Section 5.

6 Remove the centre cover as described above.

7 On early models, undo the three lower cover retaining bolts and remove the cover from the engine.

8 On later models, undo the two cover retaining bolts and remove the cover from the engine.

Lower (inner) cover - early (pre-1992) models with a semi-automatic belt tensioner
9 Remove the timing belt as described in Section 7.

10 Slacken and remove the remaining bolts, noting their correct fitted positions, and remove the cover from the end of the cylinder block.

1761 cc models
Upper cover
11 Proceed as described in paragraphs 1 and 2.

Centre cover
12 Proceed as described in paragraph 4.

Lower cover
13 Remove the crankshaft pulley as described in Section 5.

14 Remove the centre cover as described in paragraph 4.

15 Undo the two cover retaining bolts, and remove the cover from the engine.

1905 cc 16-valve models
Upper cover
16 Release the quick release clips from the timing belt cover.

17 Unscrew the upper cover securing screws and withdraw the cover.

Lower cover
18 Remove the crankshaft pulley as described in Section 5.

19 Unscrew the lower cover securing screws and withdraw the cover.

1998 cc 8-valve models
Upper cover
20 Release the retaining clip, and free the fuel hoses from the top of the timing belt cover.

21 Slacken and remove the two cover retaining bolts, then lift the upper cover upwards and out of the engine compartment.

Lower cover
22 Remove the crankshaft pulley as described in Section 5.

23 Slacken and remove the three retaining bolts, then remove the lower timing belt cover from the engine.

1998 cc 16-valve models
Upper (outer) cover
24 Undo the two upper retaining bolts securing the outer cover to the inner cover.

Slide the cover retaining clip upwards to release it from its fasteners (see illustration).

6.24 Timing belt upper (outer) cover retaining clip
6.24 Timing belt upper (outer) cover retaining clip (arrowed) - 1998 cc 16-valve models

25 Ease the outer cover away from the engine. Lift it upwards, freeing it from its locating bolts at the base of the cover, and out of the engine compartment.

Lower cover
26 Remove the crankshaft pulley (Section 5).

27 Remove the upper (outer) cover as described above.

28 Slacken and remove the two upper cover lower locating bolts, along with their spacers.

Undo the two lower cover retaining bolts, and remove the cover from the engine.

Upper (inner) cover
29 Remove the timing belt (see Section 7).

30 Remove both camshaft sprockets as described in Section 8.

31 Undo the six bolts securing the cover to the side of the cylinder head, and remove the cover from the engine.

Refitting
32 Refitting is a reversal of the relevant removal procedure, ensuring each cover section is correctly located, and the cover nuts and/or bolts are correctly tightened.


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