Peugeot 405 Manual

Timing belt - general information, removal and refitting
XU petrol engine in-car repair procedures / Timing belt - general information, removal and refitting


Note: Peugeot specify the use of a special electronic tool (SEEM C.TRONIC belt tensioning measuring tool) to correctly set the timing belt tension on all 1992-on models. If access to this equipment cannot be obtained, an approximate setting can be achieved using the method described below. In this case, the tension must be checked using the special electronic tool at the earliest opportunity. Do not drive the vehicle over large distances, or use high engine speeds, until the belt tension is known to be correct. Refer to a Peugeot dealer for advice.

General information
1 The timing belt drives the camshaft(s) and coolant pump from a toothed sprocket on the front of the crankshaft. If the belt breaks or slips in service, the pistons are likely to hit the valve heads, resulting in extensive (and expensive) damage.

2 The timing belt should be renewed at the specified intervals (see Chapter 1), or earlier if it is contaminated with oil, or if noisy in operation (a scraping noise due to uneven wear).

3 If the timing belt is being removed, it is a wise precaution to check the condition of the coolant pump at the same time (check for signs of coolant leakage). This may avoid the need to remove the timing belt again at a later stage, should the coolant pump fail.

Removal
Early (pre-1992) 1580 cc and 1905 cc 8-valve models with a semi-automatic belt tensioner
4 Disconnect the battery negative terminal.

5 Align the engine assembly/valve timing holes as described in Section 3, and lock the camshaft sprocket and crankshaft pulley in position. Do not attempt to rotate the engine whilst the pins are in position.

6 Remove the centre and lower timing belt covers as described in Section 6.

7 Slacken (but do not remove) the two nuts securing the tensioner assembly to the end of the cylinder block (see illustration).

7.7 On early 1580 cc and 1905 cc models, slacken the tensioner assembly
7.7 On early 1580 cc and 1905 cc models, slacken the tensioner assembly retaining nuts . . .

Loosen
the tensioner cam spindle locknut, located on the rear of cylinder block flange.

8 Using a suitable open-ended spanner on the square-section end of the tensioner cam spindle, rotate the cam until the tensioner spring is fully compressed and the belt tension is relieved (see illustration).

7.8 . . . and the spindle locknut, then release the belt tension by turning
7.8 . . . and the spindle locknut, then release the belt tension by turning the tensioner cam spindle

Hold the
cam in this position, and tighten the locknut.

9 If required for improved access to the timing belt, remove the right-hand engine mounting bracket as follows: Place a jack beneath the engine, with a block of wood on the jack head. Raise the jack until it is supporting the weight of the engine.

10 Slacken and remove the three nuts securing the engine/transmission right-hand mounting bracket to the engine bracket.

Remove the single nut securing the bracket to the mounting rubber, and lift off the bracket.

Undo the three bolts securing the engine bracket to the end of the cylinder head/block, and remove the bracket.

11 If the timing belt is to be re-used, use white paint or chalk to mark the direction of rotation on the belt (if markings do not already exist), then slip the belt off the sprockets.

Note that the crankshaft must not be rotated whilst the belt is removed.

12 Check the timing belt carefully for any signs of uneven wear, splitting, or oil contamination. Pay particular attention to the roots of the teeth. Renew it if there is the slightest doubt about its condition. If the engine is undergoing an overhaul, and has covered more than 36 000 miles (60 000 km) with the existing belt fitted, renew the belt as a matter of course, regardless of its apparent condition. The cost of a new belt is nothing compared with the cost of repairs, should the belt break in service. If signs of oil contamination are found, trace the source of the oil leak and rectify it. Wash down the engine timing belt area and all related components, to remove all traces of oil.

Later (1992-on) 1580 cc and 1905 cc (8-valve) models with a manuallyadjusted belt tensioner pulley, and all 1761 cc and 1998 cc (8-valve) models 13 Disconnect the battery negative terminal.

14 Align the engine assembly/valve timing holes as described in Section 3, and lock the camshaft sprocket and crankshaft pulley in position. Do not attempt to rotate the engine whilst the pins are in position.

15 Remove the centre and/or lower timing belt cover(s) - see Section 6 (as applicable).

16 Loosen the timing belt tensioner pulley retaining bolt. Pivot the pulley in a clockwise direction, using a suitable square-section key fitted to the hole in the pulley hub, then securely retighten the retaining bolt.

17 On 1580 cc, 1761 cc and 1905 cc models, dismantle the engine right-hand mounting as described above in paragraphs 9 and 10.

18 On all models, remove and inspect the timing belt (see paragraphs 11 and 12).

1905 cc 16-valve models
19 Disconnect the battery negative terminal.

20 Align the engine assembly/valve timing holes as described in Section 3, and lock the camshaft sprockets and crankshaft pulley in position. Do not attempt to rotate the engine whilst the pins are in position.

21 Remove the timing belt lower cover as described in Section 6.

22 Loosen the timing belt front and rear tensioner pulley retaining bolts. Pivot the front pulley in a clockwise direction, using a suitable square-section key fitted to the hole in the pulley hub, then securely retighten the retaining bolt. Similarly pivot the rear pulley in an anti-clockwise direction and retighten the retaining bolt.

23 Check that the camshaft sprocket and crankshaft locking pins are still in position, then remove and inspect the timing belt as described in paragraphs 11 and 12.

1998 cc 16-valve models
24 Disconnect the battery negative terminal.

25 Align the engine assembly/valve timing holes as described in Section 3, and lock the camshaft sprockets and crankshaft pulley in position. Do not attempt to rotate the engine whilst the pins are in position.

26 Remove the timing belt lower cover as described in Section 6.

27 Loosen the timing belt rear tensioner pulley retaining bolt. Pivot the pulley in a clockwise direction, using a suitable squaresection key fitted to the hole in the pulley hub, then retighten the bolt (see illustration).

7.27 Timing belt arrangement - 1998 cc 16-valve models
7.27 Timing belt arrangement - 1998 cc 16-valve models

1 Front tensioner assembly 2 Rear tensioner pulley
3 Camshaft sprocket timing holes 4 Crankshaft pulley timing hole 5 Belt tension measuring area (using Peugeot special tool)

28 Loosen the two front tensioner assembly retaining bolts. Move the tensioner pulley away from the belt, using the same squaresection key on the pulley backplate.

29 Check that the camshaft sprocket and crankshaft locking pins are still in position, then remove and inspect the timing belt as described in paragraphs 11 and 12.

Refitting
Early (pre-1992) 1580 cc and 1905 cc models with a semi-automatic belt tensioner
30 Before refitting, thoroughly clean the timing belt sprockets. Check that the tensioner pulley rotates freely, without any sign of roughness. If necessary, renew the tensioner pulley as described in Section 8.

31 Ensure that the camshaft sprocket locking pin is still in position. Temporarily refit the crankshaft pulley, and insert the locking pin through the pulley timing hole to ensure that the crankshaft is still correctly positioned.

32 Remove the crankshaft pulley. Manoeuvre the timing belt into position, ensuring that any arrows on the belt are pointing in the direction of rotation (clockwise when viewed from the right-hand end of the engine).

33 Do not twist the timing belt sharply while refitting it. Fit the belt over the crankshaft and camshaft sprockets. Ensure that the belt front run is taut - ie, any slack should be on the tensioner pulley side of the belt. Fit the belt over the water pump sprocket and tensioner pulley. Ensure that the belt teeth are seated centrally in the sprockets.

34 Slacken the tensioner cam spindle locknut, and check that the tensioner pulley is forced against the timing belt by spring pressure.

35 Refit the crankshaft pulley, tightening its retaining bolt by hand only.

36 Rotate the crankshaft through at least two complete rotations in a clockwise direction (viewed from the right-hand end of the engine). Realign the camshaft and crankshaft engine assembly/valve timing holes (see Section 3). Do not at any time rotate the crankshaft anti-clockwise. Both camshaft and crankshaft timing holes should be aligned so that the locking pins can be easily inserted.

This indicates that the valve timing is correct.

37 If the timing holes are not correctly positioned, release the tensioner assembly as described in paragraph 8, and disengage the belt from the camshaft sprocket. Rotate the camshaft and crankshaft slightly as required until both locking pins are in position.

Relocate the timing belt on the camshaft sprocket. Ensure that the belt front run is taut - ie, that any slack is on the tensioner pulley side of the belt. Slacken the tensioner locknut, then remove the locking pins and repeat the procedure in paragraph 36.

38 Once both timing holes are correctly aligned, tighten the two tensioner assembly retaining nuts to the specified torque. Tighten the tensioner cam spindle locknut to its specified torque.

39 With the belt correctly installed and tensioned, where removed refit the engine bracket to the side of the cylinder head/block, and securely tighten its retaining bolts. Refit the right-hand mounting bracket, and tighten its retaining nuts to the specified torque. The jack can then be removed from underneath the engine.

40 Remove the crankshaft pulley, then refit the timing belt covers (refer to Section 6).

41 Install the crankshaft pulley (Section 5), and reconnect the battery negative terminal.

Later (1992-on) 1580 cc and 1905 cc (8-valve) models with a manuallyadjusted belt tensioner pulley, and all 1761 cc and 1998 cc (8-valve) models Note: Peugeot specify the use of a special electronic tool (SEEM C. TRONIC belt tension measuring tool) to correctly set the timing belt tension. If this equipment is not available, an approximate setting can be achieved using the method described below. If this method is used, however, the belt tension must be checked using the special electronic tool at the earliest possible opportunity. Do not drive the vehicle over large distances, or use high engine speeds, until the belt tension is known to be correct. Refer to a Peugeot dealer for advice.

42 Install the timing belt as described above in paragraphs 30 to 33.

43 Loosen the tensioner pulley retaining bolt.

Using the square-section key, pivot the pulley anti-clockwise to remove all free play from the timing belt.

44 If the special belt tension measuring equipment is available, it should be fitted to the front run of the timing belt. The tensioner roller should be adjusted so that the initial belt tension is 16 2 units on 1998 cc 8-valve models, and 30 2 units on all other models.

45 Tighten the pulley retaining bolt to the specified torque. Refit the crankshaft pulley again, tightening its bolt by hand only.

46 Carry out the operations described in paragraph 36 (and where necessary, paragraph 37, ignoring the information about the tensioner) to ensure both timing holes are correctly aligned and the valve timing is correct.

47 If the tension is being set without using the special measuring tool, proceed as follows. Check that, under moderate pressure from the thumb and forefinger, the belt can just be twisted through 90 at the mid-point of the front run of the belt. Note that this method is only an initial setting, and the belt tension must checked at the earliest available opportunity using the special measuring tool.

Failure to do so could lead to the belt breaking (through over-tightening) or slipping (through slackness), resulting in serious engine damage. If necessary, readjust the tensioner pulley position as required. Tighten its retaining bolt to the specified torque on completion.

48 If the special measuring tool is being used, the final belt tension on the front run of the belt on all models should be 44 2 units. Readjust the tensioner pulley position as required, then retighten the retaining bolt to the specified torque. Rotate the crankshaft through a further two rotations clockwise, and recheck the tension. Repeat this procedure as necessary until the correct tension reading is obtained after rotating the crankshaft.

49 With the belt tension correctly set, on 1580 cc, 1761 cc and 1905 cc models, where removed refit the engine bracket to the side of the cylinder head/block, and securely tighten its retaining bolts. Refit the right-hand engine mounting bracket, and tighten its retaining nuts to the specified torque. The jack can then be removed from underneath the engine.

50 On all models, remove the crankshaft pulley, then refit the timing belt cover(s) as described in Section 6.

51 Refit the crankshaft pulley (Section 5), and reconnect the battery negative terminal.

1905 cc 16-valve models
Note: Peugeot specify the use of a special electronic tool (SEEM belt tension measuring tool) to correctly set the timing belt tension. If this equipment is not available, an approximate setting can be achieved using the method described below. If this method is used, however, the tension must be checked using the special electronic tool at the earliest possible opportunity. Do not drive the vehicle over large distances, or use high engine speeds, until the belt tension is known to be correct. Refer to a Peugeot dealer for advice.

52 Before refitting, thoroughly clean the timing belt sprockets. Check that each tensioner pulley rotates freely, without any sign of roughness. If necessary, renew the tensioner pulley(s) as described in Section 8.

53 Ensure that the camshaft and crankshaft sprocket locking pins are still in position.

Slacken both tensioner mounting bolts so that they are free to pivot easily.

54 Manoeuvre the timing belt into position, ensuring that any arrows on the belt are pointing in the direction of rotation (clockwise when viewed from the right-hand end of the engine). Fit the timing belt in the sequence given in the accompanying illustration (see illustration).

7.54 Fit the timing belt in the sequence given - 1905 cc 16-valve engines
7.54 Fit the timing belt in the sequence given - 1905 cc 16-valve engines

55 Note that there may be timing marks on the belt, in the form of yellow lines, to ensure it is correctly positioned on both camshaft sprockets and the crankshaft sprocket. The two single-line timing marks should be aligned with the timing dot (directly opposite the sprocket timing hole) on each camshaft sprocket. The double-line timing mark should be aligned with the crankshaft sprocket, where it will be directly opposite the sprocket Woodruff key slot. Peugeot state that the use of these timing marks is optional, but they are useful in helping to ensure that the valve timing is correctly set at the first attempt.

56 With the three locking pins in position, move both the front and rear tensioner pulleys towards the timing belt until both pulleys are contacting the belt. Securely tighten the retaining bolts.

57 If the tension is being set without the use of the special measuring tool, proceed as follows. Using the square-section key fitted to the hole in the tensioner backplate, move the front tensioner pulley against the belt until all free play is removed from the belt. Hold the tensioner in this position, and tighten the pulley retaining bolts to the specified torque.

Similarly move the rear tensioner pulley against the belt and tighten the bolt.

58 If the special belt tension measuring equipment is available, it should be fitted to the front run of the timing belt, between the front tensioner and the camshaft sprocket.

Move the front tensioner pulley anti-clockwise so that the belt is tensioned to a setting of 19 units, then tighten the retaining bolt to the specified torque setting.

59 Slacken the rear tensioner pulley retaining bolt. Using the square-section key, pivot the pulley clockwise until the belt tension on the front run is 21 units. Hold the tensioner in position, and tighten its retaining bolt to the specified torque setting.

60 Remove the locking pins from the camshaft and crankshaft sprockets and, where fitted, the tensioning measuring device from the belt.

61 Rotate the crankshaft through at least two complete rotations in a clockwise direction (viewed from the right-hand end of the engine). Realign the camshaft and crankshaft engine assembly/valve timing holes (see Section 3). Do not at any time rotate the crankshaft anti-clockwise. Both camshaft timing holes and the crankshaft timing hole should be correctly positioned so that the locking pins can be easily inserted, indicating that the valve timing is correct.

62 If the timing holes are not correctly positioned, repeat the tensioning procedure.

63 Once the valve timing is correctly set, remove the locking pins and recheck the belt tension.

64 If the tension is being set without the special measuring tool, proceed as follows.

Check that, under moderate pressure from the thumb and forefinger, the belt can just be twisted through 45, at the mid-point between the camshaft sprocket and tensioner pulley on the front run of the belt. Note that this method is only an initial setting, and the belt tension must be checked at the earliest available opportunity using the special measuring tool. Failure to do so could lead to the belt breaking (through over-tightening) or slipping (through slackness), resulting in serious engine damage.

65 If the special measuring tool is being used, the final belt tension on the front run of the belt, between the camshaft sprocket and tensioner pulley, should be 45 5 units.

Repeat the procedure as necessary, until the correct tension reading is obtained after the crankshaft has been rotated.

66 Once the belt tension is correctly set, refit the timing belt covers as described in Section 6. Refit the crankshaft pulley as described in Section 5, and reconnect the battery negative terminal 1998 cc 16-valve models
Note: Peugeot specify the use of a special electronic tool (SEEM belt tension measuring tool) to correctly set the timing belt tension. If this equipment is not available, an approximate setting can be achieved using the method described below. If this method is used, however, the tension must be checked using the special electronic tool at the earliest possible opportunity. Do not drive the vehicle over large distances, or use high engine speeds, until the belt tension is known to be correct. Refer to a Peugeot dealer for advice.

67 Before refitting, thoroughly clean the timing belt sprockets. Check that each tensioner pulley rotates freely, without any sign of roughness. If necessary, renew the tensioner pulley(s) as described in Section 8.

68 Ensure that the camshaft and crankshaft sprocket locking pins are still in position.

Slacken the tensioner mounting bolts so that they are free to pivot easily.

69 Manoeuvre the timing belt into position, ensuring that any arrows on the belt are pointing in the direction of rotation (clockwise when viewed from the right-hand end of the engine).

70 Note that there are also timing marks on the belt, in the form of yellow lines, to ensure it is correctly positioned on both camshaft sprockets and the crankshaft sprocket. The two single-line timing marks should be aligned with the timing dot (directly opposite the sprocket timing hole) on each camshaft sprocket. The double-line timing mark should be aligned with the crankshaft sprocket, where it will be directly opposite the sprocket Woodruff key slot. Peugeot state that the use of these timing marks is optional, but they are useful in helping to ensure that the valve timing is correctly set at the first attempt.

71 With the three locking pins in position, move both the front and rear tensioner pulleys towards the timing belt until both pulleys are contacting the belt. Securely tighten the rear tensioner retaining bolt.

72 If the tension is being set without the use of the special measuring tool, proceed as follows. Using the square-section key fitted to the hole in the tensioner backplate, move the front tensioner pulley against the belt until all free play is removed from the belt. Hold the tensioner in this position, and tighten the pulley retaining bolts to the specified torque.

73 If the special belt tension measuring equipment is available, it should be fitted to the front run of the timing belt, between the front tensioner and the camshaft sprocket.

Move the tensioner pulley backplate so that the belt is initially over-tensioned to a setting of 45 units, then back the tensioner off until the belt tension is 22 2 units. Hold the backplate in this position, and tighten both the tensioner pulley retaining bolts to the specified torque.

74 Slacken the rear tensioner pulley retaining bolt. Using the square-section key, pivot the pulley anti-clockwise until all free play is removed from the belt. If the belt tension measuring equipment is being used, set the tensioner pulley so that the belt tension on the front run is 32 2 units. Hold the tensioner in position, and tighten its retaining bolt to the specified torque setting.

75 Remove the locking pins from the camshaft and crankshaft sprockets and, where fitted, the tensioning measuring device from the belt.

76 Rotate the crankshaft through at least two complete rotations in a clockwise direction (viewed from the right-hand end of the engine). Realign the camshaft and crankshaft engine assembly/valve timing holes (see Section 3). Do not at any time rotate the crankshaft anti-clockwise. Both camshaft timing holes and the crankshaft timing hole should be correctly positioned so that the locking pins can be easily inserted, indicating that the valve timing is correct.

77 If the timing holes are not correctly positioned, slacken the tensioner assembly retaining bolts, and disengage the belt from the camshaft sprockets. Rotate the camshafts and crankshaft slightly as required until all locking pins are in position, then relocate the timing belt on the camshaft sprocket. Ensure that the belt top run and front run are taut - ie, ensure that any slack is on the rear tensioner pulley and water pump side of the belt. Repeat the tensioning procedure until the valve timing is correct.

78 Once the valve timing is correctly set, remove the locking pins and recheck the belt tension.

79 If the tension is being set without the special measuring tool, proceed as follows.

Check that, under moderate pressure from the thumb and forefinger, the belt can just be twisted through 45, at the mid-point between the camshaft sprocket and tensioner pulley on the front run of the belt. Note that this method is only an initial setting, and the belt tension must be checked at the earliest available opportunity using the special measuring tool. Failure to do so could lead to the belt breaking (through over-tightening) or slipping (through slackness), resulting in serious engine damage. If necessary, readjust the rear tensioner pulley position as required, and tighten its retaining bolt to the specified torque.

80 If the special measuring tool is being used, the final belt tension on the front run of the belt, between the camshaft sprocket and tensioner pulley, should be 53 2 units.

Readjust the rear tensioner pulley position as required, then retighten the retaining bolt to the specified torque. Rotate the crankshaft through a further two rotations clockwise, and recheck the tension. Repeat this procedure as necessary, until the correct tension reading is obtained after the crankshaft has been rotated.

81 Once the belt tension is correctly set, refit the timing belt covers (see Section 6). Refit the crankshaft pulley as described in Section 5, and reconnect the battery negative terminal


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