Peugeot 405 Manual

Timing belt tensioner and sprockets - removal, inspection and refitting
XU petrol engine in-car repair procedures / Timing belt tensioner and sprockets - removal, inspection and refitting


Note: This Section describes the removal and refitting of the components concerned as individual operations - if more than one is to be removed at the same time, start by removing the timing belt as described in Section 7; remove the actual component as described below, ignoring the preliminary dismantling steps.

Removal
1 Disconnect the battery negative lead.

2 Align the engine assembly/valve timing holes as described in Section 3, locking the camshaft sprocket(s) and the crankshaft pulley in position, and proceed as described under the relevant sub-heading. Do not attempt to rotate the engine whilst the pins are in position.

Camshaft sprocket - early (pre-1992) 1580 cc and 1905 cc 8-valve models with a semi-automatic belt tensioner 3 Remove the centre timing belt cover as described in Section 6.

4 Slacken (but do not remove) the two nuts securing the tensioner assembly to the end of the cylinder block. Loosen the tensioner cam spindle locknut, located on the rear of cylinder block flange.

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

6 Remove the locking pin from the camshaft sprocket. Disengage the timing belt from the sprocket and position it clear, taking care not to bend or twist the belt sharply.

7 Slacken the camshaft sprocket retaining bolt and remove it, along with its washer. To prevent the camshaft rotating as the bolt is slackened, a sprocket holding tool will be required. In the absence of the special Peugeot tool, an acceptable substitute can be fabricated from two lengths of steel strip (one long, the other short) and three nuts and bolts, as follows. One nut and bolt forms the pivot of a forked tool, with the remaining two nuts and bolts at the tips of the forks to engage with the sprocket spokes, as shown in illustration 8.39. Do not attempt to use the sprocket locking pin to prevent the sprocket from rotating whilst the bolt is slackened.

8 With the retaining bolt removed, slide the sprocket off the end of the camshaft. If the locating peg is a loose fit in the rear of the sprocket, remove it for safe-keeping. Examine the camshaft oil seal for signs of oil leakage and, if necessary, renew it as described in Section 9.

Camshaft sprocket - later (1992-on) 1580 cc and 1905 cc (8-valve) models with a manually-adjusted belt tensioner pulley, and all 1761 cc and 1998 cc (8-valve) models 9 On all except 1998 cc 8-valve models, remove the centre timing belt cover as described in Section 6.

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

11 Remove the camshaft sprocket as described above in paragraphs 6 to 8.

Camshaft sprocket(s) -
1905 cc 16-valve models
12 With the timing covers removed, loosen the timing belt front and rear tensioner pulley retaining bolts. Pivot the front pulley in a clockwise direction, using a suitable squaresection key fitted to the hole in the pulley hub, then securely retighten the retaining bolt.

Similarly pivot the rear pulley in an anticlockwise direction and retighten the bolt.

13 Remove the camshaft sprocket retaining bolt as described in paragraphs 6 and 7.

14 Slide the sprocket off the end of the camshaft. If the Woodruff key is a loose fit in the camshaft, remove it and store it with the sprocket for safe-keeping. Examine the camshaft oil seal for signs of oil leakage and, if necessary, renew it (see Section 9).

Camshaft sprocket(s) - 1998 cc 16- valve models
15 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 securely retighten the retaining bolt.

16 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.

17 Remove the camshaft sprocket retaining bolt as described in paragraphs 6 and 7.

18 Slide the sprocket off the end of the camshaft. If the Woodruff key is a loose fit in the camshaft, remove it and store it with the sprocket for safe-keeping. Examine the camshaft oil seal for signs of oil leakage and, if necessary, renew it (see Section 9).

Crankshaft sprocket -
1580 cc, 1761 cc, 1905 cc and 1998 cc 8-valve models
19 Remove the centre and/or lower timing belt cover(s) (as applicable) as described in Section 6.

20 On early (pre-1992) 1580 cc and 1905 cc models with a semi-automatic belt tensioner, release the timing belt tensioner as described above in paragraphs 4 and 5.

21 On later (1992-on) 1580 cc and 1905 cc models with a manually-adjusted belt tensioner pulley, and all 1761 cc and 1998 cc 8-valve models, release the timing belt tensioner as described in paragraph 10.

22 Disengage the timing belt from the crankshaft sprocket, and slide the sprocket off the end of the crankshaft. Remove the Woodruff key from the crankshaft, and store it with the sprocket for safe-keeping. Where necessary, also slide the flanged spacer (where fitted) off the end of the crankshaft.

23 Examine the crankshaft oil seal for signs of oil leakage and, if necessary, renew it as described in Section 16.

Crankshaft sprocket -
1905 cc and 1998 cc 16-valve models 24 Remove the lower timing belt cover as described in Section 6.

25 Release the timing belt tensioners as described above in paragraphs 12 or 15 and 16 (as applicable). Disengage the timing belt from the crankshaft sprocket, and remove the locking pin.

26 To prevent the crankshaft turning whilst the sprocket retaining bolt is being slackened, select 4th gear, and have an assistant apply the brakes firmly. If the engine has been removed from the vehicle, lock the flywheel ring gear using the arrangement shown in illustration 5.3 (Section 5). Do not be tempted to use the locking pin to prevent the crankshaft from rotating.

27 Unscrew the retaining bolt and washer, then slide the sprocket off the end of the crankshaft. If the Woodruff key is a loose fit in the crankshaft, remove it and store it with the sprocket for safe-keeping.

28 Where necessary, slide the flanged spacer (where fitted) off the crankshaft.

29 Examine the crankshaft oil seal for signs of oil leakage and, if necessary, renew it as described in Section 16.

Tensioner assembly - early (pre-1992) 1580 cc and 1905 cc 8-valve models with a semi-automatic belt tensioner 30 Remove the centre timing belt cover as described in Section 6.

31 Slacken and remove the two nuts and washers securing the tensioner assembly to the end of the cylinder block. Carefully ease the spring cover off its studs, taking care not to allow the spring to fly out as the cover is withdrawn. Remove the spring and cover from the engine (see illustration).

8.31 Timing belt tensioner assembly components - early 1580 cc and 1905 cc
8.31 Timing belt tensioner assembly components - early 1580 cc and 1905 cc 8-valve models

32 Slacken and remove the tensioner cam spindle locknut and washer, located on the rear of cylinder block flange, and withdraw the cam spindle.

33 The tensioner pulley and backplate assembly can then be manoeuvred out from behind the timing belt.

Tensioner pulley - later (1992-on) 1580 cc and 1905 cc 8-valve models with a manually-adjusted belt tensioner pulley, and all 1761 cc and 1998 cc 8-valve models
34 On all except 1998 cc 8-valve models, remove the centre timing belt cover as described in Section 6.

35 Slacken and remove the timing belt tensioner pulley retaining bolt, and slide the pulley off its mounting stud. Examine the mounting stud for signs of damage and if necessary, renew it.

Tensioner pulleys -
1905 cc 16-valve models
36 The front and rear tensioner pulleys are removed as described above.

Tensioner pulleys -
1998 cc 16-valve models
37 The rear tensioner pulley is removed as described above.

38 To remove the front tensioner pulley, slacken and remove the two bolts securing the pulley backplate to the cylinder block, and remove the assembly from the engine.

Inspection
39 Clean the camshaft/crankshaft sprockets thoroughly, and renew any that show signs of wear, damage or cracks.

40 Clean the tensioner assembly, but do not use any strong solvent which may enter the pulley bearing. Check that the pulley rotates freely on the backplate, with no sign of stiffness or free play. Renew the assembly if there is any doubt about its condition, or if there are any obvious signs of wear or damage.

41 On early 1580 cc and 1905 cc models, the tensioner spring should also be carefully checked, as its condition is critical for the correct tensioning of the timing belt. The only way to check the spring tension is to compare it with a new one; if there is any doubt as to its condition, the spring should be renewed.

Refitting
Camshaft sprocket - early (pre-1992) 1580 cc and 1905 cc 8-valve models with a semi-automatic belt tensioner 42 Refit the locating peg (where removed) to the rear of the sprocket. Locate the sprocket on the end of the camshaft, ensuring that the locating peg is correctly engaged with the cutout in the camshaft end.

43 Refit the sprocket retaining bolt and washer, and tighten it to the specified torque.

Retain the sprocket with the tool used on removal (see illustration).

8.43 Using a home-made tool for retaining the camshaft sprocket whilst the
8.43 Using a home-made tool for retaining the camshaft sprocket whilst the sprocket bolt is tightened (TU engine shown)

44 Realign the hole in the camshaft sprocket with the corresponding hole in the cylinder head, and refit the locking pin. Check that the crankshaft pulley locking pin is still in position.

45 Refit the timing belt to the camshaft sprocket. Ensure that the front run of the belt is taut - ie, that any slack is on the tensioner pulley side of the belt. Do not twist the belt sharply while refitting it, and ensure that the belt teeth are seated centrally in the sprockets.

46 Release the tensioner cam spindle locknut, and check that the tensioner pulley is forced against the timing belt under spring pressure.

47 Tension the timing belt (see Section 7).

48 With the belt correctly tensioned, and the tensioner retaining nuts and locknut tightened to the specified torque setting, refit the timing belt covers as described in Section 6.

Reconnect the battery on completion.

Camshaft sprocket - later (1992-on) 1580 cc and 1905 cc (8-valve) models with a manually-adjusted belt tensioner pulley, and all 1761 cc and 1998 cc (8-valve) models 49 Refit the camshaft sprocket as described above.

50 With the timing belt correctly engaged on the sprockets, tension the belt as described in Section 7.

51 Once the belt is correctly tensioned, refit the timing belt covers (see Section 6).

Camshaft sprocket(s) - 1905 cc and 1998 cc 16-valve models
52 Refit the Woodruff key to its slot in the camshaft end. Slide on the sprocket, aligning its slot with the Woodruff key.

53 Refit the sprocket retaining bolt and washer. Tighten the bolt to the specified torque, whilst retaining the sprocket with the tool used on removal.

54 Realign the hole in the camshaft sprocket with the corresponding hole in the cylinder head, and refit the locking pin.

55 Relocate the timing belt on the camshaft sprocket(s), and tension the timing belt as described in Section 7.

56 Once the belt is correctly tensioned, refit the timing belt cover (Section 6).

Crankshaft sprocket -
1580 cc, 1761 cc, 1905 cc and 1998 cc 8-valve models
57 Slide on the flanged spacer (where fitted), and refit the Woodruff key to its slot in the crankshaft end.

58 Slide on the crankshaft sprocket, aligning its slot with the Woodruff key.

59 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.

60 Remove the crankshaft pulley. Engage the timing belt with the crankshaft sprocket.

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

61 On early (pre-1992) 1580 cc and 1905 cc models with a semi-automatic tensioner, release the tensioner cam spindle locknut, checking that the tensioner pulley is forced against the timing belt under spring pressure.

Tension the timing belt as described in Section 7.

62 On later (1992-on) 1580 cc and 1905 cc models with a manually-adjusted belt tensioner pulley, and all 1761 cc and 1998 cc 8-valve models, tension the timing belt as described in Section 7.

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

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

Crankshaft sprocket - 1905 cc and 1998 cc 16-valve models
65 Slide on the flanged spacer (where fitted), and refit the Woodruff key to its slot in the crankshaft end.

66 Slide on the crankshaft sprocket, aligning its slot with the Woodruff key.

67 Thoroughly clean the threads of the sprocket retaining bolt, then apply a coat of locking compound to the threads of the bolt.

68 Refit the crankshaft sprocket retaining bolt and washer. Tighten the bolt to the specified torque, whilst preventing crankshaft rotation using the method employed on removal.

69 Refit the locking pin to the crankshaft sprocket, and check that both the camshaft sprocket locking pins are still in position.

70 Relocate the timing belt on the crankshaft sprocket, and tension the timing belt as described in Section 7.

71 Once the belt is correctly tensioned, refit the timing belt cover (see Section 6).

Tensioner assembly - early (pre-1992) 1580 cc and 1905 cc 8-valve models with a semi-automatic belt tensioner 72 Manoeuvre the tensioner pulley and backplate assembly into position behind the timing belt, and locate it on the mounting studs.

73 Insert the tensioner cam spindle through the backplate from the front of the block, and refit its washer and locknut, tightening it by hand only at this stage.

74 Fit the spring to the inside of the spring cover. Compress the spring, and slide the spring cover onto the two mounting studs, ensuring that the spring end is correctly located behind the backplate tang.

75 Refit the tensioner mounting nuts and washers, tightening them by hand only. Check that the tensioner is forced against the timing belt by spring pressure, and is free to move smoothly and easily.

76 Ensure that the front run of the belt is taut - ie, that any slack is on the pulley side of the belt. Check that the belt is centrally located on all its sprockets, then release the tensioner assembly and allow it to tension the belt.

77 Tension the timing belt, and check the valve timing as described in Section 7.

78 With the belt correctly tensioned, and the tensioner retaining nuts and locknut tightened to the specified torque setting, refit the timing belt covers as described in Section 6.

Reconnect the battery on completion.

Tensioner pulley - later (1992-on) 1580 cc and 1905 cc models with a manually-adjusted belt tensioner pulley, and all 1761 cc and 1998 cc 8-valve models
79 Refit the tensioner pulley to its mounting stud, and fit the retaining bolt.

80 Ensure that the front run of the belt is taut - ie, that any slack is on the pulley side of the belt. Check that the belt is centrally located on all its sprockets. Rotate the pulley anti-clockwise to remove all free play from the timing belt, and securely tighten the pulley retaining nut.

81 Tension the belt (see Section 7).

82 Once the belt is correctly tensioned, refit the timing belt covers as described in Section 6.

Tensioner pulleys - 1905 cc 16-valve models
83 Refit the tensioner pulleys to their studs, and fit the retaining bolts. Tighten the bolts finger-tight only, so that both tensioners are free to pivot.

84 Tension the timing belt (see Section 7).

85 Once the belt is correctly tensioned, refit the timing belt cover (see Section 6).

Tensioner pulleys - 1998 cc 16-valve models
86 Refit the rear tensioner pulley to its mounting stud, and fit the retaining bolt. Align the front pulley backplate with its holes, and refit both its retaining bolts. Tighten all retaining bolts finger-tight only, so that both tensioners are free to pivot.

87 Tension the timing belt (see Section 7).

88 Once the belt is correctly tensioned, refit the timing belt cover (see Section 6).


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