How to Replace timing belt on Peugeot 206 2.0 HDi -2001

Replacement Interval Guide

• Peugeot recommend:
• 206:
• Replacement every 96,000 miles or 10 years under normal conditions.
• Replacement every 80,000 miles or 10 years under adverse conditions.
• 306:
• Replacement every 96,000 miles or 5 years under normal conditions.
• Replacement every 80,000 miles or 5 years under adverse conditions.
• 307:
• Replacement every 96,000 miles or 10 years under normal conditions.
• Replacement every 72,000 miles or 10 years under adverse conditions.
• 406:
• Replacement every 96,000 miles or 10 years under normal conditions.
• Replacement every 72,000 miles or 5 years under adverse conditions.
• 806:
• Replacement every 72,000 miles or 5 years under normal conditions.
• Replacement every 60,000 miles or 5 years under adverse conditions.
• Expert:
• Replacement every 96,000 miles or 10 years under normal conditions.
• Replacement every 72,000 miles or 5 years under adverse conditions.
• The previous use and service history of the vehicle must always be taken into account.

Check For Engine Damage

CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head(s).

Repair Times – hrs

Remove & install:
206/307	3,30
306	3,80
406	4,40
806	4,50
Expert	4,50

Special Tools

• Flywheel locking tool – Peugeot No.(-).0188-F.
• Crankshaft pulley puller – Peugeot No.(-).0188-P2.
• Flywheel timing pin – Peugeot No.(-).0188-Y.
• Camshaft timing pin – Peugeot No.(-).0188-M.
• Timing belt retaining clip – Peugeot No.(-).0188-K.
• Tensioning tool – Peugeot No.(-).0188-J2.
• Tension gauge – SEEM C.Tronic 105.5.
• Set of blanking plugs – Peugeot No.(-).0188-T.

Special Precautions

• Disconnect battery earth lead.
• DO NOT turn crankshaft or camshaft when timing belt removed.
• Remove glow plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• DO NOT turn engine via camshaft or other sprockets.
• Observe all tightening torques.

Removal

NOTE: The high-pressure fuel pump fitted to this engine does not require timing.

1. Raise and support front of vehicle.
2. Disconnect exhaust front pipe from manifold.
3. Remove:
   • RH front wheel.
   • RH splash guard.
   • Engine upper cover.
   • Auxiliary drive belt.
   • Turbocharger air hoses.
   • Flywheel housing lower cover.
4. Lock flywheel. Use tool No.(-).0188-F.
5. Remove:
   • Emission filter from pre-catalytic converter (if fitted).
   • Crankshaft pulley bolt [1] .
   • Crankshaft pulley [2] . Use tool No.(-).0188-P2.
   • Flywheel locking tool.
   • Lower torque reaction link.
6. Reposition:
   • Except 307/Expert: Coolant expansion tank. DO NOT disconnect hoses.
   • Except 307/Expert: Engine control module (ECM) and tray (leave harness multi-plug connected).
   • Expert: Wiring harness and PAS reservoir.
7. Disconnect and seal off fuel pipes. Use tool No.(-).0188-T.
8. Support engine.
9. Remove:
   • RH engine mounting and bracket.
   • Timing belt covers [3] , [4] & [5] .
10. Turn crankshaft clockwise to setting position.
11. Insert timing pin in flywheel [6] . Tool No.(-).0188-Y.
12. Insert timing pin in camshaft sprocket [7] . Tool No.(-).0188-M.
13. Slacken tensioner bolt [8] .
14. Turn tensioner pulley clockwise away from belt. Use tool No.(-).0188-J2.
15. Lightly tighten tensioner bolt [8] .
16. Remove timing belt.

Installation

1. Check tensioner pulley and guide pulley for smooth operation.
2. Ensure timing pins located correctly [6] & [7] .
3. Slacken camshaft sprocket bolts [9] . Tighten bolts finger tight, then slacken 1/6 turn.
4. Turn camshaft sprocket fully clockwise in slotted holes.

   NOTE: Sprocket should turn with slight resistance.

5. Fit timing belt to crankshaft sprocket.
6. Secure belt to crankshaft sprocket with retaining clip. Tool No.(-).0188-K [10] .
7. Fit timing belt in anti-clockwise direction. Ensure belt is taut between sprockets.
8. Lay belt on camshaft sprocket teeth. Engage belt teeth by turning sprocket slightly anti-clockwise.

   NOTE: Angular movement of sprocket must not be more than one tooth space [11] .

9. Fit timing belt to water pump sprocket and tensioner pulley.
10. Slacken tensioner bolt [8] .
11. Turn tensioner pulley anti-clockwise to temporarily tension belt. Use tool No.(-).0188-J2.
12. Lightly tighten tensioner bolt [8] . Tightening torque: 10 Nm.
13. Remove retaining clip [10] .
14. Attach tension gauge to belt at  [12] . Tool No.SEEM C-Tronic 105.5.
15. Turn tensioner pulley anti-clockwise until tension gauge indicates 98±2 SEEM units.
16. Tighten tensioner bolt [8] . Tightening torque: 25 Nm.
17. Remove tension gauge [12] .
18. Ensure sprocket bolts not at end of slotted holes [13] .
19. If necessary: Repeat installation procedure.
20. Tighten camshaft sprocket bolts [9] . Tightening torque: 20 Nm.
21. Remove timing pins [6] & [7] .
22. Turn crankshaft eight turns clockwise to setting position.

    NOTE: DO NOT allow crankshaft to turn anti-clockwise.

23. Insert timing pins [6] & [7] .
24. Slacken camshaft sprocket bolts [9] . Tighten bolts finger tight, then slacken 1/6 turn.
25. Slacken tensioner bolt to release tension on belt [8] .
26. Attach tension gauge to belt at  [12] .
27. Turn tensioner pulley anti-clockwise until tension gauge indicates 54±2 SEEM units.
28. Hold tensioner pulley in position. Tighten tensioner bolt [8] . Tightening torque: 25 Nm.
29. Tighten camshaft sprocket bolts [9] . Tightening torque: 20 Nm.
30. Remove tension gauge [12] .
31. Check belt tension. Attach tension gauge to belt at  [12] . Tension gauge should indicate 51-57 SEEM units.
32. If not: Repeat tensioning procedure.
33. Remove tension gauge [12] .
34. Remove timing pins [6] & [7] .
35. Turn crankshaft two turns clockwise to setting position.
36. Insert timing pins [6] & [7] .

    NOTE: Ensure timing pins can be inserted easily.

37. Remove timing pins [6] & [7] .
38. Install components in reverse order of removal.
39. Clean crankshaft pulley bolt and crankshaft threads.
40. Coat crankshaft pulley bolt with suitable thread locking compound.
41. Tighten crankshaft pulley bolt [1] :
    • 206/306/307 DW10TD: Tightening torque: 40 Nm + 51°. Check torque setting of crankshaft pulley bolt is 195 Nm.
    • 307 DW10ATED/406/806/Expert: Tightening torque: 50 Nm + 62°. Check torque setting of crankshaft pulley bolt is 145 Nm.