How to Replace timing belt on Peugeot 206 1.4 HDi 2001-2009

Replacement Interval Guide

• Peugeot recommend:
• 206/206+:
• →10/04:
• Replacement every 144,000 miles or 10 years under normal conditions.
• Replacement every 120,000 miles or 10 years under adverse conditions.
• 10/04-07:
• Replacement every 160,000 miles or 10 years under normal conditions.
• Replacement every 108,000 miles or 10 years under adverse conditions.
• 2008→:
• Replacement every 160,000 miles or 10 years under normal conditions.
• Replacement every 112,500 miles or 10 years under adverse conditions.
• 307:
• Replacement every 144,000 miles or 10 years under normal conditions.
• Replacement every 120,000 miles or 10 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.

Repair Times – hrs

Remove & install:
206/206+	2,60
307	2,80

Special Tools

• Camshaft sprocket locking tool – Peugeot No.(-).0194.B.
• Flywheel locking tool – Peugeot No.(-).0194.C.
• Crankshaft/high-pressure fuel pump aligning tool – Peugeot No.(-).0194.A.

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

1. Raise and support front of vehicle.
2. Remove:
   • RH front wheel.
   • RH inner wing panel.
3. Disconnect wiring harness from timing belt upper cover.
4. Remove:
   • Auxiliary drive belt.
   • Timing belt upper cover [1] .
   • Blanking plug from bell housing.
5. Turn crankshaft until flywheel locking tool can be inserted.
6. Fit flywheel locking tool. Tool No.(-).0194.C [2] .
7. Remove:
   • Crankshaft position (CKP) sensor.
   • Timing belt guide [3] .
   • Crankshaft pulley bolt [4] .
   • Crankshaft pulley [5] .
   • Timing belt lower cover [6] .
   • Flywheel locking tool [2] .
8. Fit crankshaft pulley bolt [4] .
9. Turn crankshaft slowly clockwise until camshaft sprocket timing hole aligned [7] .
10. Fit camshaft sprocket locking tool. Tool No.(-).0194.B [7] .
11. Insert crankshaft aligning tool. Tool No.(-).0194.A [8] .
12. Remove crankshaft aligning tool [8] .
13. Insert high-pressure fuel pump aligning tool [9] . Tool No.(-).0194.A.
14. Remove high-pressure fuel pump aligning tool [9] .
15. Support engine.
16. Remove RH engine mounting and bracket.
17. Slacken tensioner pulley bolt [10] .
18. Remove timing belt.NOTE: Ensure crankshaft position (CKP) sensor reluctor is not damaged.

Installation

1. Check tensioner pulley, guide pulley and water pump sprocket for smooth operation.
2. Ensure camshaft sprocket locking tool located correctly [7] .
3. Ensure high-pressure fuel pump sprocket aligned correctly [9] . Use tool No.(-).0194.A.
4. Ensure crankshaft aligning tool located correctly [8] .
5. Fit timing belt in following order:
   • Crankshaft sprocket.
   • Guide pulley.
   • Camshaft sprocket.
   • Water pump sprocket.
   • High-pressure fuel pump sprocket.
   • Tensioner pulley.
6. Turn tensioner pulley anti-clockwise until pointer aligned in window [11] . Use Allen key.
7. Tighten tensioner pulley bolt [10] . Tightening torque: 25 Nm.
8. Remove camshaft sprocket locking tool [7] .
9. Remove crankshaft aligning tool [8] .
10. Ensure high-pressure fuel pump sprocket aligned correctly [9] . Use tool No.(-).0194.A.
11. Turn crankshaft slowly ten turns clockwise.NOTE: Ensure crankshaft sprocket remains in position.
12. Insert:
    • Camshaft sprocket locking tool [7] .
    • Crankshaft aligning tool [8] .
13. Remove crankshaft aligning tool [8] .
14. Insert high-pressure fuel pump aligning tool [9] .
15. Remove:
    • Camshaft sprocket locking tool [7] .
    • High-pressure fuel pump aligning tool [9] .
16. If tools cannot be inserted: Repeat installation procedure.
17. Ensure tensioner pulley pointer aligned in window [11] .
18. If not: Repeat installation procedure.
19. Install components in reverse order of removal.
20. Tighten crankshaft pulley bolt [4] . Tightening torque:
    • 206/307 – A: 30 Nm + 180°.
    • 206+ – B: 35 Nm + 190°.