How to Replace timing belt on Peugeot 308 2.0i Flex 2012-

Replacement Interval Guide

• Peugeot recommend:
• Replacement every 84,000 miles or 10 years under normal conditions.
• Replacement every 80,000 miles or 10 years under adverse conditions.
• The previous use and service history of the vehicle must always be taken into account.
• Refer to Timing Belt Replacement Intervals at the front of this manual.

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

3,10

Special Tools

• Auxiliary drive belt tensioner locking tool – No.(-).0189-E.
• Auxiliary drive belt tensioner pulley adjusting tool adaptor – No.(-).0189-W.
• Auxiliary drive belt tensioner pulley adjusting tool – No.(-).0188-Z.
• Camshaft timing pin – No.(-).0194-A.
• Flywheel/drive plate locking tool – No.(-).0189-R.
• Timing belt retaining clip – No.(-).0189-K.
• Tensioner pulley adjusting tool – No.(-).0189-S1.
• Tensioner pulley locking tool – No.(-).0189-S2.

Special Precautions

• Disconnect battery earth lead.
• DO NOT turn crankshaft or camshaft when timing belt removed.
• Remove spark 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

WARNING: Engines with variable valve timing: Mark camshaft sprockets and camshaft adjusters with chalk or paint prior to timing belt removal to assist alignment on installation.

1. Raise and support front of vehicle.
2. Remove:
   • Evaporative emission (EVAP) canister purge valve and bracket.
   • Engine top cover.
   • RH front wheel.
   • RH wheel arch liner.
   • Engine undershield.
   • RH support bracket securing chassis to body.
   • Auxiliary drive belt. Use tool Nos.(-).0189-W, (-).0188-Z & (-).0189-E.
3. Support engine.
4. Remove:
   • RH engine mounting.
   • Timing belt upper cover [1] .
5. Turn crankshaft clockwise to setting position.
6. Insert flywheel/drive plate locking tool. Tool No.(-).0189-R:
   • MT: [2] .
   • AT: [3] .

   NOTE: Vehicles with AT: Drive plate locking tool will not fit flush in housing.

7. Insert timing pins in camshaft sprockets [4] & [5] . Tool No.(-).0194-A.
8. Remove:
   • Crankshaft pulley bolt [6] .
   • Crankshaft pulley [7] .
   • Timing belt lower cover [8] .
9. Slacken tensioner pulley bolt [9] .
10. Turn tensioner pulley clockwise. Use Allen key [10] .
11. Remove timing belt.

    NOTE: Timing belt must always be renewed once it has been removed.

Installation

1. Check tensioner pulley, water pump sprocket and guide pulley for smooth operation. Replace if necessary.
2. Ensure flywheel/drive plate locking tool located correctly [2] or [3] .
3. Ensure timing pins located correctly [4] & [5] .
4. Ensure crankshaft sprocket Woodruff key at 9 o’clock position.
5. Turn tensioner pulley clockwise until pointer passes window in baseplate [11] & [12] . Use tool No.(-).0189-S1 [13] .
6. Fit locking tool to tensioner pulley [14] . Tool No.(-).0189-S2.
7. Remove adjusting tool from tensioner pulley [13] .
8. Fit timing belt to crankshaft sprocket.
9. Secure belt to crankshaft sprocket with retaining clip. Tool No.(-).0189-K [15] .
10. Fit timing belt in following order:
    • Guide pulley.
    • Camshaft sprocket (CA1).
    • Camshaft sprocket (CA2).
    • Water pump sprocket.
    • Tensioner pulley.

    NOTE: Ensure timing belt is fitted flush with sprockets and pulleys.

11. Remove tools [15] , [4] & [14] .
12. Fit timing belt lower cover [8] .
13. Fit crankshaft pulley [7] .
14. Clean crankshaft pulley bolt and crankshaft threads.
15. Fit crankshaft pulley bolt [6] . Tightening torque: 40±4 Nm + 53±4°.
16. Turn tensioner pulley anti-clockwise until pointer [16] at position shown [17] . Use Allen key [10] .

    NOTE: The pointer should pass notch [18] by at least 10°. If not, replace tensioner pulley.

17. Tighten tensioner pulley bolt [9] . Tightening torque: 21±2 Nm.WARNING: Hold tensioner pulley during tightening to prevent it from turning. If tensioner pulley turns when bolt is tightened, repeat tensioning procedure.
18. Remove tools [2] or [3] & [5] .
19. Turn crankshaft 10 turns clockwise to setting position.

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

20. Insert flywheel/drive plate locking tool [2] or [3] .
21. Insert timing pin in inlet camshaft sprocket (CA1) [5] .
22. If timing pin cannot be inserted easily, repeat installation and tensioning procedures.
23. Slacken crankshaft pulley bolt [6] .
24. Slacken tensioner pulley bolt [9] whilst holding Allen key [10] .
25. Turn tensioner pulley clockwise until pointer and notch aligned [16] & [18] .

    NOTE: If pointer passes notch [18] , repeat tensioning procedure.

26. Tighten tensioner pulley bolt [9] . Tightening torque: 21±2 Nm.WARNING: Hold tensioner pulley during tightening to prevent it from turning. If tensioner pulley turns when bolt is tightened, repeat tensioning procedure.
27. Fit new crankshaft pulley bolt [6] . Tightening torque: 40±4 Nm + 53±4°.
28. Remove tools [2] or [3] & [5] .
29. Turn crankshaft 2 turns clockwise to setting position.

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

30. Insert timing pin in inlet camshaft sprocket (CA1) [5] .
31. Ensure tensioner pulley pointer and notch aligned [16] & [18] . If not, repeat tensioning procedure.
32. Remove timing pin from inlet camshaft sprocket (CA1) [5] .
33. Install components in reverse order of removal.