How to Replace timing belt on Peugeot 206 1.6 HDi 2004-2007

Replacement Interval Guide

• Peugeot recommend:
• →2007:
• Replacement every 144,000 miles or 10 years under normal conditions.
• Replacement every 120,000 miles or 10 years under adverse conditions.
• 2008:
• Replacement every 150,000 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	2,70
307	2,30

Special Tools

• Camshaft sprocket locking tool – Peugeot No.(-).0194-B.
• Crankshaft aligning tool – Peugeot No.(-).0194-A.
• Flywheel locking tool – Peugeot No.(-).0194-C.
• High-pressure fuel pump sprocket locking tool (Bosch pump) – Peugeot No.(-).0194-A 1.

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 wheel arch liner.
   • Auxiliary drive belt.
3. Fit flywheel locking tool [1] . Tool No.(-).0194-C. Ensure flywheel locked with tool. If not: Turn crankshaft slowly clockwise.
4. Disconnect wiring harness from timing belt upper cover.
5. Remove:
   • Crankshaft pulley bolt [2] .
   • Crankshaft pulley [3] .
   • Flywheel locking tool [1] .
6. Support engine.
7. Remove:
   • RH engine mounting and bracket.
   • Timing belt lower cover [4] .
   • Timing belt upper cover [5] .
   • Timing belt guide [6] .
   • Crankshaft position (CKP) sensor.

   NOTE: Ensure reluctor is not damaged [7] .

8. Fit crankshaft pulley bolt [2] .
9. Turn crankshaft slowly clockwise until camshaft sprocket timing hole at 10 o’clock position [8] .
10. Fit camshaft sprocket locking tool [9] . Tool No.(-).0194-B.
11. Insert crankshaft aligning tool [10] . Tool No.(-).0194-A.
12. Fit high-pressure fuel pump sprocket locking tool [11] . Tool No.(-).0194-A 1 (Bosch pump).
13. Slacken tensioner pulley bolt [12] .
14. Turn tensioner pulley clockwise to release tension on belt. Use Allen key [13] .
15. Remove timing belt.

Installation

1. Check tensioner pulley, guide pulley and water pump sprocket for smooth operation.
2. Ensure camshaft sprocket locking tool located correctly [9] .
3. Ensure crankshaft aligning tool located correctly [10] .
4. Ensure high-pressure fuel pump sprocket locking tool located correctly [11] .
5. Fit timing belt in following order:
   • Crankshaft sprocket.
   • Guide pulley.
   • Camshaft sprocket.
   • High-pressure fuel pump sprocket.
   • Water pump sprocket.
   • Tensioner pulley.
6. Tighten tensioner pulley bolt [12] . Tightening torque: 25 Nm.
7. Install:
   • Timing belt guide [6] .
   • Crankshaft position (CKP) sensor.

   NOTE: Ensure reluctor is not damaged [7] .

8. Slacken tensioner pulley bolt [12] .
9. Turn tensioner pulley anti-clockwise until pointer aligned in window [14] . Use Allen key [13] .
10. Tighten tensioner pulley bolt [12] . Tightening torque: 25 Nm.
11. Remove:
    • Camshaft sprocket locking tool [9] .
    • Crankshaft aligning tool [10] .
    • High-pressure fuel pump sprocket locking tool [11] .
12. Turn crankshaft slowly ten turns clockwise.
13. Insert:
    • Camshaft sprocket locking tool [9] .
    • Crankshaft aligning tool [10] .
    • High-pressure fuel pump sprocket locking tool [11] .
14. Ensure tensioner pulley pointer aligned in window [14] . If not: Repeat installation procedure.
15. Remove:
    • Camshaft sprocket locking tool [9] .
    • Crankshaft aligning tool [10] .
    • High-pressure fuel pump sprocket locking tool [11] .
16. Fit flywheel locking tool [1] .
17. Remove crankshaft pulley bolt [2] .
18. Fit:
    • Timing belt upper cover [5] .
    • Timing belt lower cover [4] .
    • Crankshaft pulley [3] .
    • Crankshaft pulley bolt [2] . Tightening torque: 27-33 Nm + 180°.
19. Remove flywheel locking tool [1] .
20. Install components in reverse order of removal.