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

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.

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