How to Replace timing belt on Peugeot 406 2.2 2004

Peugeot 406 2.2 2004 cambelt change instructions and replacement inteval. Full guide!

Special tools

• Crankshaft timing pin – Peugeot No.(-).0189-B.
• Exhaust camshaft timing pin – Peugeot No.(-).0189-AZ.
• Inlet camshaft timing pin – Peugeot No.(-).0189-L.
• Timing belt retaining clip – Peugeot No.(-).0189-K.
• Tensioner positioning tool – Peugeot No.(-).0189-J.
• Crankshaft locking tools – Peugeot No.(-).0606-A1 & (-).0606-A2.

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.

Repair times – hrs

Camshaft drive belt/chain – R & I

2,20

Valve timing procedures

Removal

1. Raise and support front of vehicle.
2. Remove:
   • Engine upper cover (if fitted).
   • RH front wheel.
   • RH splash guard.
   • Auxiliary drive belt.
   • Engine torque reaction link.
3. Support engine (406).
   NOTE: To prevent exhaust damage, ensure engine remains in initial position.
4. Remove RH engine mounting (406).
5. Remove:
   • Timing belt upper cover [1] .
   • Crankshaft pulley bolts [2] .
   • Crankshaft pulley [3] .
   • Timing belt lower cover [4] .
6. Turn crankshaft clockwise to setting position.
7. Insert timing pin in crankshaft pulley hub [5] . Tool No.(-).0189-B.
8. Insert timing pin in exhaust camshaft sprocket [6] . Tool No.(-).0189-AZ.
9. Insert timing pin in inlet camshaft sprocket [7] . Tool No.(-).0189-L.
10. DO NOT slacken inlet camshaft sprocket bolts [8] .
11. Slacken tensioner pulley bolt [9] .
12. Unhook tensioner pulley bracket from cylinder block rib [10] .
13. Move tensioner pulley away from belt.
14. Remove timing belt.
    NOTE: Timing belt must always be renewed once it has been removed.

Installation

NOTE: Belt adjustment must be carried out when engine is cold.

1. Ensure timing pins located correctly [5] , [6] & [7] .
2. Fit timing belt to crankshaft sprocket.
   NOTE: Ensure arrow on belt faces direction of rotation.
3. Secure belt to crankshaft sprocket with retaining clip. Tool No.(-).0189-K [11] .
4. Fit timing belt to remaining sprockets and pulleys in following order:
   • Guide pulley.
   • Inlet camshaft sprocket.
   • Exhaust camshaft sprocket.
   • Water pump sprocket.
   • Tensioner pulley.

   NOTE: Ensure belt is taut between sprockets.

5. Fit tensioner pulley bracket to cylinder block rib [10] .
6. Tighten tensioner pulley bolt finger tight [9] .
7. Remove timing belt retaining clip [11] .
8. Turn tensioner anti-clockwise until belt tensioned to maximum. Use Allen key [12] . Ensure pointer positioned as shown [13] .
9. Ensure pointer moves away from notch by at least 10° [14] . If not, replace tensioner pulley.
10. Insert tensioner positioning tool [15] . Tool No.(-).0189-J.
11. Turn tensioner clockwise until pointer and positioning tool are just touching [15] & [16] . Use Allen key [12] .
    NOTE: Pointer and notch are also aligned.
12. Tighten tensioner pulley bolt [9] . Tightening torque: 20 Nm.
13. Remove tensioner positioning tool [15] .
14. Remove timing pins [5] , [6] & [7] .
15. Turn crankshaft ten turns clockwise to setting position.
    NOTE: DO NOT allow crankshaft to turn anti-clockwise.
16. Ensure pointer and notch aligned [16] .
17. If not: Repeat tensioning procedure.
18. Insert timing pin in inlet camshaft sprocket [7] .
19. Insert timing pin in crankshaft pulley hub [5] .
20. If timing pin [5] cannot be inserted, reposition crankshaft pulley hub as follows:
    • Lock crankshaft pulley hub. Use tool Nos.(-).0606-A1/A2 [17] .
    • Slacken crankshaft pulley hub bolt [18] .
    • Turn crankshaft pulley hub until timing pin can be inserted [5] . Use tool Nos.(-).0606-A1/A2 [17] .
21. Tighten crankshaft pulley hub bolt [18] . Tightening torque:
    • (A) 406 – 130±13 Nm.
    • (B) 607 – 40±4 Nm + 53±4°.
22. Remove timing pins [5] & [7] .
23. Install components in reverse order of removal.
24. Tighten crankshaft pulley bolts [2] . Tightening torque: 20 Nm.
25. 406: Tighten RH engine mounting:
    • Three bolts securing intermediate bracket to engine bracket – 61 Nm.
    • Nut securing engine mounting to intermediate bracket – 45 Nm.
26. Tighten engine torque reaction link bolts. Tightening torque: 45 Nm.