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How to Replace timing chain 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

How to Replace timing belt on Peugeot 406 2.2 2004
How to Replace timing belt on Peugeot 406 2.2 2004

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.
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