Peugeot 205 Manual

Timing belt tensioner and sprockets - removal, inspection and refitting
XU series engine in-car repair procedures / Timing belt tensioner and sprockets - removal, inspection and refitting


Removal
Camshaft sprocket
1 Remove the timing belt as described in Section 4.

2 Remove the locking pin from the camshaft sprocket, slacken the sprocket retaining bolt and remove it, along with its washer. To prevent the camshaft rotating as the bolt is slackened, restrain the sprocket with a suitable tool through the holes in the sprocket face (see Tool Tip). Do not attempt to use the sprocket locking pin to prevent the sprocket from rotating whilst the bolt is slackened.

3 With the retaining bolt removed, slide the sprocket off the end of the camshaft. If the locating peg is a loose fit in the rear of the sprocket, remove it for safe-keeping. Examine the camshaft oil seal for signs of oil leakage and, if necessary, renew it as described in Section 6.

Crankshaft sprocket
4 Remove the timing belt as described in Section 4.

5 Slide the sprocket off the end of the crankshaft. Remove the Woodruff key from the crankshaft, and store it with the sprocket for safe-keeping. Where necessary, also slide the spacer (where fitted) off the end of the crankshaft.

6 Examine the crankshaft oil seal for signs of oil leakage and, if necessary, renew it as described in Section 12.

Tensioner assembly (models with spring-loaded tensioner) 7 Remove the timing belt as described in Section 4.

8 Undo the two bolts at the front and single nut at the rear and withdraw the spring housing spring and tensioner pulley. Take care to keep the spring under control as the bolts are undone to prevent it flying out.

Tensioner assembly (models with eccentric roller tensioner) 9 Remove the timing belt as described in Section 4.

10 Slacken and remove the timing belt tensioner pulley retaining bolt, and slide the pulley off its mounting stud. Examine the mounting stud for signs of damage and if necessary, renew it.

Inspection
11 Clean the camshaft/crankshaft sprockets thoroughly, and renew any that show signs of wear, damage or cracks.

12 Clean the tensioner assembly, but do not use any strong solvent which may enter the pulley bearing. Check that the pulley rotates freely on the backplate, with no sign of stiffness or free play (see illustration).

5.12 Spring loaded timing belt tensioner components
5.12 Spring loaded timing belt tensioner components

Renew the assembly if there is any doubt about its condition, or if there are any obvious signs of wear or damage.

Refitting
Camshaft sprocket
13 Refit the locating peg (where removed) to the rear of the sprocket. Locate the sprocket on the end of the camshaft, ensuring that the locating peg is correctly engaged with the cut-out in the camshaft end.

14 Refit the sprocket retaining bolt and washer, and tighten it to the specified torque.

Retain the sprocket with the tool used on removal. Note that on early models the sprocket is secured with an M12 bolt whereas this has been reduced to M10 on later engines. Ensure that the correct torque wrench setting is used according to bolt type.

15 Realign the hole in the camshaft sprocket with the corresponding hole in the cylinder head, and refit the locking pin. Check that the crankshaft pulley locking pin is still in position.

16 Refit the timing belt (Section 4).

Crankshaft sprocket
17 Slide the spacer (where fitted) into position, taking great care not to damage the crankshaft oil seal, and refit the Woodruff key to its slot in the crankshaft end.

18 Slide on the crankshaft sprocket, aligning its slot with the Woodruff key.

19 Refit the timing belt (Section 4).

Tensioner assembly (models with spring-loaded tensioner) 20 Assemble the tensioner spring, spring housing and pulley then locate the assembly on the engine.

21 Fit the front bolts and rear locknut finger tight only. Use a spanner on the square end of the tensioner cam spindle to turn the cam to the horizontal position and so compress the tensioner spring. Tighten the cam locknut.

22 Refit the timing belt (Section 4).

Tensioner assembly (models with eccentric roller tensioner) 23 Refit the tensioner pulley to its mounting stud, and fit the retaining bolt.

24 Refit the timing belt (Section 4).


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