Peugeot 405. Manual - part 12

rotate the crankshaft slightly, to get the holes
to align.
5 With the flywheel correctly positioned,
insert a 10 mm diameter bolt or a drill through
the timing hole in the camshaft sprocket, and
locate it in the hole in the cylinder head (see
illustration).
6 The crankshaft and camshaft are now
locked in position, preventing unnecessary
rotation.

4

Cylinder head cover -
removal and refitting

2

Removal

1 Disconnect the battery negative lead.
2 Where necessary, undo the bolts securing

the HT lead retaining clips to the rear of the
cylinder head cover, and position the clips
clear of the cover.
3 Slacken the retaining clip, and disconnect
the breather hose from the left-hand end of
the cylinder head cover (see illustration).
Where the original crimped-type Peugeot
hose clip is still fitted, cut it off and discard it.
Use a standard worm-drive clip on refitting.
4 Undo the two retaining nuts, and remove
the washer from each of the cylinder head
cover studs (see illustration).
5 Lift off the cylinder head cover, and remove
it along with its rubber seal (see illustration).
Examine the seal for signs of damage and
deterioration, and if necessary, renew it.
6 Lift off the spacer from each stud, and
remove the oil baffle plate (see illustrations).

Refitting

7 Carefully clean the cylinder head and cover
mating surfaces, and remove all traces of oil.
8 Fit the rubber seal over the edge of the
cylinder head cover, ensuring that it is
correctly located along its entire length (see
illustration).
9 Refit the oil baffle plate to the engine, and
locate the spacers in their recesses in the
baffle plate.
10 Carefully refit the cylinder head cover to
the engine, taking great care not to displace
the rubber seal.
11 Check that the seal is correctly located,
then refit the washers and cover retaining
nuts, and tighten them to the specified torque.
12 Where necessary, refit the HT lead clips to

the rear of the head cover, and securely
tighten their retaining bolts.
13 Reconnect the breather hose to the
cylinder head cover, securely tightening its
retaining clip, and reconnect the battery
negative lead.

5

Timing belt covers - removal
and refitting

2

Removal

Upper cover

1 Slacken and remove the two retaining bolts
(one at the front and one at the rear), and
remove the upper timing cover from the
cylinder head (see illustrations).

Centre cover

2 Remove the upper cover as described in
paragraph 1, then free the wiring from its clips
on the centre cover (see illustration).
3 Slacken and remove the three retaining
bolts (one at the rear of the cover, beneath the
engine mounting plate, and two directly above
the crankshaft pulley), and manoeuvre the
centre cover out from the engine
compartment 

(see illustration).

Lower cover

4 Remove the auxiliary drivebelt as described
in Chapter 1.
5 Remove the upper and centre covers as
described in paragraphs 1 to 3.

4.8  On refitting, ensure the rubber seal is

located on the cylinder head cover

2A•4 TU engine in-car repair procedures

3.5  . . . then insert a 10 mm bolt through

the cam sprocket timing hole, and locate it

in the cylinder head

4.4  . . . then slacken and remove the cover

retaining nuts and washers (arrowed) . . .

4.6b  . . . and remove the oil baffle plate

4.6a  Lift off the spacers 

(second one arrowed) . . .

4.5  . . . and lift off the cylinder head cover

4.3  Disconnect the breather hose from the

cylinder head cover . . .

6 Undo the three crankshaft pulley retaining
bolts and remove the pulley, noting which way
round it is fitted (see illustrations).
7 Slacken and remove the single retaining
bolt, and slide the lower cover off the end of
the crankshaft (see illustration).

Refitting

Upper cover

8 Refit the cover, ensuring it is correctly
located with the centre cover, and tighten its
retaining bolts.

Centre cover

9 Manoeuvre the centre cover back into
position, ensuring it is correctly located with
the lower cover, and tighten its retaining bolts.
10 Clip the wiring loom into its retaining clips
on the front of the centre cover, then refit the
upper cover as described in paragraph 8.

Lower cover

11 Locate the lower cover over the timing
belt sprocket, and tighten its retaining bolt.
12 Fit the pulley to the end of the crankshaft,
ensuring it is fitted the correct way round, and
tighten its retaining bolts to the specified
torque.
13 Refit the centre and upper covers as
described above, then refit and tension the
auxiliary drivebelt as described in Chapter 1.

6

Timing belt - 
general information, 
removal and refitting

4

Note: Peugeot specify the use of a special
electronic tool (SEEM C.TRONIC type 105 or
105.5 belt tensioning measuring tool) to
correctly set the timing belt tension. If access
to this equipment cannot be obtained, an
approximate setting can be achieved using
the method described below. If the method
described is used, the tension must be
checked using the special electronic tool at
the earliest possible opportunity. Do not drive
the vehicle over large distances, or use high
engine speeds, until the belt tension is known
to be correct. Refer to a Peugeot dealer for
advice.

General information

1 The timing belt drives the camshaft and
coolant pump from a toothed sprocket on the
front of the crankshaft. If the belt breaks or
slips in service, the pistons are likely to hit the

valve heads, resulting in extensive (and
expensive) damage.
2 The timing belt should be renewed at the
specified intervals (see Chapter 1), or earlier if
it is contaminated with oil, or if it is at all noisy
in operation (a “scraping” noise due to uneven
wear).
3 If the timing belt is being removed, it is a
wise precaution to check the condition of the
coolant pump at the same time (check for
signs of coolant leakage). This may avoid the
need to remove the timing belt again at a later
stage, should the coolant pump fail.

Removal

4 Disconnect the battery negative terminal.
5 Align the engine assembly/valve timing
holes as described in Section 3, and lock both
the camshaft sprocket and the flywheel in
position. Do not attempt to rotate the engine
whilst the locking tools are in position.
6 Remove the timing belt centre and lower
covers as described in Section 5.
7 Loosen the timing belt tensioner pulley
retaining nut. Pivot the pulley in a clockwise
direction, using a square-section key fitted to
the hole in the pulley hub, then retighten the
retaining nut.
8 If the timing belt is to be re-used, use white
paint or similar to mark the direction of
rotation on the belt (if markings do not already
exist) (see illustration). Slip the belt off the
sprockets.
9 Check the timing belt carefully for any signs
of uneven wear, splitting, or oil contamination.
Pay particular attention to the roots of the
teeth. Renew the belt if there is the slightest

TU engine in-car repair procedures  2A•5

5.2  Free the wiring loom from its 

retaining clip . . .

5.6b  . . . and remove the crankshaft pulley

5.6a  Undo the three retaining bolts

(arrowed) . . .

5.3  . . . then undo the three bolts (locations

arrowed) and remove the centre belt cover

5.1b  . . . and remove the 

upper timing belt cover

5.1a  Undo the two retaining bolts

(arrowed) . . .

2A

5.7  Undo the retaining bolt and remove

the lower timing belt cover

doubt about its condition. If the engine is
undergoing an overhaul, and has covered
more than 36 000 miles (60 000 km) with the
existing belt fitted, renew the belt as a matter
of course, regardless of its apparent
condition. The cost of a new belt is nothing
when compared to the cost of repairs, should
the belt break in service. If signs of oil
contamination are found, trace the source of
the oil leak, and rectify it. Wash down the
engine timing belt area and all related
components, to remove all traces of oil.

Refitting

10 Prior to refitting, thoroughly clean the
timing belt sprockets. Check that the
tensioner pulley rotates freely, without any
sign of roughness. If necessary, renew the
tensioner pulley as described in Section 7.
Make sure that the locking tools are still in
place, as described in Section 3.
11 Manoeuvre the timing belt into position,
ensuring the arrows on the belt are pointing in
the direction of rotation (clockwise, when
viewed from the right-hand end of the engine).
12 Do not twist the timing belt sharply while
refitting it. Fit the belt over the crankshaft and
camshaft sprockets. Make sure that the “front
run” of the belt is taut - ie, ensure that any
slack is on the tensioner pulley side of the
belt. Fit the belt over the coolant pump
sprocket and tensioner pulley. Ensure that the
belt teeth are seated centrally in the
sprockets.
13 Loosen the tensioner pulley retaining nut.
Pivot the pulley anti-clockwise to remove all
free play from the timing belt, then retighten
the nut. Tension the timing belt as described
under the relevant sub-heading.

Tensioning without the special
electronic measuring tool

Note: If this method is used, ensure that the
belt tension is checked by a Peugeot dealer at
the earliest possible opportunity.
14 Peugeot dealers use a special tool to
tension the timing belt. A similar tool may be
fabricated using a suitable square-section bar
attached to an arm made from a metal strip; a
hole should be drilled in the strip at a distance
of 80 mm from the centre of the square-
section bar. Fit the tool to the hole in the

tensioner pulley, keeping the tool arm as close
to the horizontal as possible, and hang a 1.5
kg (3.3 lb) weight (aluminium block engine) or
2.0 kg (4.4 lb) weight (cast-iron block engine)
from the hole in the tool (see illustration). In
the absence of an object of the specified
weight, a spring balance can be used to exert
the required force, ensuring that the spring
balance is held at 90° to the tool arm. Slacken
the pulley retaining nut, allowing the weight or
force exerted (as applicable) to push the
tensioner pulley against the belt, then
retighten the pulley nut.
15 If this special tool is not available, an
approximate setting may be achieved by
pivoting the tensioner pulley anti-clockwise
until it is just possible to twist the timing belt
through 90° by finger and thumb, midway
between the crankshaft and camshaft
sprockets. The deflection of the belt at the
mid-point between the sprockets should be
approximately 6.0 mm.
16 Remove the locking tools from the
camshaft sprocket and flywheel.
17 Using a suitable socket and extension bar
on the crankshaft sprocket bolt, rotate the
crankshaft through four complete rotations in
a clockwise direction (viewed from the right-
hand end of the engine). Do not at any time
rotate the crankshaft anti-clockwise.
18 Slacken the tensioner pulley nut, re-
tension the belt as described in paragraph 14
or 15, then tighten the tensioner pulley nut to
the specified torque.
19 Rotate the crankshaft through a further
two turns clockwise, and check that both the
camshaft sprocket and flywheel timing holes
are still correctly aligned.
20 If all is well, refit the timing belt covers as
described in Section 5, and reconnect the
battery negative terminal.

Tensioning using the special
electronic measuring tool

21 Fit the special belt tensioning measuring
equipment to the “front run” of the timing belt,
approximately midway between the camshaft
and crankshaft sprockets. Position the
tensioner pulley so that the belt is tensioned
to a setting of 45 units, then retighten its
retaining nut.
22 Remove the locking tools from the
camshaft sprocket and flywheel, and remove
the measuring tool from the belt.
23 Using a suitable socket and extension bar
on the crankshaft sprocket bolt, rotate the
crankshaft through four complete rotations in
a clockwise direction (viewed from the right-
hand end of the engine). Do not at any time
rotate the crankshaft anti-clockwise.
24 Slacken the tensioner pulley retaining nut,
and refit the measuring tool to the belt. If a
“new” belt is being fitted, tension it to a
setting of 40 units. If an “old” belt is being re-
used, tighten it to a setting of 36 units. Note:
Peugeot state that a belt becomes “old” after
1 hour’s use.

With the belt correctly

tensioned, tighten the pulley retaining nut to
the specified torque.
25 Remove the measuring tool from the belt,
then rotate the crankshaft through another
two complete rotations in a clockwise
direction, so that both the camshaft sprocket
and flywheel timing holes are realigned. Do
not at any time rotate the crankshaft anti-
clockwise. Fit the measuring tool to the belt,
and check the belt tension. A “new” belt
should give a reading of 51 ± 3 units; an “old”
belt should be 45 ± 3 units.
26 If the belt tension is incorrect, repeat the
procedures in paragraphs 24 and 25.
27 With the belt tension correctly set, refit the
timing belt covers as described in Section 5,
and reconnect the battery negative terminal.

7

Timing belt tensioner and
sprockets - removal,
inspection and refitting

4

Note: This Section describes the removal and
refitting of the components concerned as
individual operations. If more than one of them
is to be removed at the same time, start by
removing the timing belt as described in
Section 6; remove the actual component as
described below, ignoring the preliminary
dismantling steps.

Removal

1 Disconnect the battery negative terminal.
2 Position the engine assembly/valve timing
holes as described in Section 3, and lock both
the camshaft sprocket and flywheel in
position. Do not attempt to rotate the engine
whilst the pins are in position.

Camshaft sprocket

3 Remove the centre timing belt cover as
described in Section 5.

2A•6 TU engine in-car repair procedures

6.8  Mark the direction of rotation on the

belt, if it is to be re-used

6.14  Using the Peugeot special tool to

tension the timing belt

4 Loosen the timing belt tensioner pulley
retaining nut. Rotate the pulley in a clockwise
direction, using a suitable square-section key
fitted to the hole in the pulley hub, then
retighten the retaining nut.
5 Disengage the timing belt from the
sprocket, and move the belt clear, taking care
not to bend or twist it sharply. Remove the
locking pin from the camshaft sprocket.
6 Slacken the camshaft sprocket retaining
bolt and remove it, along with its washer. To
prevent the camshaft rotating as the bolt is
slackened, a sprocket-holding tool will be
required. In the absence of the special
Peugeot tool, an acceptable substitute can be
fabricated as follows. Use two lengths of steel
strip (one long, the other short), and three nuts
and bolts; one nut and bolt forms the pivot of
a forked tool, with the remaining two nuts and
bolts at the tips of the “forks” to engage with
the sprocket spokes as shown in the
accompanying “Tool Tip”. Do not attempt to
use the sprocket locking pin to prevent the
sprocket from rotating whilst the bolt is
slackened.
7 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 8.

Crankshaft sprocket

8 Remove the centre and lower timing belt
covers as described in Section 5.
9 Remove the timing belt from the sprockets
as described in Section 6.
10 To prevent crankshaft rotation whilst the
sprocket retaining bolt is slackened, select
4th gear, and have an assistant apply the
brakes firmly. If the engine has been removed
from the vehicle, lock the flywheel ring gear,
using an arrangement similar to that shown
(see illustration). Do not be tempted to use
the flywheel locking pin to prevent the
crankshaft from rotating; temporarily remove
the locking pin from the rear of the flywheel
prior to slackening the pulley bolt, then refit it
once the bolt has been slackened. Do not
allow the crankshaft to turn more than a few
degrees while loosening the bolt otherwise
the pistons may touch the valves.
11 Unscrew the retaining bolt and washer,
then slide the sprocket off the end of the
crankshaft  (see illustrations). Refit the
locating pin to the rear of the timing hole in the
rear of the flywheel.
12 If the Woodruff key is a loose fit in the
crankshaft, remove it and store it with the
sprocket for safe-keeping. If necessary, also
slide the flanged spacer off the end of the
crankshaft  (see illustration). Examine the
crankshaft oil seal for signs of oil leakage and,
if necessary, renew it (refer to Section 14).

Tensioner pulley

13 Remove the centre timing belt cover as
described in Section 5.

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

Inspection

15 Clean the sprockets thoroughly, and
renew any that show signs of wear, damage
or cracks.
16 Clean the tensioner assembly, but do not
use any strong solvent which may enter the
pulley bearing. Check that the pulley rotates
freely about its hub, with no sign of stiffness
or free play. Renew the tensioner pulley if
there is any doubt about its condition, or if
there are any obvious signs of wear or
damage.

Refitting

Camshaft sprocket

17 Refit the locating peg (where removed) to
the rear of the sprocket, then locate the
sprocket on the end of the camshaft. Ensure
that the locating peg is correctly engaged with
the cutout in the camshaft end.
18 Refit the sprocket retaining bolt and
washer. Tighten the bolt to the specified
torque, whilst retaining the sprocket with the
tool used on removal (see Tool Tip).
19 Realign the timing hole in the camshaft
sprocket (see Section 3) with the
corresponding hole in the cylinder head, and
refit the locking pin.
20 Refit the timing belt to the camshaft
sprocket. Ensure that the “front run” of the

belt is taut - ie, ensure that any slack is on the
tensioner pulley side of the belt. Do not twist
the belt sharply while refitting it, and ensure
that the belt teeth are seated centrally in the
sprockets.
21 Loosen the tensioner pulley retaining nut.
Rotate the pulley anti-clockwise to remove all
free play from the timing belt, then retighten
the nut.
22 Tension the belt as described in
paragraphs 14 to 19 of Section 6.
23 Refit the timing belt covers as described
in Section 5.

Crankshaft sprocket

24 Where removed, locate the Woodruff key
in the crankshaft end, then slide on the

TU engine in-car repair procedures  2A•7

7.11b  . . . then slide off the sprocket

7.12  Remove the flanged spacer if

necessary

7.11a  Remove the crankshaft sprocket

retaining bolt . . .

7.10  Use the fabricated tool shown to lock

flywheel ring gear and prevent the

crankshaft rotating

2A

Using a home-made tool to hold the
camshaft sprocket stationary whilst the
retaining bolt is tightened (shown with
cylinder head removed)