Table of contents: Removal 🠇 Camshaft sprocket 🠇 Crankshaft sprocket 🠇 Fuel injection pump sprocket 🠇 Tensioner pulley 🠇 Idler pulley 🠇 Inspection 🠇 Refitting 🠇 Crankshaft sprocket 🠇 Fuel injection pump sprocket 🠇 Tensioner pulley 🠇 Idler pulley 🠇
Removal
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.
1. Disconnect the battery negative terminal (refer to "Disconnecting the battery").
2. Align the engine assembly/valve timing holes as described in Section 3, and lock the camshaft sprocket, injection pump sprocket and flywheel in position. Do not attempt to rotate the engine whilst the locking tools are in position.
Camshaft sprocket
3. 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.
4. Disengage the timing belt from the sprocket, and move the belt clear, taking care not to bend or twist it sharply. Remove the locking tool from the camshaft sprocket.
5. Slacken the camshaft sprocket retaining bolt and remove it, along with its washer, (see illustration). Do not attempt to use the sprocket locking tool to prevent the sprocket from rotating whilst the retaining bolt is slackened.
7.5. Remove the retaining bolt and washer, then remove the camshaft sprocket
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.
6. With the retaining bolt removed, slide the sprocket off the end of the camshaft. Note that the key on the rear of the sprocket engages with a cut-out on the end of the camshaft. Examine the camshaft oil seal for signs of oil leakage and, if necessary, renew it as described in Section 8.
Crankshaft sprocket
7. Remove the lower timing belt cover as described in Section 5.
8. 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.
9. Disengage the timing belt from the crankshaft sprocket, and move the belt clear, taking care not to bend or twist it sharply.
10. To prevent crankshaft rotation whilst the sprocket retaining bolt is slackened, select top 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 in illustration 7.10 in Part A of this Chapter. Do not be tempted to use the flywheel locking pin/bolt to prevent the crankshaft from rotating; temporarily remove the pin/bolt from the rear of the flywheel prior to slackening the pulley bolt, then refit it once the bolt has been slackened.
11. Unscrew the retaining bolt and washer, then slide the sprocket off the end of the crankshaft. Refit the locking pin/bolt through the timing hole into 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. Examine the crankshaft oil seal for signs of oil leakage and, if necessary, renew as described in Section 16 in Part A of this Chapter.
Fuel injection pump sprocket
13. 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.
14. Disengage the timing belt from the injection pump sprocket, and move the belt clear, taking care not to bend or twist it sharply. If necessary, remove the right-hand headlight unit as described in Chapter 12 to improve access to the sprocket.
15. Unscrew the locking bolts from the pump sprocket.
16. Slacken the injection pump sprocket retaining nut whilst holding the sprocket stationary with a suitable peg spanner which engages with the sprocket holes, similar to that described in paragraph 5 (see illustration). Unscrew the nut slightly so that it is clear of the sprocket.
7.16. Using a home-made tool to hold the injection pump sprocket stationary whilst the retaining bolt is slackened - viewed through headlight aperture
17. A suitable tool will now be needed to free the sprocket from its taper on the pump shaft. In the absence of the special Peugeot clamp (No. 0157H), a suitable home-made alternative can be made out of a stout piece of steel strip and two 7x1 mm bolts which are approximately 40 mm in length. Drill two 8 mm holes in the strip, with their centres 45 mm apart. Align the holes in the strip with the two threaded holes in the sprocket, then screw in the bolts, tightening them evenly and progressively, until the sprocket is freed from the pump shaft taper (see illustration). Do not be tempted to strike the pump with a hammer in an attempt to free the sprocket, as the pump internals will almost certainly be damaged.
7.17. Home-made injection pump sprocket removal tool in position on the sprocket
18. Remove the bolts and the strip, then remove the sprocket retaining nut, and slide off the sprocket. If the Woodruff key is a loose fit in the pump shaft, remove it and store it with the sprocket for safe-keeping (see illustrations).
7.18a. Unscrew the retaining nut, then remove the sprocket...
7.18b.... and recover the Woodruff key (arrowed) from the injection pump shaft
Tensioner pulley
19. Slacken and remove the timing belt tensioner pulley retaining nut, and slide the pulley off its mounting stud (see illustration). Examine the mounting stud for signs of damage and, if necessary, renew it - it is removed by unscrewing it from the cylinder block.
7.19. Timing belt tensioner pulley retaining nut (arrowed)
Idler pulley
20. 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. in order to provide some slack in the timing belt between the crankshaft and injection pump sprockets, it will be necessary to remove the locking tool from the flywheel and rotate the crankshaft slightly anti-clockwise.
21. Unscrew the bolt retaining the idler to the cylinder block (see illustration), and withdraw the idler pulley. Carefully tie the timing belt up so that it is kept in full engagement with all of the sprockets.
7.21. Timing belt idler pulley retaining bolt (arrowed)
Inspection
22. Clean the sprockets thoroughly, and renew any that show signs of wear, damage or cracks.
23. Clean the tensioner pulley and idler, but do not use any strong solvent which may enter the bearings. Check that each roller rotates freely about its hub, with no sign of stiffness or free play. Renew the tensioner pulley or idler if there is any doubt about its condition, or if there are any obvious signs of wear or damage.
Refitting
Camshaft sprocket
24. Locate the sprocket on the end of the camshaft. Ensure that the locating key is correctly engaged with the cut-out in the camshaft end (see illustration).
7.24. When refitting, ensure that the camshaft sprocket key and camshaft slot are correctly aligned (arrowed)
25. Refit the sprocket retaining bolt and washer (on TUD 5 engines, coat the bolt with Locite). Tighten the bolt to the specified torque, whilst retaining the sprocket with the tool used on removal.
26. Realign the timing hole in the camshaft sprocket (see Section 3) with the corresponding hole in the cylinder head, and refit the locking tool.
27. With the crankshaft, injection pump and camshaft locked in position, refit the timing belt to the camshaft sprocket. Ensure that the belt is taut around the crankshaft sprocket, idler pulley and injection pump sprocket, so 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.
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28. Loosen the tensioner pulley retaining nut. Rotate the pulley anti-clockwise to remove all free play from the timing belt, then retighten the nut.
29. Tension the belt as described under the relevant sub-heading of Section 6.
30. Refit the timing belt covers as described in Section 5.
31. Reconnect the battery negative terminal.
Crankshaft sprocket
32. Where removed, locate the Woodruff key in the crankshaft end, then slide on the flanged spacer, aligning its slot with the Woodruff key.
33. Align the crankshaft sprocket slot with the Woodruff key, and slide it onto the end of the crankshaft.
34. Temporarily remove the locking tool from the rear of the flywheel, then refit the crankshaft sprocket retaining bolt and washer. Tighten the bolt to the specified torque, whilst preventing crankshaft rotation using the method employed on removal. Refit the locking tool to the rear of the flywheel.
35. With the crankshaft, injection pump and camshaft locked in position, refit the timing belt to the crankshaft sprocket. Ensure that the belt is taut between the crankshaft, idler pulley, injection pump and camshaft sprockets, so 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.
36. Loosen the tensioner pulley retaining nut. Rotate the pulley anti-clockwise to remove all free play from the timing belt, then retighten the nut.
37. Tension the belt as described under the relevant sub-heading of Section 6.
38. Refit the timing belt covers as described in Section 5.
Fuel injection pump sprocket
39. Where applicable, refit the Woodruff key to the pump shaft, ensuring that it is correctly located in its groove.
40. Locate the sprocket on the injection pump shaft, and engage it with the key (see illustration).
7.40. Align the sprocket groove (arrowed) with the Woodruff key when refitting the injection pump sprocket
41. Tighten the sprocket retaining nut to the specified torque, preventing the pump shaft from turning as during removal. Align the sprocket timing holes, and refit the locking tools.
42. With the crankshaft, injection pump and camshaft locked in position, refit the timing belt to the pump sprocket. Ensure that the belt is taut between the crankshaft, idler pulley, injection pump and camshaft sprockets, so 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.
43. Loosen the tensioner pulley retaining nut. Rotate the pulley anti-clockwise to remove all free play from the timing belt, then retighten the nut.
44. Tension the belt as described under the relevant sub-heading of Section 6.
45. Refit the timing belt covers as described in Section 5 and, where necessary, refit the headlight unit as described in Chapter 12.
Tensioner pulley
46. Check that the mounting stud is tightened in the cylinder block.
47. Locate the tensioner pulley on the stud, and lightly tighten its retaining nut.
48. With the crankshaft, injection pump and camshaft locked in position, ensure that the belt is taut between the crankshaft, idler pulley, injection pump and camshaft sprockets, so that any slack is on the tensioner pulley side of the belt.
49. Loosen the tensioner pulley retaining nut. Rotate the pulley anti-clockwise to remove ali free play from the timing belt, then retighten the nut.
50. Tension the belt as described under the relevant sub-heading of Section 6.
51. Refit the timing belt covers as described in Section 5.
Idler pulley
52. Refit the idler pulley to the cylinder block, and tighten its retaining bolt securely.
53. Carefully turn the crankshaft clockwise until the locking tool can be inserted into the flywheel.
54. With the crankshaft, injection pump and camshaft locked in position, ensure that the belt is taut between the crankshaft, idler pulley, injection pump and camshaft sprockets, so that any slack is on the tensioner pulley side of the belt.
55. Loosen the tensioner pulley retaining nut. Rotate the pulley anti-clockwise to remove all free play from the belt, then retighten the nut.
56. Tension the belt as described under the relevant sub-heading of Section 6.
57. Refit the timing belt covers as described in Section 5.