Removal and installation the camshaft (Peugeot 206)

Engine DW10 TD

When removing and installing the camshaft, Peugeot service centers use the following special tool:

• seal Installation Tool - 0188-N;
• engine Flywheel Fixing Tool - 0188-Y;
• flywheel stopper - 0188-F;
• camshaft locking tool - 0188-M.

Remove the camshaft in the following order:

• remove decorative cover 1 (figure 4.58);
• remove air cleaner assembly 3;
• disconnect and move node 2;
• disconnect the engine crankcase ventilation system tube;

• disconnect connector 3 (figure 4.59);
• remove caliper 1;
• remove the hub with pulley 2;
• remove the cylinder head cover 4;

• move hose 1 to the side (figure 4.60) vacuum brake booster;
• remove vacuum pump 2;

• loosen the camshaft bearing housing mounting bolts one by one in the order shown in Figure 4.61;

• remove case 2 (figure 4.62) camshaft bearings;
• remove camshaft 1;
• remove the camshaft oil seal;
• clean the camshaft seal seating surfaces using an approved cleaner.

Warning! It is prohibited to use abrasive or piercing-cutting devices and tools.

Install the camshaft in the following order:

• install the stopper (see figure 4.42);
• install the crankshaft pulley mounting bolt;
• remove the stopper from the flywheel;
• turn the crankshaft a quarter turn in the opposite direction (the pistons are in the middle of the working stroke);

• apply SILICONE CATEGORIE 2 sealant (AUTOJOINT OR) around the entire perimeter of A (figure 4.63) surfaces for gaskets;

• install camshaft 1 (figure 4.64) in the housing 2 bearings;
• install the bearing housing with the camshaft on the cylinder head;
• tighten the bearing housing mounting bolts by hand, and then tighten them to a torque of 10 N·m in the sequence shown in Figure 4.61;
• before installing the camshaft oil seal, make sure there is no sealant residue in the seat;
• pack the space between the lips of the seal with grease;

Caution! Do not allow grease to come into contact with the outer surface of the seal.

• install a new seal using tool 1 (figure 4.65);

• install flange 1 (figure 4.66) camshaft;
• screw in bolt 2;
• set the camshaft hub mark using tool 3;
• tighten bolt 2 to 43 Nm;
• lubricate the O-ring seals before installing them;

• install new sealing ring 1 (figure 4.67);
• install a new sealing ring 3;
• install vacuum pump 2;
• tighten the mounting bolts to 20 Nm and the nut to 20 Nm;
• install the head cover with a new gasket;
• tighten the cylinder head cover mounting bolts one by one, in a spiral in the order shown in Figure 4.61, starting with the inner one, to a torque of 10 N·m;
• turn the crankshaft 1/4 turn in the direction of working rotation;
• lock the flywheel with the locking pin 1 (see figure 4.42);
• install the camshaft pulley;

• adjust the gap of sensor 1 (figure 4.68);
• proceed with installation in the reverse order of removal.

DW8 Engine

When removing and installing the camshaft, Peugeot service centers use the following special tool:

• auxiliary key - 0132-AA;
• seal installation tool - 0188-C2;
• mandrel for installing camshaft oil seal - 0188-C1.

Remove the camshaft in the following order:

• disconnect the negative battery cable;
• install the stopper on the flywheel;

• remove decorative cover 5 (see figure 4.16);
• remove block 4 of the air cleaner with all the wiring;
• remove the air intake distributor;
• remove the exhaust gas recirculation valve tube;
• remove the vacuum pump;
• remove the mounting clamps, disconnect and move aside the contact connectors and wire harnesses passing in the cylinder head area;

• release the tube 3 (figure 4.69);
• remove the timing belt as described above;
• remove the pulley with the hub on the camshaft using a device;
• remove the top cover 2 of the cylinder head;
• remove the lower cover 1 of the cylinder head;

• remove key 1 (figure 4.70);
• gradually, one by one, unscrew the bolts securing the 3 bearing caps;
• remove camshaft 2.

Install the camshaft in the following order:

• remove the tool from the flywheel;
• turn the crankshaft a quarter turn in the opposite direction (the pistons are located in the middle of the working stroke);

• if replacing the camshaft or tappets, install the base adjusting washers 1 (figure 4.71) 2.425 mm thick;
• lubricate the bearings and cams with engine oil;
• install camshaft 2 (see figure 4.70);
• install 3 bearing caps (the mark is located on the flywheel side of the crankshaft);
• tighten the bearing caps one by one to a torque of 20 Nm;
• check the valve clearances;

• place a new seal on the mandrel 1 (figure 4.72) using tool 2;
• install a new seal using tool 1;
• install key 1 (see figure 4.70);
• install the pulley with the hub on the camshaft;
• tighten the mounting bolt to 43 Nm;

• install the vacuum pump, lubricating the O-ring seals 1 (figure 4.73) before installation;
• install the bottom cover 1 (see figure 4.69) cylinder heads;
• install the top cover 2 of the cylinder head;
• tighten the mounting bolts to 20 Nm;
• continue installation in the reverse order of removal;
• program all electronic devices in the vehicle.