Note. A 6.0mm diameter bolt or rod is required to lock the spring loaded idler pulley.
Removing
76. Follow the steps described in paragraphs 1 and 2, if you have not already done so.
77. Disconnect the wire «masses» from battery (refer to paragraph «Disconnecting the battery»).
78. Loosen the bolt on the manual idler pulley.
79. With a square wrench inserted into the hole in the pulley hub, turn the manual idle pulley clockwise to move the spring loaded pulley. Position the idler pulley so that the hole in its lever is aligned with the corresponding hole in the bracket, and then lock the pulley by inserting a 6.0mm bolt/rod (pic. 12.79). Make sure the spring-loaded idler pulley is securely locked, then release the manual idler pulley.
Pic. 12.79. Accessory drive belt and tensioner (DW series engines with air conditioning)
1. Peugeot/Citroen special tool to move the manual idler pulley
2. Peugeot/Citroen Locking Rod for Spring Loaded Tensioner
3. Drive belt
4. Manual tension pulley
5. Spring loaded idler pulley
6. Hole for locking the lever of the spring-loaded idler pulley
7. Square hole in the spring-loaded idler arm (only available with the drive belt removed)
80. Remove the belt from all pulleys, noting for yourself the correct wiring, and remove it from the engine.
Note. If the belt is to be reused, mark the direction of rotation on the belt before removing it. This will ensure that the belt is installed correctly.
Installation and tension
81. Make sure the spring-loaded idler pulley is locked.
Note. The pulley arm has a square cutout to allow the pulley to be moved with a ratchet/extension, but this hole is only accessible after the drive belt has been removed.
82. When replacing a belt, make sure that the new belt is of the correct type, and if a removed belt is being installed, follow the marks made during removal to install it correctly. Put the belt on the pulleys in the following order:
- A) power steering pump;
- b) manual tension pulley;
- V) generator;
- G) air conditioning compressor;
- d) crankshaft;
- e) spring loaded tension pulley.
83. Make sure the ribs of the belt are properly seated in the grooves on the pulleys, and then turn the manual idler pulley clockwise to fully take up any slack in the belt.
84. To correctly tension the drive belt, position the manual tensioning pulley so that the spring force is completely removed from the blocking bolt/rod inserted into the spring tensioner arm. Once the manual idler pulley is correctly positioned, securely tighten its mounting bolt.
85. Remove the blocking bolt/rod, and then turn the crankshaft four full turns. Make sure the locking bolt/rod can still be inserted easily. If not, loosen the manual idler pulley mounting bolt and repeat the adjustment procedure.
86. Having ensured the correct belt tension, remove the blocking bolt / rod, fix the coolant hoses in their original position (if applicable) and install locker (or technological cover). Install the wheel and lower the car.
87. Finally, connect the wire «masses» to the battery.