How to Replace timing belt on

Peugeot 206 2.0i S16 2000-2007

Published August 13, 2015

-Crankshaft Pulley with 4 bolts

Replacement Interval Guide

Peugeot recommend:

206/CC/GTi/406/607/806:

Replacement every 80,000 miles or 10 years under normal conditions.

Replacement every 48,000 miles or 5 years under adverse conditions.

206 180/RC:

Replacement every 72,000 miles or 10 years under normal conditions.

Replacement every 60,000 miles or 10 years under adverse conditions.

The previous use and service history of the vehicle must always be taken into
account.

Check For Engine Damage

CAUTION: This engine has been identified as an INTERFERENCE engine in which
the possibility of valve-to-piston damage in the event of a timing belt failure is MOST
LIKELY to occur. A compression check of all cylinders should be performed before
removing the cylinder head(s).

Repair Times hrs

Remove & install:

206/CC/GTi

3,90

206 180/RC

4,40

406

2,20

607

1,80

806

2,10

AC

+0,10

Special Tools

Camshaft timing pins Peugeot Nos.(-).0189-AZ/L.

Crankshaft timing pin Peugeot No.(-).0189-B.

Timing belt retaining clip Peugeot No.(-).0189-K.

Tensioner positioning tool Peugeot No.(-).0189-J.

Crankshaft locking tools Peugeot No.(-).0606-A1 & (-).0606-A2.

Special Precautions

Disconnect battery earth lead.

DO NOT turn crankshaft or camshaft when timing belt removed.

Remove spark plugs to ease turning engine.

Turn engine in normal direction of rotation (unless otherwise stated).

DO NOT turn engine via camshaft or other sprockets.

Observe all tightening torques.

Removal
WARNING: Engines with variable valve timing: Mark camshaft sprockets and
camshaft adjusters with chalk or paint prior to timing belt removal to assist alignment
on installation.
1. Raise and support front of vehicle.
2. Remove:

Engine upper cover (if fitted).

Engine undershield (if fitted).

RH front wheel.

RH splash guard.

Auxiliary drive belt.

Battery and battery tray (if necessary).

Engine lower torque reaction link (if necessary).

206: Engine control module (ECM) and bracket.

3. 406 RLZ engine: Disconnect engine control module (ECM) multi-plugs.

Move wiring harness to one side.
4. 206/406: Support engine.
5. Remove:

RH engine mounting (206/406).

206: LH gearbox mounting nut.

6. 206: Move engine/gearbox assembly towards the left.

7. Remove:

Timing belt upper cover [1] .

Crankshaft pulley bolts [2] .

Crankshaft pulley [3] .

Timing belt lower cover [4] .

8. Turn crankshaft clockwise to setting position.

9. Insert timing pin in crankshaft pulley hub [5] . Tool No.(-).0189-B.
10. Insert timing pin in exhaust camshaft sprocket (CA2) [6] . Tool No.(-).0189-AZ.
NOTE: DO NOT slacken camshaft sprocket bolt(s).
11. Insert timing pin in inlet camshaft sprocket (CA1) [7] :

Engines without variable valve timing: Tool No.(-).0189AZ.

Engines with variable valve timing: Tool No.(-).0189-L.

NOTE: DO NOT slacken camshaft sprocket bolt(s).

12. Slacken tensioner pulley bolt [8] .
13. Unhook tensioner pulley bracket from cylinder block rib [9] .
14. Move tensioner pulley away from belt.
15. Remove timing belt.
NOTE: Timing belt must always be renewed once it has been removed.

Installation
NOTE: Belt adjustment must be carried out when engine is cold.
1. Ensure timing pins located correctly [5] , [6] & [7] .
2. Fit timing belt to crankshaft sprocket.
NOTE: Ensure arrow on belt faces direction of rotation.

3. Secure belt to crankshaft sprocket with retaining clip. Tool No.(-).0189-K [10] .
4. Fit timing belt to remaining sprockets and pulleys in following order:

Guide pulley.

Inlet camshaft sprocket.

Exhaust camshaft sprocket.

Water pump sprocket.

Tensioner pulley.

NOTE: Ensure belt is taut between sprockets.

5. Fit tensioner pulley bracket to cylinder block rib [9] .
6. Tighten tensioner pulley bolt finger tight [8] .
7. Remove timing belt retaining clip [10] .
8. Turn tensioner anti-clockwise until belt tensioned to maximum. Use Allen
key [11] . Ensure pointer positioned as shown [12] .
9. Ensure pointer moves away from notch by at least 10 [13] . If not, replace
tensioner pulley.
10. Insert tensioner positioning tool [14] . Tool No.(-).0189-J.
11. Turn tensioner clockwise until pointer and positioning tool are just
touching [14] & [15] . Use Allen key [11] .
NOTE: Pointer and notch are also aligned.
12. Tighten tensioner pulley bolt [8] . Tightening torque: 20 Nm.
13. Remove tensioner positioning tool [14] .
14. Remove timing pins [5] , [6] & [7] .
15. Turn crankshaft ten turns clockwise to setting position.
NOTE: DO NOT allow crankshaft to turn anti-clockwise.

16. Ensure pointer and notch aligned [15] .

17. If not: Repeat tensioning procedure.
18. Insert timing pin in inlet camshaft sprocket [7] .
19. Insert timing pin in crankshaft pulley hub [5] .
20. If timing pin [5] cannot be inserted, reposition crankshaft pulley hub as follows:

Lock crankshaft pulley hub. Use tool Nos.(-).0606A1/A2 [16] .

Slacken crankshaft pulley hub bolt [17] .

Turn crankshaft pulley hub until timing pin can be

inserted [5] . Use tool Nos.(-).0606-A1/A2 [16] .

21. Tighten crankshaft pulley hub bolt [17] . Tightening torque: 40 Nm + 534.
22. Remove timing pins [5] & [7] .
23. Install components in reverse order of removal.
24. Tighten crankshaft pulley bolts [2] . Tightening torque: 20 Nm.
25. 206/406: Tighten RH engine mounting:

Three bolts securing intermediate bracket to engine

bracket 60 Nm.

Nut securing engine mounting to intermediate bracket

45 Nm.

Two bolts securing strut brace to intermediate bracket

20 Nm.

26. 206: Tighten LH gearbox mounting nut. Tightening torque: 65 Nm.

27. Tighten engine lower torque reaction link bolts. Tightening torque: 45 Nm.