Peugeot 205 - Manual (Page 67)

Removal
1 Disconnect the battery negative lead.
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 6.
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, restrain the sprocket with a
suitable tool through the holes in the sprocket
face (see 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 9.
Crankshaft sprocket
8 Remove the centre and lower timing belt
covers as described in Section 6.
9 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.
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
(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.
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 oil leakage and, if
necessary, renew as described in Section 14.
Tensioner pulley
13 Remove the centre timing belt cover as
described in Section 6.
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
of 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 cut-out 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.
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.
TU series engine in-car repair procedures 2C•7
2C
8.10 Use the tool shown to lock the
flywheel ring gear and prevent the
crankshaft rotating
8.11a Remove the crankshaft sprocket
bolt . . .
8.11b . . . then slide off the sprocket 8.12 Remove the flanged spacer if
necessary
To make a camshaft sprocket holding
tool, obtain two lengths of steel strip
about 6 mm thick by 30 mm wide or
similar, one 600 mm long, the other 200
mm long (all dimensions approximate).
Bolt the two strips together to form a
forked end, leaving the bolt slack so
that the shorter strip can pivot freely. At
the end of each ‘prong’ of the fork,
secure a bolt with a nut and a locknut,
to act as the fulcrums; these will engage
with the cut-outs in the sprocket, and
should protrude by about 30 mm