timing belt change?
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Re: timing belt change?
Jasper, when checking tension, do you ever do the "twist test" to check tension on the belt, if so what angle should i expect the belt to twist to on its longest run? I've heard 90, but want to be sure...
'02 406 2.0 HDi Rapier Estate, now with added cruise control!
Re: timing belt change?
The "twist test" is too unreliable, I never use that method.
My way of checking the tension on these engines is to make sure all the locking pins are removed, put a 16mm spanner on the camshaft bolt, then GENTLY tap the spanner with your hand towards the windscreen until the belt feels tight on the injection pump side, it will hardly move (don't hit it hard or you may undo the bolt).
Set the tension by lightly tightening the tensioner bolt and pressing the tensioner pulley against the belt until you can just about turn it without putting any great force on the pulley...then tighten the the tensior bolt fully, fit the crank pulley and bolt (without fully tightening it), mark the pulley at the top and turn it 2 full turns by hand clockwise.....tap the camshaft bolt with the spanner again until tension is on the injection pump side and re-check the tensioner pulley, you should be able to turn it without having to force it but without it being easy (firm resistance against the belt as you turn the pulley).If you can't turn the pulley, it's too tight.If it turns easy, it's too slack.Make sure all the tipex marks are lined up and your locking pins will fit back in correctly.
Remove the crank pulley....knock the socket bar and socket with your hand to undo the pulley nut.Refit the casing etc.
My way of checking the tension on these engines is to make sure all the locking pins are removed, put a 16mm spanner on the camshaft bolt, then GENTLY tap the spanner with your hand towards the windscreen until the belt feels tight on the injection pump side, it will hardly move (don't hit it hard or you may undo the bolt).
Set the tension by lightly tightening the tensioner bolt and pressing the tensioner pulley against the belt until you can just about turn it without putting any great force on the pulley...then tighten the the tensior bolt fully, fit the crank pulley and bolt (without fully tightening it), mark the pulley at the top and turn it 2 full turns by hand clockwise.....tap the camshaft bolt with the spanner again until tension is on the injection pump side and re-check the tensioner pulley, you should be able to turn it without having to force it but without it being easy (firm resistance against the belt as you turn the pulley).If you can't turn the pulley, it's too tight.If it turns easy, it's too slack.Make sure all the tipex marks are lined up and your locking pins will fit back in correctly.
Remove the crank pulley....knock the socket bar and socket with your hand to undo the pulley nut.Refit the casing etc.
Re: timing belt change?
Couple of last questions before I get my elbows greasy.....
I've got the following new bits to go on...
Timing belt kit (Belt, tensioner & idler pulley)
Crank pulley
Crank pulley bolt
Water pump and gasket (does this need a sealant like hylomars or instant gasket to fit it?)
Tube of loctite for the crank bolt
2l of antifreeze to mix up and top up.
2x 8mm bolts for locking the engine
Bottle of tipex for marking pulleys, and marking the route the belt follows.
Have I forgotten anything?
The adjuster for the cam belt, there's a bolt hole and an 8mm square hole is the square hole used for tensioning (i'll have to get hold of some 8mm square rod if it is)
Finally how do you rotate the engine for checking the pins line up? can you turn the crank pulley using a spanner on the bolt head, or is there a different method?
I've got the following new bits to go on...
Timing belt kit (Belt, tensioner & idler pulley)
Crank pulley
Crank pulley bolt
Water pump and gasket (does this need a sealant like hylomars or instant gasket to fit it?)
Tube of loctite for the crank bolt
2l of antifreeze to mix up and top up.
2x 8mm bolts for locking the engine
Bottle of tipex for marking pulleys, and marking the route the belt follows.
Have I forgotten anything?
The adjuster for the cam belt, there's a bolt hole and an 8mm square hole is the square hole used for tensioning (i'll have to get hold of some 8mm square rod if it is)
Finally how do you rotate the engine for checking the pins line up? can you turn the crank pulley using a spanner on the bolt head, or is there a different method?
'02 406 2.0 HDi Rapier Estate, now with added cruise control!
Re: timing belt change?
You could replace the alternator belt whilst you are at it.
A small allen key or pin of some sort for the alternator belt tensioner to lock it when you undo the tension.
To be able to turn the engine 2 turns, refit the crank pulley and the old bolt (don't tighten it up as turning it clockwise will do that), to undo the bolt afterwards knock the socket and ratchet bar by hand anti clockwise, then fit the pulley back on without the bolt so that you can move the engine to line up the marks/pins.
There can be 2 sizes of square hole in the tensioner, 8 or 9mm, the 9mm on is the same size as the Peugeot gearbox drain tool.
As for the alternator belt, draw the position of the pulleys and the way the belt fits around them on a piece of card or paper.
Yes, you need instant gasket for the waterpump gasket.
A small allen key or pin of some sort for the alternator belt tensioner to lock it when you undo the tension.
To be able to turn the engine 2 turns, refit the crank pulley and the old bolt (don't tighten it up as turning it clockwise will do that), to undo the bolt afterwards knock the socket and ratchet bar by hand anti clockwise, then fit the pulley back on without the bolt so that you can move the engine to line up the marks/pins.
There can be 2 sizes of square hole in the tensioner, 8 or 9mm, the 9mm on is the same size as the Peugeot gearbox drain tool.
As for the alternator belt, draw the position of the pulleys and the way the belt fits around them on a piece of card or paper.
Yes, you need instant gasket for the waterpump gasket.
Re: timing belt change?
Was thinking of doing the Aux drive belt at the start of next month when I'm giving it a full service, see if i can get one from GSF tomorrow afternoon.
Thanks for all the advice, I'll get a heap of photos, and try to stick em up.
BTW managed to get the turner at work to make a couple of 7.95mm pins today, and I've made an 8mm square alloy belt tensioning tool.
Thanks for all the advice, I'll get a heap of photos, and try to stick em up.
BTW managed to get the turner at work to make a couple of 7.95mm pins today, and I've made an 8mm square alloy belt tensioning tool.
'02 406 2.0 HDi Rapier Estate, now with added cruise control!
Re: timing belt change?
Well this evening I've pulled off the top timing belt covers (that front top one seemed to be designed by Satan, with how difficult it was to remove once all the bolts were off!), the Aux belt, and the crank pulley, taken some photos on the way.
Getting the crank pulley off was quite easy really, I've got a nice big knuckle bar about 3 feet long, with a 7/8" socket on, that was long enough to undo the bolt. Jack up the right hand front wheel, and support on an axle stand for a little extra room to turn the bolt. Stick the car in 5th, and get your wife to put her foot on the brake pedal. Then Pull like buggery on the bar and socket. It will crack free, then eventually switch to a ratchet and undo.
More to follow, I'll let you know how it goes....
Getting the crank pulley off was quite easy really, I've got a nice big knuckle bar about 3 feet long, with a 7/8" socket on, that was long enough to undo the bolt. Jack up the right hand front wheel, and support on an axle stand for a little extra room to turn the bolt. Stick the car in 5th, and get your wife to put her foot on the brake pedal. Then Pull like buggery on the bar and socket. It will crack free, then eventually switch to a ratchet and undo.
More to follow, I'll let you know how it goes....
'02 406 2.0 HDi Rapier Estate, now with added cruise control!
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steve_earwig
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Re: timing belt change?
Cool, keep 'em coming 
Unskilled meddling sin©e 2007
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Re: timing belt change?
EvilTwin wrote:Well this evening I've pulled off the top timing belt covers (that front top one seemed to be designed by Satan, with how difficult it was to remove once all the bolts were off!), the Aux belt, and the crank pulley, taken some photos on the way.
Getting the crank pulley off was quite easy really, I've got a nice big knuckle bar about 3 feet long, with a 7/8" socket on, that was long enough to undo the bolt. Jack up the right hand front wheel, and support on an axle stand for a little extra room to turn the bolt. Stick the car in 5th, and get your wife to put her foot on the brake pedal. Then Pull like buggery on the bar and socket. It will crack free, then eventually switch to a ratchet and undo.
More to follow, I'll let you know how it goes....
The top cover is easy to remove if you lower the engine, when you refit it make sure the engine is lowered.
The water pump bolts will be easier to access with the engine lowered.
Re: timing belt change?
Job done, it runs, just need to pack away my tools and go for a drive.
Thanks jasper for all the advice...
How to to follow.
Thanks jasper for all the advice...
How to to follow.
'02 406 2.0 HDi Rapier Estate, now with added cruise control!
Re: timing belt change?
Excellent, well done 
You are most welcome
You are most welcome