How to change the timing belt on Peugeot 206 GTi 180 by Richard Stephens, Feb 2018

A. Gaining Access
1. Disconnect battery earth lead
2. Raise and support front of vehicle.
3. Remove RH front wheel, splash guard, auxiliary drive belt, battery and battery tray. Undo the
jubilee clip & release the throttle body rubber inlet from the air filter housing
4. Disconnect engine lower torque reaction link (lower engine mount, middle rear)
5. Remove ECU/ engine control module (ECM) and bracket
6. Support engine on jack
7. Remove RH engine mounting
8. Remove LH engine mounting below battery tray (aka gearbox upper mounting). Check drive shafts
are clear of lower wishbones (I left the engine resting on the LH drive shaft at times and split the
gaiter)
9. Move (shove) engine / gearbox assembly to the left
10. Remove timing belt upper cover

B. Familiarise Self With Layout (see image)

CS = Crank Shaft
WP = Water Pump
T = Tensioner Pulley
CA2 = Exhaust Cam Pulley (shows locking position for GTi180 corrected by RS)
CA1 = Inlet Cam Pulley (correct locking position for GTi180 added in red. Ignore label “3”)
G = Guide Pulley

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C. Removing Old Belt
1. Turn crankshaft clockwise to setting position (see image corrected by RS for 2004 GTi180)

2. Insert flywheel/drive plate locking tool at the rear of the block into the flywheel.

The block hole is approx 20mm in diameter but the flywheel hole is smaller so you need the special
locking tool to do this. You MUST lock the engine this way rather than at the crank pulley because
these engines have a “floating pulley”. This just means that the crank pulley does not have a recess /
key but it can be fitted at any orientation once the crank pulley bolt is loosened. This took ages. My
mate Craig was turning the crank pulley and I was right under the car with my hand in the narrow
gap between the block and the RH driveshaft trying to push the tool into the recess. It’s strange as it
seemed that for the full cycle there was no recess for the tool to engage with. In fact, at certain
points in the cycle the tool would barely get into the large recess let alone get anywhere near the
flywheel (I was convinced it was the wrong size tool) but as Craig turned the crank it became possible
to push in. It was very difficult to find the locking hole in the flywheel. We went round full 360 degree
cycles with the tool pushed against the flywheel but there was no clear click / engagement the hole.
We finally did it by finding the barest hint of a notch and wiggling the crank pulley as I pushed the
tool home. Once the engine seemed locked (but the tool had only engaged by mm) I used a hammer
to tap it the final 10mm into secure lock position. I had to wrap an old bike inner tube round it to pull
it out. When I needed later re-locked it I put some grease on the tool and it went in and came out
more easily. Suggest clean the hole up if it hasn’t been locked for a while.

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3. Insert timing pins (5mm torx key) to lock camshaft sprockets. The exhaust sprocket locking hole
did not seem to line up with any recess on the block to lock it. This was OK as I could rely on the
following method to ensure it was aligned: Using Tipex, mark the positions of the cam pulley notches
on the pulleys, belt and rear cambelt cover. Under the car mark the position of the crank pulley notch
on the engine block. Mark the OLD cambelt with the same three marks as above. Later on use these
marks to mark the new belt (count the teeth to make sure they all line up) and ensure all is aligned at
fitment. CAN’T EMPHASIS ENOUGH HOW IMPORTANT THIS IS. Turned out the exhaust sprocket was
out by a tooth (it was one tooth too late; advancing it by one tooth the cam lobes on the inlet and
exhaust cams were aligned and the sprocket locking hole lined up with the recess on the block.).

4. There is no need to remove the central Crankshaft pulley bolt on the GTi180. You will need to
remove the Crankshaft pulley (4 bolts) and Timing belt lower cover (3 x 10mm bolts and one x 13mm
bolt)

5. Slacken tensioner pulley bolt 13mm [7] and turn tensioner pulley clockwise using an Allen key [8]
(see image) to de-tension the belt.

6. Remove timing belt

3
D. Installing New Belt
1. Check tensioner pulley, water pump sprocket and guide pulley for smooth operation & replace if
necessary. If doing the water pump I drained the system from the water pump location by loosening
it. This seemed fine.

2. Ensure flywheel/drive plate locking tool is still located correctly & timing pins are still located
correctly in cam pulleys

3. Turn tensioner pulley anti-clockwise until pointer above notch [10] this is to slacken off the tension
(see pic)

4. Fit new timing belt in following order:

Inlet camshaft sprocket (CA1).
Exhaust camshaft sprocket (CA2).
Guide pulley.
Crank pulley.
Water pump sprocket.
Tensioner pulley.

5. Ensure timing belt is fitted flush with sprockets and pulleys

6. Remove locking tool at the Exhaust Cam

E. Tensioning the belt

1. Use Allen key to turn tensioner pulley anti-clockwise until pointer [13] at position [14] NOTE: The
arrow should pass notch [15] by at least 10°. If not, replace tensioner pulley. Have to admit I don’t
fully understand this

2. Turn tensioner pulley clockwise until pointer and notch aligned [13] & [15]. NOTE: If pointer
passes notch [15] , repeat tensioning procedure.

3. Tighten tensioner pulley bolt to 21±2 Nm [7] .WARNING: Hold tensioner pulley during tightening
to prevent it from turning. Allen key socket must be approximately 15° below cylinder head gasket
level. If not, replace tensioner pulley.

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F. Checking for Misalignment & reassembly

1. Remove remaining locking tools (flywheel and inlet cam pulley). NB It was a real struggle to
remove the flywheel locking tool. It is a very tight fit and there is limited room to get your hand in to
grip it. I got Craig to wiggle the crank nut too and fro and wrapped a bike innertube around the tool
which enabled me to pull on it. 5-10 mins of this was needed before the locking tool was removed.

2. Turn crankshaft 10 turns clockwise to setting position (check for misalignment)

3. ReInsert timing pin in inlet camshaft sprocket

4. Ensure tensioner pointer and notch aligned [13] & [15] NOTE: If pointer passes notch [15] , repeat
tensioning procedure

5. Remove timing pin from inlet camshaft sprocket

6. Install components in reverse order of removal

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Photos of correctly aligned cam shafts/ lobes

Exhaust

Inlet

6
Diagram of AUX belt route

References
http://replace-timing-belt.com/how-to-replace-timing-belt-on-peugeot-206-2-0i-s16-2000-2007-
with-centre-bolt/ WHAT ABOVE COMES FROM; FOR CRANKSHAFT PULLEY WITH CENTRE BOLT

https://www.justanswer.com/peugeot/5eu09-peugeot-need-full-diagram-timing-belt-procedure-
peugeot.html THIS SET OF INSTRUCTIONS SLIGHTLY DIFFERENT AND STATE THAT THE CRANK PULLEY
HAS A TIMING PIN HOLE ALIGNED AT 10 OCLOCK. THIS IS FOR EW10J4 ENGINE 136 OUTPUT I.E. THIS
IS FOR THE STANDARD GTI NOT THE 180

http://www.206info.co.uk/Forums/viewtopic/t=14845.html General chat

https://www.youtube.com/watch?v=uFEyBus9Hxw GENERAL 206 VIDEO BUT NOT THE GTI180

http://www.peugeot206cc.co.uk/viewtopic.php?f=4&t=11459 Guide to cambelt change on a 206CC

http://www.206info.co.uk/Forums/viewtopic/t=765.html Guide to cambelt change on a 206GTi136

– VERY DETAILED AND LOTS OF PHOTOS

Parts

Gates Kit ebay 59.78 ORDERED

Drive Belt ebay 9.02 ORDERED
Water Pump ebay 19.99 ORDERED
RH Engine Mount ebay 34.82 ORDERED

7
 Induction pipe 24.99 ORDERED
Flywheel & cams locking tool 13.39 ORDERED

TOTAL 173.00

Timing Belt / Cam Belt Retaining Clip £9.99

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0132AK/180679774716?hash=item2a115a91fc:m:mCQCAT-fdQtp3dm53jKEMIg

ContiTech Cam Belt £21.12

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ContiTech Drive Belt £14.54 CP4L; £9.02 Ebay ORDERED

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CD6PK1725/112214955200?fits=Car+Make%3APeugeot%7CModel%3A206%7CCars+Year%3A2004%
7CPlat_Gen%3A2A%2FC%7CCars+Type%3A2.0+RC&hash=item1a208854c0:g:3aAAAOSwT-FZCjHi

Water Pump Magnetti Morelli £19.99 ORDERED

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407-607-WATER-
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t_Gen%3A2A%2FC%7CCars+Type%3A2.0+RC%7CVariant%3A2A%2FC+%5B1998-
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Gates Timing Belt Kit £59.78 ORDERED

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Tensioner-
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7CPlat_Gen%3A2A%2FC%7CCars+Type%3A2.0+RC&hash=item283ae1f817:g:F9gAAOSw6dNZb5Ww

Right hand engine mount Febi Bilstein £34.82 ORDERED

https://www.ebay.co.uk/itm/Peugeot-206-2-0-RC-Genuine-Febi-Right-Engine-
Mount/291771470804?_trkparms=aid%3D222007%26algo%3DSIM.MBE%26ao%3D2%26asc%3D495
68%26meid%3D4d97bd2f9e9b4115b8239a82bccc1895%26pid%3D100005%26rk%3D2%26rkt%3D6
%26sd%3D361582226039&_trksid=p2047675.c100005.m1851

Dual cam locking tool £10.99 inc postage ORDERED

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Flywheel & cams locking tool £13.39 free postage ORDERED

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