306 1.9TD Cam Belt replacement

I'm about to replace the cam and auxiliary belts on my 1999 'S' 306 1.9TD
(XUD9 engine).

According to the Halfords manual, the camshaft and fuel pump sprockets can
be locked in position using 8mm bolts in the holes provided. The crankshaft
allegedly can be locked in TDC position by inserting an 8mm rod or drill
shaft into a hole in the flywheel via "the hole in the left-hand flange of
the cylinder block by the starter motor".

This area on my car is completely obscured by the oil filler, fuel filter
and a coolant manifold, and perhaps the starter motor. It is impossible to
see where the hole might be, let alone gain access to insert a rod.

The Haynes book makes no mention of the need to remove all these items. Am
I missing something? There are no alignment marks on the new belt, so I
assume there will be no alignment marks on the sprockets as there have been
on previous cars I have owned.

Would it be safe to lock the camshaft and fuel pump sprockets, and then
carefully mark the position of the crankshaft sprocket before removal of the
old belt?

Peter

 

if in doubt
remove the starter so you can get to the hole in the block

 

I have just replaced the cambelt on my 406 with a 1.9TD engine and had the
same problem. The solution is simple At the bottom of the bell housing is a
removable segment used to fit a Peugeot flywheel locking tool for locking
the engine when it has been removed from the car. Make a metal detent to fit
one flywheel tooth and bolt in place once the crank shaft bolt has been
released and the locking bolts have been fitted in the fuel pump and cam
shaft pulleys. This replaces the need for the rod which is impossible to use
unless the starter motor etc have been removed.
Mike

 

Thank you gentlemen. I shall explore both options.

I think I might go for the locking tool option. Can I also use it to lock
the engine when I loosen the crankshaft bolt? Haynes actually shows such a
tool in position for this purpose, but with the engine out and gearbox
removed. They don't mention the removable segment. Haynes specifically
advises against using the 8mm rod for this purpose, presumably because it
might shear or bend. I have some 1/4" steel plate handy which should do the
job.

Peter

 

I did one of these engines a couple of weeks ago and it is quite possible to
insert a rod into the back of the flywheel, but you won't get anything
larger than 6 mm into the hole.
I used an allen key with some stiff wire wrapped round it to hold it in
place. Use a small torch and look at an angle down behind the starter, and
you will see the hole in the V of the webs cast into the block.
I think it is safer to use the correct rod, as otherwise it could be that
you repeat an error made by the last person to replace the belt, or the old
belt could have jumped a tooth from being a little too slack - I have seen
this.
To undo the crankshaft nut, I lock the front disc (I had the ventilated
ones) with a stout screwdriver in the vent slot and against the brake
calliper. Then you need a socket and VERY long bar to stand any chance of
undoing it. Oh, and put it into 5th gear.
On the car I did, I could not, for anything, remove the bolt from the
crankshaft, so I had to remove the lower plastic cover, then pull the belt
out round the aux belt pulley.

 

To loosen the crank shaft pulley I used a second person with the car in 5
gear and their foot hard on the brake. You will need a long bar on the
socket as the bolt should be liberally coated with locktight. I used an air
compressor and ratchet tool to subject the crank shaft bolt to some good
vibrations to free the locktight. The Peugeot locking tool works across 3
flywheel teeth so a home made détente is likely to slip or damage a single
tooth with the force needed to remove the nut.
Mike

 

two methods I have used to overcome the above problems,
1,, crank pulley bolt
fit long bar and socket, jam bar on the floor, or ground or axle stand,
turn the ignition key for 1 - 2 seconds pulley turns clockwise bolt is
loosened,

2,, belt locking tools, if they are not available,very carefully cut the
belt in half, right around the circumference and remove the outer section,
leaving the inner section to maintain the timing, carefully fit the new belt
until it pushes the old section off the pulleys, cut the old belt to remove,
these methods will work on most vehicles,
some people will frown on these methods, but they have got me out of the
proverbial, many times, when the standard methods have failed,

Fitzy