Timing belt replacement, need help

[David_CH]

Hi there !

Finally i got all the tools needed for the timing belt replacement.
I've done all the steps until i've reached the timing belt zone (removing engine support, remove accessory belt, etc etc).

At this point, i have a problem and i need your advice.
First thing i have noticed, is that the Camshaft pulleys are different from the manual, one has the hole for the pin, the other one is "filled" (see picture), so i don't know where to put the pin to lock the camshaft.

Second problem : the pins kit i have bought doesn't work with this pulley, i have found the hole into the engine block, but it's smaller than the pin. Ok... not a big deal, i can use a 5mm drill bit BUT... but now there is another problem >

Third problem : i've rotated the crankshaft until i've found the hole for the Flywheel pin. It doesn't enter completely so maybe i have to clean it a bit but... with this hole aligned, the hole on the camshaft pulley is not aligned with any hole. I start to ask myself how this engine can work ???

4th thing : by looking at the timing belt completely, i can see that it's not in bad shape, but... the Tensioner looks very wrong to me ! By following the service manual, the pointer should not be so much at left... there is something wrong with this tensioner.

Maybe that i can avoid all this job and simply adjust the tensioner ? I have a new replacement but if i can't find where to lock the camshaft, it will become a bigger problem..

Thanks for your time !
David

[David_CH]

oh btw, and those are the pins

[David_CH]

Just a little update : I've found the holes on the Camshaft pulleys, and those holes are 5mm ! So the two 9mm pins that i got with the UK kit are wrong Ok, the two camshaft are locked in place, but still can't full insert the Flywheel pin, it looks bigger than the hole, or i simply can't find the correct orientation. I don't want to use an hammer because i'm scared that after i can't remove it.

[doctle]

Can you post a link to the locking kit?

[David_CH]

Can you post a link to the locking kit?

It is this one : https://www.ebay.ch/itm/Peugeot-Citroen ... 1438.l2649

i can use only the flywheel pin, but i've just checked the measurements.. it's done over tolerance. instead of 29.5mm diameter is 30 , instead of 15mm is 15.1 and the small 9mm is 9.10mm
This is probably the reason that i can't push it in, i'll adjust it on my lathe.

[David_CH]

Ooooooh yeah !!! i'm back from my workshop.

And now, after correcting the measures with the lathe, my flywheel pin fit like a glove !!
Also i've used 2x 5mm drill bits for the camshaft pulleys.

This UK machinist need some Swiss precision training

[doctle]

well spotted keep us updated

[white exec]

Make sure you leave a suitable ebay review!

[David_CH]

For informations, the pin holes are those two.

The left camshaft pulley (exhaust side) hole must be at around 07:00 o'clock , the right pulley (intake side) must be at arount 05:00

[JEREMYH]

I would just like to add about the appearance of the belt
They can look like they are OK but when you get them on the bench and shine the light on it you will see lots of small cracks all the way around
I actually keep a new belt and an old belt in my garage to show anybody that wants to listen
Never judge a belt on its appearance I would say 70K on this engine is enough

[doctle]

I assume you will change the water pump and coolant at the same time?

[David_CH]

I assume you will change the water pump and coolant at the same time?

Yes, i have already flushed the coolant from the engine. The actual pump is black, i suppose it's still the original, the new one is aluminum color.

[David_CH]

Never judge a belt on its appearance I would say 70K on this engine is enough

My engine has 170'000km on his back
I want to change the belt since the dealer wasn't able to confirm that it was done at the last service. This and the fact that i was hearing grinding noise from the belt cover, convinced me to change it in any case.
Also on another thread i've shown how the timing belt has moved on the side. Well.. for some miracle, she is returned on his right path by self. But after seeing how the tensioner pulley is mounted... i'm pretty sure that something bad was waiting if i avoided this job.

[JEREMYH]

one of the idlers might be a bit knackered or worse the water pump bearing is starting to fail
Crack on with this job you wont regret it

[David_CH]

Good morning,

new day new troubles.

Now i was finally able to remove the crankshaft pulley, the timing belt, and the front face of the water pump, since to save some time i wanted to replace only the front part but.... the new one and the old one have different holes position

Ok, time to replace the full body of the pump, but again, something is different from the service manual, the old pump has some sort of "shield" around it, so i'm studyiing how i can remove that... there is really no space here

The old pump bearing are a little worn, i can feel the bearings loud, but if i can't find a way to remove the full body of the pump, i will reassemble this one.

Any suggestion is welcome !!!
David