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Peugeot ZDJL Engine, Remove & Reinstall Timing Belt

By Peugeot Pete

PRINT THIS FOR USE LATER Use this as your tech manual Follow the instruction sheet to the letter, it's written that way for a purpose, to do everything and get you running the quickest without doubling back on something.

Now some basic terms just in case a term may be unfamiliar to you.

Direction- measured by sitting in the drivers seat, front, rear, left, right, LF is left front and RR is right rear.
Example: the fuse box is located in the LR.
Shafts are measured by OD, outside diameter, hoses are measured by ID, inside diameter.
The directions given are as the part is mounted in the car.
The throttle body mounts to the intake log manifold.
DFWI -- Don't Fiddle With It.
Crank - -consist of battery, switch and starter, all good, the engine cranks.
Start -- to cranking you add fuel, air, and ignition, all good it starts and runs.
Run -- after the cranking, the starting, we get to the running which consist of fixed fuel, fixed ign, and controlled air.

Locate and identify these items. Mounted on the front top of the engine is the auxiliary air device. The two (2) 3/4" ID hoses coming off the auxiliary air device go to the intake hose just behind the air flow sensor, Idle adjustment and to the rear side of the throttle control, (remember sitting in the drivers seat). Air flow sensor is mounted over the air filter. The ign ECU is located under the passenger front floor mat. The inj ECU is located behind the glove box. Throttle body mounted to intake manifold. Wire #22 located between air filter and fender. DO NOT USE A SILICONE BASED SEALER, the fumes will give the sensors a false reading.


Drain the coolant system and remove, the battery ground cable, the radiator shroud on automatic cars, the radiator, the spark plugs, the auxiliary air device, the thermostat housing and the alternator. On manual shift cars, engage fifth gear and apply park brake. On automatic shift cars, remove the bell housing inspection plate with the TDC sensor (do not alter its setting). Lock the ring gear to keep the crank from moving, the book calls for a special tool { (-).0144B } to lock the ring gear but any means will suffice. Remove the crank pulley and timing belt cover. Slide the pulley back on. Remove the ring gear lock or shift to neutral on manual shift cars.

Look at the cam sprocket and locate the rectangular hole. On the outer edge, locate the timing mark. Rotate the crank until that hole and timing mark is in a 45 degree position on the passenger side (its right, your left) of the car and the distributor finger is perpendicular to the engine's axis (straight up).

Loosen the tensioner nut and bolt, with a screwdriver or pry bar, force the tensioner against the spring, to slacken the timing belt, until the support plate is at the end of its travel, lock the nut and bolt. Remove the timing belt.

Handling of the timing belt should be done with great care. Never bring the belt in contact with oil or greasy substances. Never make the belt bow to an arc less than 60mm diameter (don't fold it).


Check the condition of the belt. Check the gap between the tensioner support plate and the set screw mounted above the intermediate sprocket, should be between 0,10 and 0,15 mm, If this is not the case then remove the lock nut, coat the threads with LOCTITE, adjust the gap and tighten the lock nut.

Make sure the crankshaft is in the timing position with the mark to your left and parallel to the ground. Remove the pulley. Check the intermediate sprocket, make sure the timing mark is about 20 degrees below parallel and to your right. Double check the cam and install the belt. The arrows on the outside of the belt indicate the direction of engine rotation. Insure that each reference mark on the belt lines up with the timing marks on the sprockets, starting with the crankshaft. Center the belt on the sprockets and on the tensioner, loosen the tensioner bolt and nut. The belt is automatically adjusted by the spring. Double check the reference marks and tighten the tensioner nut and bolt to a torque of 2,5 mdaN (18.13 ft lbs).
Reinstall the timing belt cover.

Make sure the two (2) split pins are in place and reinstall the pulley. Degrease and brush clean the pulley bolt, coat the threads with LOCTITE and torque to 13 mdaN (94.25 ft lbs).
Reinstall all the items removed on disassembly in reverse order of removal. Reconnect all electrical equipment and adjust belt tension.
Refill cooling system and use proper bleeding procedures.
Reset ignition timing (covered in ZDJL check sheet).
Any questions, give me a call :-)


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