Do-it-yourself device for setting timing marks for an ep6 engine

The engine gas distribution mechanism is equipped with a drive that regulates the distribution phases of the intake/exhaust valves and mechanisms in the cylinder-piston system. There are three types of drives: chain, belt and gear. The Peugeot 308 with the most common 120-horsepower EP 6 unit is equipped with a chain drive.

EP 6 is a four-cylinder unit with an overhead camshaft arrangement with two valves per cylinder (DONS). Depending on the modifications, there are naturally aspirated and turbocharged diesel versions with a volume of 1.4 and 1.6 liters with a power of 90 to 270 hp.

In both versions of engines, the timing drive on the Peugeot 308 operates on the same principle; the difference will be in the permissible wear of the chain guides during diagnostics. A new timing chain installation kit is selected according to the vehicle’s VIN, which takes into account the engine parameters for each specific model.

Main drive components:

The principle of operation of the timing belt is the synchronous operation of two shafts: camshaft and crankshaft. The camshafts are driven through the valve timing clutch, receiving rotation from the crankshaft.

The cams on the camshafts run onto the spring valve levers, providing the phases of intake of the fuel mixture and exhaust gases. Adjusting the phase distribution of the mechanism depends on two factors: the location of special marks on the shafts and the size of the chain tensioner.

Subject to routine maintenance, the timing chain of a Peugeot 308 can last up to 150 thousand km. Chain wear will be manifested by the following symptoms:

• When starting the engine, a characteristic engine hum is heard at idle speed; malfunctions in the operation of the valve system at low speeds are possible
• Problems with starting at sub-zero temperatures of a cold unit and signs of “tripping” at idle
• There is increased fuel and oil consumption
• Sudden engine stops at idle and low speeds
• Unstable operation of the unit with obvious signs of smoky exhaust gases
• Failure to start the engine when the starter and ignition system are running

A problem with the timing chain is detected by the on-board computer, which issues a check for the “antipollution system faulty” error. Also, during failures, the “Check Engine” indicator will light up on the on-board instrument panel. If the problem cannot be solved by adjusting the chain tensioner, then the drive must be completely replaced. The replacement can be done with your own hands, subject to compliance with technical regulations and a special set of tools.

Replacing the timing chain on a Peugeot with an EP6 and EP6 Turbo engine, model series 308, 3008 and 408

Before replacing, the timing chain must be checked for tension; a special device (tensioner template) will help you find out whether it is the case by measuring it, this is what it looks like in the photo

In the EP6 engine, the template is screwed in instead of the tensioner; first, the internal pin is unscrewed in it, screwed into its place along the main thread until it stops by hand, and the internal rod is also screwed in by hand until it stops lightly; , then measure with a ruler or caliper; on a naturally aspirated engine, EP6 should be up to 73 mm. on a turbocharged EP6DT 71 mm engine. You can buy this template with a set for fixing timing marks in the online tool store I have checked, where the prices are quite low.

Replacing the timing chain on a Peugeot 308 with an EP6 engine is best done on a lift; if there is no current one, you will have to tinker a little with the jack, since you need to unscrew the right engine mount and install the flywheel mark, which is located at the very bottom of the engine, otherwise in the photo you'll see everything.

the Peugeot 308 Turbo as an example , a non-turbocharged engine is even easier to repair and everything is roughly similar, except that the valve cover is different and there is a phase shifter on the exhaust camshaft.

Indirect signals about the need for replacement

The timing chain itself is a much more reliable consumable than a belt, and can withstand a mileage of more than 150 thousand kilometers if you treat the car with care and follow all technical regulations prescribed by the manufacturer in the instructions. This applies not only to naturally aspirated, but also to turbocharged versions of this car.

The following symptoms most often indicate the need to replace the chain:

• Unusual engine noise, reminiscent of a diesel engine, when idling or at low speeds.
• Troubling, engine operation with failures and sudden shutdowns.
• Problems starting the engine.
• Oil is consumed in volumes exceeding standard values, and fuel consumption increases.

The message “Anti-pollution system faulty” or other errors appear on the on-board computer screen, indicating problems in the operation of the gas distribution mechanism.

• The "Check Engine" signal appears.

When the timing chain wears out on a Peugeot 308, other problems are possible. You should pay special attention to them if the car has already accumulated the appropriate mileage and was operated in urban mode.

When to change the timing chain on a Peugeot 308 (regulations and signs of replacement)

Despite the fact that externally the drive chain of the naturally aspirated EP6 gas distribution mechanism looks flimsy, it is capable of working properly for at least 150-170 thousand if you take good care of the engine and comply with technical regulations . The same applies to the timing chain for this engine with a turbine, and the replacement process differs little. The difference lies in some nuances in the replacement and adjustment process, as well as wear tolerances.

The timing chain is capable of running 150-170 thousand km.

A break in the drive chain is unlikely, so replacing it is only considered if certain symptoms, sometimes indirect, appear.

Indirect symptoms

The main ones are considered:

1. Increased “diesel” noise when the engine is running at idle and low speeds.
2. The engine starts to stall and has trouble starting.
3. Oil consumption is increasing at a rate of 0.25-0.5 liters per 1000 km, and high gasoline consumption is observed.
4. Unstable operation, failures, the engine suddenly stalls.
5. The on-board computer may display the Antipollution system faulty error and a number of profile errors related to the gas distribution system.

   
   The Antipollution system faulty error may indicate problems with the timing chain.

6. The Check Engine light may come on unexpectedly, especially in damp and wet weather.

There may be even more symptoms, but the main reason for replacing the chain is the corresponding mileage, especially in cases where the car is used in the city, where the mileage is about two kilometers.

When is replacement needed?

Despite the rather flimsy appearance of the timing chain, it has a long service life. On atmospheric EP6 engines it lasts for about 170 thousand km. But this is subject to the condition that all technical regulations will be unquestioningly observed, and the attitude towards the engine will be as careful as possible. But even if the engine is not naturally aspirated, but with a turbine, the timing drive lasts about the same. But there are minor nuances when diagnosing the condition of the timing chain; we will definitely mention this in our article.

The repair procedure is no different for naturally aspirated and turbocharged types. It is worth noting that a break is unlikely to occur, so replacement should only be carried out if certain symptoms are present, which are sometimes quite difficult to identify. Now we will look at all the symptoms that indicate that the timing drive needs to be repaired.

In what cases is it necessary?

The timing chain has the same purpose as a timing belt. They serve for synchronous interaction of the crankshaft and camshaft. Thanks to them, valves and pistons move simultaneously without interfering with each other. If this is violated, for example, if the belt breaks, then the valves meet the pistons and bend, which can lead to engine overhaul. The advantage of the chain is that it does not break, so there is no risk of major repairs due to a break.

Timing chain slack

When using a Peugeot 308 for a long time, the timing chain stretches over time. This happens due to wear of the hinge joints. They wear out, the pitch between the links increases. The chain needs to be changed if:

• the possibility of regulating its tension has been exhausted;
• if the marks on the camshaft match, the marks on the crankshaft do not match;
• Chips were found on the bushings, cracks appeared on the cheeks.

If the pitch increases, the engine does not idle smoothly. Worn links stretch unevenly, so the chain around the sprockets becomes tighter or looser.

A stretched chain makes more noise, the engine starts harder, and fuel consumption increases.

It is dangerous for the chain to jump 1-5 teeth. In the best case, the car will simply stop; in the worst case, the pistons will meet the valves and a major engine overhaul may be required. Therefore, the timing chain tension should be checked regularly.

It can be checked using a special device that acts as a tensioner.

This template is installed in place of the tensioner. First, the inner pin is unscrewed, and the inner rod is screwed in at the same time. The gap is measured using a ruler or caliper. For a naturally aspirated Peugeot 308 engine it should not exceed 73 mm, for a turbocharged engine - 71 mm.

Tensioner template for checking tension

Consequences of wear

Over time, the chain's hinge joints wear out, causing it to stretch. The pitch between the links increases, and the consumable will no longer work efficiently. The chain needs to be changed in the following cases:

• it is no longer possible to adjust the chain tension;
• the marks on the shafts no longer match;
• chips or other damage are visible on the consumable.

If the chain stretches, the engine will run rough. It begins to make extraneous noises, making it harder to start. The car begins to consume more fuel. On a stretched chain, the links can slip over the teeth. It’s good if after this the car simply stops moving, but this may well cause the valves to meet the pistons, and this is a major overhaul

Therefore, it is always very important to regularly check the current condition of the consumable. Although a chain is more practical than a belt, it also wears out its resource

Chain transmission has its undeniable advantages:

• the chain rarely breaks, much more often it stretches;
• the chain is made of solid material;
• in case of interruptions in the operation of the circuit, the valves are not subject to external mechanical influence.

Replacing this consumable is not an easy task, which many car enthusiasts entrust to professionals, but you can carry out the replacement procedure yourself. To do this, you must follow the instructions exactly and try to do everything correctly.

Changing the timing chain on a Peugeot 308 EP6 with your own hands: when to change, video inside

The fairly technologically advanced and durable naturally-aspirated engine EP6, which is installed on a number of Peugeot models, including the 308, requires complex repairs from time to time. Without experience working with engines of this level and without the appropriate equipment, there is no need to talk about complex repairs. Nevertheless, replacing the timing chain on a Peugeot 308 with an EP6 engine is possible with your own hands. Before this, you need to know when to change, know where the installation marks are and how to correctly align the camshafts and crankshaft relative to each other. Let's try to figure this out.

Features of the timing drive

The Peugeot 308 is equipped with a durable and technologically advanced EP6 engine. It is naturally aspirated, which means that there are no turbines or intercoolers in it. This engine can also be found on other Peugeot models, for example on the 308. If you have little experience, then it is better to entrust serious engine repairs to professionals.

But if we are only talking about replacing the chain, then you can deal with this problem in one evening. But you need to know when to replace it, as well as the location of all the marks on which the camshafts and crankshafts are installed. We will talk about this in our article.

When and why should you change the timing chain on a Peugeot 308?

Home > Useful information > Peugeot repair > Peugeot 308 - the most common breakdowns and their repairs > When and why should you change the timing chain on a Peugeot 308? If you are the owner of a Peugeot 308, do not forget to follow the rules for replacing such an undoubtedly important component as the timing chain. The manufacturer recommends doing this once every 80 thousand km. mileage Sometimes this chain can break even earlier. There are examples where the timing chain was regularly exposed to oil that leaked from a worn camshaft oil seal. As a result, the oil “ate” the chain quite quickly.

This proves the fact that in order to avoid this, it is worth diagnosing the engine compartment of the Peugeot 308 at least a couple of times a year. You need to check not only the chain, but also other components, so that your frivolity does not provoke an emergency overhaul of the engine, you know, God saves the best . Also, the timing chain must be replaced if you purchase a used car from a stranger.

Consequences of a broken timing chain on a Peugeot 308

If these rules are neglected, the result may be a broken chain, which will cause the pistons to hit the valves, which will certainly lead to their deformation. As a result, you will have to repair the cylinder block and change the valves, and this “pleasure” is not cheap.

Replacing the chain and pump

Let's be honest, replacing a timing chain is a rare procedure. But if you are already doing this, then, as experienced car owners advise, it is worth changing the tensioner and damper right there. These parts will have to be purchased. At the same time, we advise you to change the pump, since replacing it is advisable for the reason that it also changes every 80-100 thousand km, but without removing the latter it is problematic to get to it. In other words, this way you will immediately kill two birds with one stone, and you will not have to overpay subsequently for essentially the same work.

Read more:

Reasons for high fuel consumption on Peugeot 308

vtauto.ru

You will need a kit to install timing marks on a Peugeot.

Tool

• Special tool for installing marks on EP6, Licota and JTC engines (links to installation kits), Likota is of course cheaper.
• Collars, small 1/4 and large 1/2

Heads:

• 18 for the crankshaft pulley bolt
• 10 to unscrew the valve cover
• 8 to unscrew the upper damper
• 27 for chain tensioner
• E16 for camshaft bolts
• Torex T40 for unscrewing the lower stabilizers
• Torex T30 for removing the throttle body (for non-turbocharged model)
• 16mm wrench to remove support from engine block
• Torque wrench (how to tighten with a torque wrench)

For convenience, so as not to look for all this tool, it’s easier to immediately buy a set and not have to worry, it will still be useful.

Removal:

1. Unscrew the air filter unit, remove it from the guides and move it to the side
2. We unscrew the valve cover and remove it, take the 18th head with a knob and turn the crankshaft pulley, roughly align the camshafts to set the mark from below. Attention, if a mark is missed, it is not recommended to turn the shaft counterclockwise; turn the shaft forward another two turns until it hits.
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3. We remove the ICE (Internal Combustion Engine) protection, if any.
4. Jack up the car or lift it on a lift and install the bottom mark in the hole
5. We unscrew the right wheel and locker, it will also interfere with us.
6. If you are not making the replacement on a lift, then you will have to put something under the engine sump, such as a stump, and lower the engine with the car on it and remove the right support,
7. We install the upper device for the camshaft marks.
8. Remove the generator belt.
9. We unscrew the pump drive roller, it is secured with three 10mm bolts
10. Next, unscrew the upper damper and chain tensioner

11. We also unscrew the knee pulley
12. Bolt 18 which presses and holds the lower sprocket support
13. We take out this very support from the oil seal. (it is best to replace the oil seal with a new one)
14. Remove the lower chain guides by unscrewing 3 bolts as shown in the photo
15. We take out the oil dipstick, since inside the block it passes through the chain guide
16. We pull the chain upward along with the dampers and the lower sprocket.
17. We install everything in the reverse order with the timing marks set.

Attention: The crankshaft service unit is located in such a way that all pistons are at the same level in an intermediate state, between top and bottom dead centers.

You should first assemble the entire structure of the chain and dampers before installation, as shown in the photo, and then lower the timing belt into the installation location

It is imperative to degrease the timing sprocket and crankshaft hub before installing it in the seat.

To replace the timing chain, according to the manufacturer's regulations, new spare parts are required:

1. 0805K1 — Camshaft gear, intake
2. 0805K3 — Camshaft gear, exhaust (Peugeot EP6CDT) Turbo
3. 0513C8 — Timing chain drive gear, lower (Peugeot EP6)
4. 0249E6 — Valve cover gasket (Peugeot EP6CDT)
5. 082028 — Sealing washer
6. 0249E7 — Valve cover gasket (Plug wells) (Peugeot EP6CDT)
7. 025057 — Bolt DIAM 6X100-20
8. 0516K5 — Crankshaft bolt
9. 080677 — Camshaft bolt
10. 080678 — Camshaft bolt
11. 082026 — Timing chain guide bolt
12. 082027 - Bolt
13. 1606466680 — Crankshaft pulley bolt
14. 0829G3 — Timing chain tensioner
15. V861831780 — Timing chain (Peugeot EP6CDT) Turbo
16. 081830 — Timing chain guide, right. (Peugeot EP6CDT) Turbo
17. 081831 — Left timing chain guide. (Peugeot EP6CDT) Turbo
18. 081829 — Upper timing chain guide. (Peugeot EP6CDT) Turbo

It is recommended to coat the crankshaft sprocket mounting bolt with stop thread

Tightening torques with a torque wrench:

1. Chain tensioner - 8.5 da.N.m
2. 3 mounting bolts for dampers - 2.5 da.N.m
3. Crankshaft hub mounting bolt - tighten to a torque of 5 da.Nm, then tighten at an angle of 180 degrees
4. Three attachment pulley bolts - 2.8 da.N.m
5. Phase shifter mounting bolt - tighten to a torque of 2 da.Nm, then tighten at an angle of 180 degrees
6. Camshaft sprocket mounting bolt - tighten to a torque of 2 da.Nm, then tighten at an angle of 90 degrees

Be careful not to confuse the phase shifters - the inlet is marked IN35, the exhaust is EX30

Step-by-step instruction

It is better to replace the chain on a lift or platform, since it will be necessary to remove the right support to install the flywheel mark, located at the very bottom of the engine.

Tools

To carry out the work you should prepare:

• small and large collars (1/4 and 1/2, respectively);
• set of heads;
• a set of keys;
• Thorex T30 and T40;
• screwdriver

Supplies you need to prepare:

• chain;
• chain tensioner;
• 3 pcs. sedative;
• new camshaft bolts;
• camshaft and crankshaft sprockets;
• valve cover gasket.

When buying a replacement chain, you should pay attention to quality. It's better to buy the original. The quality of the metal from which the consumable is made can be determined using a needle file, since the links and bushings are hardened. To avoid someone slipping a used chain into the market, you need to hold it flat with your hand and check how much it slacks. If the sag is 7-10 mm, then the product is new, if 17-20 mm, it is old.

Engine compartment of Peugeot 308

Stages

1. After placing the car on a lift, you need to disconnect the negative terminal on the battery to turn off the power to the car.
2. Remove the front right wheel, fender liner and engine protection.
3. We take out the air filter and disconnect the air intake pipe.
4. Then we remove the decorative engine cover.
5. Disconnect the camshaft position sensors and electrical wires from the engine.
6. Having disconnected the power from the ignition coils, remove them.
7. Disconnect the crankcase ventilation hose and all pipes. It is advisable to plug technological plugs into them so that nothing gets in there.
8. Removing the cylinder head cover (cylinder head).

   
   Cylinder block without cover

9. Raise the engine and remove the dipstick to measure the oil level.
10. We remove the engine mount.
11. Next, remove the accessory drive belt.
12. After unscrewing the three mounting bolts, remove the additional equipment pulley.
13. Then we turn the crankshaft by the mounting bolt to the position in which the flywheel is fixed.
14. Using a special device, we secure the flywheel and camshafts.
15. Remove the chain tensioner.
16. Remove the intake and exhaust camshaft pulleys.
17. Unscrew the crankshaft hub.
18. Remove the timing chain.
19. Then you need to remove the fixed guide and the tensioner guide.
20. Next, remove the crankshaft gear and sealing ring.
21. Before replacing consumables on the Peugeot 308 and installing components in their original places, everything should be thoroughly cleaned of dirt.
22. Next, assemble the tensioner guide, fixed guide, timing chain and timing gear. The finished structure must be installed on the cylinder head.
23. We set the timing marks. You can watch the video to see how to do it correctly.
24. Install the timing gear drive gear pulley onto the crankshaft.
25. Reinstall the crankshaft hub.
26. We return the intake and exhaust camshaft pulleys to their original place.
27. Then we install the chain tensioner and damper.
28. We install the sealing ring in its original place.
29. We mount the attachment drive pulley.

    
    Chain drive assembly

30. Remove the camshaft and crankshaft clamps.
31. We put on the Peugeot 308 accessory belts and adjust their tension.
32. Install the block head cover.
33. We connect all the pipes.
34. We return the oil dipstick to its place.
35. Reinstall the ignition coil and connect its power.
36. We connect all sensors and electrical wiring.
37. Screw on the decorative cover.
38. We install the pipe, the air filter and the cover of its housing.
39. The engine protection is put in place.
40. The fender liner and the right front wheel are installed.
41. Lastly, connect the negative terminal to the battery.

After the procedure, you should check the operation of the engine. At this point, the process of replacing the timing belt can be considered complete. Although the procedure is labor-intensive, it is quite doable. Thus, you will save on car service costs and gain invaluable experience.

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Replacing the timing chain on Peugeot 308 1.6 EP6 and EP6TD at the FransAvto technical center.

The Peugeot 308 timing chain is an important component under the hood of the car. If you do not replace it with a new one in time, unpleasant consequences are possible. Because The head valves may be damaged, which entails high repair costs. How can you determine its wear? First of all, monitor the car’s mileage; if it has exceeded more than 60,000 kilometers, you should pay more attention to every sound. If the idle speed begins to float, the engine does not operate evenly in cold weather, and the “Antipollution faulty” error appears on the dashboard or fuel consumption increases. Most likely the cause is a stretched timing chain. In this case, we advise you to go to a service center and get a diagnosis.

The cost of replacing the chain in our technical center.

Standard chain replacement for Peugeot 308 1.6 EP6 work with spare parts price: 15,000 RUR

The kit includes:

• Job
• Timing chain 9822827080
• Chain tensioner 9816058580
• Upper chain stabilizer 081841
• Chain guide 2 pcs. 081833/081840
• Front crankshaft oil seal 0514C8
• Valve cover gasket (kit) 0249F4
• Crankshaft gear 0513C8
• Bolts 3 pcs. 082026*2/082027

Complete replacement of the timing chain for Peugeot 308 1.6 work with spare parts price: 24,000 rub.

The kit includes:

• Job
• Timing chain 9822827080
• Chain tensioner 9816058580
• Upper chain stabilizer 081841
• Chain guide 2 pcs. 081833/081840
• Front crankshaft oil seal 0514C8
• Valve cover gasket (kit) 0249F4
• Crankshaft gear 0513C8
• Exhaust camshaft gear (variable exhaust valve timing clutch) 0805K1
• Intake camshaft gear (intake variable valve timing clutch) 0805K2
• Bolts 3 pcs. 082026*2/082027

You can get advice or sign up for repairs and maintenance by calling us at +7(495)507-26-33 . Call!

The address of our technical center where we replace chains for Peugeot and Citroen.

Catalog numbers

If, after taking measurements, you find out that the Peugeot 308 chain needs to be replaced, you will need to buy spare parts. But to do this you need to know their catalog numbers, use the table.

Timing chain selection: original and analogues

Engines of the EP 6 type are installed on Peugeot, Citroen and Mini-Cooper cars in different generations; their analogue timing chain kits are also suitable for a certain type of unit. When choosing, take into account the catalog number and article number, which corresponds to the VIN of the car.

The price of analog sets may vary depending on the brand and country of manufacture. When purchasing, pay attention to the full labeling of the product, which should have a barcode of the country of manufacture, an article number, and pictograms of OE and EU certificates of conformity. Counterfeit kits made in China that do not have a brand license are often passed off as analogues.

Peugeot 308 timing chain kits

Peugeot 308: replacing the chain with your own hands. Checking chain wear, tools and necessary spare parts

In the article we will talk about how to replace the chain on a Peugeot 308 in a garage. The car is not very representative, and the fact that it is a foreign car does not mean that only an experienced mechanic can repair it. You just need to understand the principle of operation of the internal combustion engine, have the desire and tools to carry out any repairs yourself. This is a budget car, which is not much different in design from the domestic Prior and Ten (except that they are much more comfortable and, despite the fact that it is a Pyzhik, more reliable).

Tightening torque and reassembly

As you can see, on an ep6 motor, replacing the chain is a complex procedure, but it requires special tools and skills

It is also important to know with what torque (force) to tighten previously unscrewed bolts. This information is in the manual, it is recommended that you read it before starting assembly.

For example, the tightening of the chain tensioner with a torque wrench is 8.5 da.N.m, the stabilizer bolts are 2.5, the crankshaft hub mounting bolt is 5, the attachment pulley bolts are 2.8, the phase shifter mounting bolt is 2, the camshaft sprocket is 2, etc.

It is also recommended to lubricate the crankshaft sprocket mounting bolt with the so-called liquid fixative.

It is also important not to make mistakes when installing phase shifters on the intake and exhaust shafts (intake is marked IN35, exhaust EX30)

What tools are needed?

We mentioned that to replace the timing chain on a Peugeot 308, you need a set of special tools. But you may also need the following tools:

1. Collars.
2. Standard set of heads.
3. Torex bits.
4. Torque wrench.
5. Sealing sealant.
6. Silicone sealant for gaskets.
7. Screwdriver set.

What is needed for replacement?

To replace the chain, you will need the following parts:

• New timing chain.
• Tensioner.
• Upper, right and left dampers.
• Camshaft and crankshaft gears.
• Sealing couplings for the camshaft inlet valve.
• Bolts for the camshaft gear.
• Hub, bolt for fixing the hub and crankshaft oil seal.
• Valve cover gasket.

This is a minimum set of parts; other consumables may also be required (if the engine is very worn).

In addition, you need to prepare a set of tools:

• 1/2 and 1/4 collars.
• Heads.
• Torex bits.
• Torque wrench.
• Screwdrivers.
• Retaining sealant and gasket sealant.

Once everything is ready, you can start making repairs.