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Important Note

All service items are vital to the smooth running and reliability of a vehicle, none more so than the timing belt and its associated
components. For this reason we have highlighted important information from the manufacturers' service schedules covering the
intervals for checks and replacements. Be sure that you make the vehicle owner aware of this information. Industry best practice
is to ensure that the vehicle owner is made aware of the importance of replacing the timing belt and its associated components
according to the manufacturers' specification. The service history and the use of the vehicle must be considered when deciding
the correct course of action. If there is any doubt to the serviceability of the belt and its components, they should be replaced.

Timing belt replacement intervals

Where possible the recommended intervals have been compiled from vehicle manufacturers' information. In a few instances no
recommendation has been made by the manufacturer and the decision to replace the belt must be made from the evidence of a
thorough examination of the condition of the existing belt.
Apart from the visible condition of the belt, which is explained fully in the General Instructions/Toothed Timing Belts section, there
are several other factors which must be considered when checking a timing belt:

1. Is the belt an original or a replacement?

2. When was the belt last replaced and was it at the correct mileage?
3. Is the service history of the vehicle known?
4. Has the vehicle been operated under arduous conditions which might warrant a shorter replacement interval?
5. Is the general condition of other components in the camshaft drive, such as the tensioner, pulleys, and other ancillary components
driven by the timing belt, typically the water pump, sound enough to ensure that the life of the replacement belt will not be affected?
6. If the condition of the existing belt appears good, can you be satisfied that the belt will not fail before the next check or service is
due?
7. If the belt does fail, have you considered the consequences? If the engine is an INTERFERENCE type then considerable expensive
damage may well be the result.
8. The cost of replacing a belt as part of a routine service could be as little as 5 to 10% of the repair cost following a belt failure. Make
sure your customer is aware of the consequences.
9. If in doubt about the condition of the belt - RENEW it.
10. Refer to the Toothed Timing Belts/Service Replacement section for further information relating to arduous or adverse operating
conditions, inspection and service replacement.

Check For Engine Damage

CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston
damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be
performed before removing the cylinder head.

Repair Times - hrs

Manufacturer: Peugeot Model: 407 2,0D HDi (c) Autodata Lim ited 2013
Engine code: DW 10BTED4 (RHR) Output: 100 (136) 4000 . 29/01/2019
Tuned for: Year: 2004-10 V9.200-
 With diesel particulate filter (DPF) and 6 speed automatic transmission
Camshaft drive belt/chain - R & I 3,30

With diesel particulate filter (DPF), all other transmissions

Camshaft drive belt/chain - R & I 3,30
Without diesel particulate filter (DPF)
Camshaft drive belt/chain - R & I 3,30

Special Tools

Auxiliary drive belt tensioner tool - Peugeot Nos.(-).0188.Z/Q1.

Camshaft sprocket locking tool - Peugeot No.(-).0188.M.
Crankshaft reluctor puller - Peugeot No.(-).0188.P.
Crankshaft sprocket centralizing tool - Peugeot No.(-).0188.AH.
Flywheel timing pin - Peugeot No.(-).0188.X.
Flywheel locking tool - Peugeot No.(-).0188.F.
Tensioner pulley locking pin - Peugeot No.(-).0153-AL.

Special Precautions

Disconnect battery earth lead.

DO NOT turn crankshaft or camshaft when timing belt removed.
Remove glow plugs to ease turning engine.
Turn engine in normal direction of rotation (unless otherwise stated).
DO NOT turn engine via camshaft or other sprockets.
Observe all tightening torques.

Removal

1. Raise and support front of vehicle.

2. Remove:
Engine top cover.
Engine undershield.
RH front wheel.
RH splash guard.
Auxiliary drive belt. Use tool Nos.(-).0188.Z/Q1.
Scuttle panel.

3. Support engine.
4. Remove:
RH engine mounting bolts [1] .
RH engine mounting.
RH engine mounting intermediate bracket bolts [2] .
RH engine mounting intermediate bracket.

5. Disconnect fuel pipes from timing belt upper cover.

6. Remove:
Timing belt upper cover [3] .
Turbocharger air hoses.
Subframe reinforcement plate (if fitted).
Lower engine steady bar.

7. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure camshaft sprocket timing hole at 4 o'clock position [4] .
8. Insert:
Camshaft sprocket locking tool [5] . Tool No.(-).0188.M.

Manufacturer: Peugeot Model: 407 2,0D HDi (c) Autodata Lim ited 2013
Engine code: DW 10BTED4 (RHR) Output: 100 (136) 4000 . 29/01/2019
Tuned for: Year: 2004-10 V9.200-
 Flywheel timing pin [6] . Tool No.(-).0188.X.

9. Fit flywheel locking tool [7] . Tool No.(-).0188.F.

10. Remove:
Crankshaft position (CKP) sensor.
Crankshaft pulley bolt [8] .
Crankshaft pulley [9] .
Timing belt lower cover [10] .
Reluctor [11] . Use tool No.(-).0188.P.

NOTE: Ensure reluctor is not damaged.

11. Slacken tensioner pulley bolt [12] .
12. Turn tensioner pulley away from belt. Use Allen key [13] .
13. Insert tensioner pulley locking pin [14] . Tool No.(-).0153-AL.
14. Remove timing belt.

Installation

1. Check tensioner pulley and guide pulley for smooth operation.

2. Check water pump sprocket for smooth operation.
3. Check crankshaft sprocket has free movement on keyway.
4. Ensure flywheel locking tool located correctly [7] .
5. Ensure flywheel timing pin located correctly [6] .
6. Ensure camshaft sprocket locking tool located correctly [5] .
7. Ensure tensioner pulley locking pin located correctly [14] .
8. Centralize crankshaft sprocket. Use tool No.(-).0188.AH [15] .
9. Fit timing belt in following order:
Crankshaft sprocket.
Guide pulley.
Camshaft sprocket.
Water pump sprocket.
Tensioner pulley.

10. Ensure belt is taut between camshaft sprocket and guide pulley.
11. Remove locking pin [14] . Finger tighten tensioner pulley bolt [12] .
12. Turn tensioner pulley anti-clockwise until pointer at maximum setting. Use Allen key [13] .
13. Tighten tensioner pulley bolt [12] . Tightening torque: 21 Nm.
14. Remove tool [15] .
15. Install:
Reluctor [11] .
Crankshaft pulley [9] .
Crankshaft pulley bolt [8] .

16. Tighten crankshaft pulley bolt [8] . Tightening torque: 50 Nm.

17. Remove tools [5] , [6] & [7] .
18. Turn crankshaft four turns clockwise.
19. Install:
Flywheel timing pin [6] .
Camshaft sprocket locking tool [5] .
Flywheel locking tool [7] .

20. Remove:
Crankshaft pulley bolt [8] .
Crankshaft pulley [9] .

21. Hold tensioner pulley in position. Use Allen key [13] .

22. Slacken tensioner pulley bolt [12] .
23.
Manufacturer: Peugeot Model: 407 2,0D HDi (c) Autodata Lim ited 2013
Engine code: DW 10BTED4 (RHR) Output: 100 (136) 4000 . 29/01/2019
Tuned for: Year: 2004-10 V9.200-
 23. Turn tensioner pulley clockwise until pointer aligned with notch [16] & [17] . Use Allen key [13] .
NOTE: If pointer passes notch [17] , repeat tensioning procedure.
24. Tighten tensioner pulley bolt [12] . Tightening torque: 21 Nm.
25. Install:
Timing belt lower cover [10] .
Crankshaft position (CKP) sensor.

26. Coat crankshaft pulley bolt with suitable thread locking compound.
27. Install:
Crankshaft pulley [9] .
Crankshaft pulley bolt [8] .

28. Tighten crankshaft pulley bolt [8] . Tightening torque: 70 Nm + 62°.

29. Check torque setting of crankshaft pulley bolt is 260 Nm.
30. Remove tools [5] , [6] & [7] .
31. Install components in reverse order of removal.
32. Tighten RH engine mounting intermediate bracket bolts [2] . Tightening torque: 60 Nm.
33. Tighten RH engine mounting bolts [1] . Tightening torque: 60 Nm.

Manufacturer: Peugeot Model: 407 2,0D HDi (c) Autodata Lim ited 2013
Engine code: DW 10BTED4 (RHR) Output: 100 (136) 4000 . 29/01/2019
Tuned for: Year: 2004-10 V9.200-
Manufacturer: Peugeot Model: 407 2,0D HDi (c) Autodata Lim ited 2013
Engine code: DW 10BTED4 (RHR) Output: 100 (136) 4000 . 29/01/2019
Tuned for: Year: 2004-10 V9.200-