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How to Replace timing chain on Citroen Jumper 2.2HDi 2003

Citroen Jumper 2.2HDi 2003 cambelt change instructions and replacement inteval. Full guide!

Special tools

  • Flywheel locking tool – Citroen No.(-).188.F.
  • Flywheel timing pin – Citroen No.(-).0188.Y.
  • Camshaft timing pin – Citroen No.(-).0188.M.
  • Tensioning tool – Citroen No.(-).0188.J2.
  • Timing belt retaining clip – Citroen No.(-).0188.K.
  • Tension gauge – SEEM CTG 105.5M.
  • Crankshaft pulley puller – Citroen No.(-).0188.P.

Special precautions

  • Disconnect battery earth lead.
  • DO NOT turn crankshaft or camshaft when timing belt removed.
  • Remove spark 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.

Repair times – hrs

Camshaft drive belt/chain – C & A 3,00
Camshaft drive belt/chain, AC – C & A 3,30
Camshaft drive belt/chain – R & I 3,70
Camshaft drive belt/chain, AC – R & I 4,00

Valve timing procedures

How to Replace timing belt on Citroen Jumper 2.2HDi 2003
How to Replace timing belt on Citroen Jumper 2.2HDi 2003

Removal

NOTE: The high-pressure fuel pump fitted to this engine does not require timing.

  1. Raise and support front of vehicle.
  2. Remove:
    • Engine lower cover.
    • RH front wheel.
    • RH splash guard.
    • Auxiliary drive belt.
  3. Lock flywheel [1] . Use tool No.(-).188.F.
  4. Remove crankshaft pulley bolt [2] .
  5. Refit crankshaft pulley bolt without thrust washer [2] .
  6. Fit crankshaft pulley puller. Tool No.(-).0188.P.
  7. Detach crankshaft pulley from crankshaft.
  8. Remove:
    • Crankshaft pulley puller.
    • Crankshaft pulley bolt [2] .
    • Crankshaft pulley [3] .
    • Flywheel locking tool [1] .
  9. Support engine.
  10. Remove:
    • EGR pipe heat shield.
    • EGR pipe.
    • RH engine mounting and bracket.
    • Bolt [4] .
    • Timing belt upper covers [5] .
    • Timing belt lower cover [6] .
  11. Refit bolt fitted with a 17 mm thick spacer [4] . Tighten bolt to 15±1 Nm.
  12. Turn crankshaft clockwise to setting position.
  13. Insert timing pin in flywheel [7] . Tool No.(-).0188.Y.
  14. Insert timing pin in camshaft sprocket [8] . Tool No.(-).0188.M.
  15. Slacken camshaft sprocket bolts [9] .
  16. Slacken tensioner pulley bolt [10] .
  17. Turn tensioner pulley clockwise away from belt. Use tool No.(-).0188.J2.
  18. Remove timing belt.

Installation

  1. Check tensioner pulley, guide pulley and water pump sprocket for smooth operation.
  2. Ensure timing pins located correctly [7] & [8] .
  3. Tighten bolts finger tight [9] .
  4. Turn camshaft sprocket fully clockwise in slotted holes.
  5. Fit timing belt to crankshaft sprocket.
  6. Secure belt to crankshaft sprocket with retaining clip [11] . Use tool No.(-).0188.K.
  7. Fit timing belt in anti-clockwise direction. Ensure belt is taut between sprockets.
  8. Lay belt on camshaft sprocket teeth. Engage belt teeth by turning sprocket slightly anti-clockwise.
    NOTE: Angular movement of sprocket must not be more than one tooth space [12] .
  9. Fit timing belt to water pump sprocket and tensioner pulley.
  10. Remove retaining clip [11] .
  11. Attach tension gauge to belt at [13] . Tool No.SEEM CTG 105.5M.
  12. Turn tensioner pulley anti-clockwise until tension gauge indicates 98±2 SEEM units.
  13. Tighten tensioner pulley bolt [10] . Tightening torque: 25 Nm.
  14. Ensure sprocket bolts not at end of slotted holes [14] .
  15. If necessary: Repeat installation procedure.
  16. Tighten camshaft sprocket bolts [9] . Tightening torque: 20 Nm.
  17. Remove:
    • Timing pins [7] & [8] .
    • Tension gauge [13] .
  18. Turn crankshaft eight turns clockwise to setting position.
  19. Insert timing pin [7] .
  20. Slacken camshaft sprocket bolts [9] .
  21. Insert timing pin [8] .
  22. Slacken tensioner pulley bolt to release tension on belt [10] .
  23. Attach tension gauge to belt at [13] .
  24. Turn tensioner pulley anti-clockwise until tension gauge indicates 54±2 SEEM units.
  25. Tighten tensioner pulley bolt [10] . Tightening torque: 25 Nm.
  26. Tighten camshaft sprocket bolts [9] . Tightening torque: 20±2 Nm.
  27. Remove tension gauge [13] .
  28. Check belt tension: Attach tension gauge to belt at [13] . Tension gauge should indicate 54±3 SEEM units.
  29. If not: Repeat tensioning procedure.
  30. Remove:
    • Tension gauge [13] .
    • Timing pins [7] & [8] .
  31. Turn crankshaft two turns clockwise to setting position.
  32. Insert timing pin in flywheel [7] .
  33. Ensure timing pin can be inserted easily [8] .
  34. If locking tool cannot be inserted: Visually check camshaft sprocket hole [15] aligned with hole in cylinder head. If holes are misaligned, this should be less than 1 mm. If misalignment of holes more than 1 mm, repeat installation procedure.
  35. Remove timing pins [7] & [8] .
  36. Remove bolt and 17 mm spacer [4] .
  37. Fit:
    • Timing belt upper covers [5] .
    • Timing belt lower cover [6] .
    • Bolt [4] . Tighten bolt to 15±1 Nm.
    • Flywheel locking tool [1] .
  38. Remove crankshaft pulley bolt [2] .
  39. Refit crankshaft pulley [3] .
  40. Coat crankshaft pulley bolt with suitable thread locking compound.
  41. Tighten crankshaft pulley bolt [2] . Tightening torque: 70 Nm + 62°.
  42. Remove flywheel locking tool [1] .
  43. Install components in reverse order of removal.
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