How to Replace timing chain on Peugeot Boxer 3 2.2 HDI 250L U9 2006-

Special tools

• Camshaft sprocket timing pin x 2 – Peugeot No.(-).0198.B2.
• Crankshaft holding/turning tool – Peugeot No.(-).0198.2.A.
• Crankshaft timing pin – Peugeot No.(-).0198.A.
• Tensioner locking pin – Peugeot No.(-).0198.J.

General precautions

• Disconnect battery earth lead.
• Remove glow plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• Observe tightening torques.
• If fitted: Mark position of crankshaft position (CKP) sensor before removal.
• Do NOT turn crankshaft via camshaft or other sprockets.
• Do NOT turn crankshaft or camshaft with timing chain removed.

Valve timing procedures

Removal

• Remove crankshaft position (CKP) sensor.
• Turn crankshaft clockwise to setting position.
• Fit crankshaft timing pin [1] .
• Fit camshaft sprocket timing pin [2] .
• Lock timing chain tensioner in retracted position:
  • Release ratchet [3] .
  • Depress tensioner blade [4] .
  • Insert tensioner locking pin [5] .
• Remove:
  • Camshaft sprocket timing pin [2] .
  • Upper chain guide.
  • Camshaft sprockets.
  • Timing chain.
  • Lower chain guide.

Installation

• Ensure crankshaft timing pin inserted [1] .
• Align black coloured chain links with timing mark on each sprocket [6] & [7] .
• Fit timing chain and crankshaft sprockets. Finger tighten bolts.
• Ensure camshaft sprockets turn freely but do not tilt.
• Fit chain guides.
• Fit camshaft sprocket timing pin [2] .
• Remove tensioner locking pin [5] .
• Ensure bolts of camshaft sprockets not at end of slotted holes [8] .
• Tighten bolts of each camshaft sprocket [9] . Tightening torque: 33 Nm.
• Remove crankshaft timing pin and camshaft sprocket timing pins [1] & [2] .
• Coat crankshaft pulley bolts [10] with suitable thread locking compound.
• Tighten crankshaft pulley bolts [10] . Tightening torque: 45 Nm + 120±5°.