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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

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

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°.

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