How to Replace timing chain on Peugeot Boxer 3 3.0 HDI 107KW 250L U9 2006-

F1CE348IN

Special tools

• Camshaft locking tool x 2 – No.0191-2B.
• Crankshaft pulley holding tool – No.0191-2K.
• Crankshaft timing pin – No.0191-2A.
• PAS pump sprocket locking tool – No.0191-2J.

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

• Removal/installation of timing chain requires:
  • Engine removal.
• Install camshaft locking tools [1] .
• Turn crankshaft in direction of rotation until both camshaft locking tools engage.
• Remove crankshaft pulley.
• Install crankshaft timing pin [2] .
• Slacken idler sprocket bolt [3] .
• Remove:
  • Secondary timing chain tensioner [4] .
  • Primary timing chain tensioner [5] .
  • Primary timing chain tensioner rail.
  • Bolt of each camshaft sprocket.
  • Camshaft sprockets.
  • Secondary timing chain.
  • Oil pump.
  • PAS pump.
• Install PAS pump sprocket locking tool.
• Remove:
  • PAS pump sprocket bolt [6] .
  • PAS pump sprocket locking tool.
  • PAS pump sprocket [7] .
  • Primary timing chain guides.
  • Primary timing chain.

Installation

• Ensure camshaft locking tools correctly fitted [1] .
• Ensure crankshaft timing pin correctly fitted [2] .
• Install:
  • Primary timing chain.
  • PAS pump sprocket [7] .
• Tighten bolt of PAS pump sprocket finger tight [6] .
• Ensure primary timing chain is taut between sprockets on non-tensioned side.
• Install:
  • Primary timing chain guides.
  • Secondary timing chain.
  • Camshaft sprockets.
• Tighten bolt of each camshaft sprocket finger tight.
• Ensure secondary timing chain is taut between sprockets on non-tensioned side.
• Install PAS pump sprocket locking tool.
• Tighten bolt of PAS pump sprocket. Tightening torque: 130 Nm.
• Remove PAS pump sprocket locking tool.
• Install:
  • Primary timing chain tensioner rail.
  • Primary timing chain tensioner [5] . Tightening torque: 50 Nm.
  • Oil pump.
  • New secondary timing chain tensioner [4] .
• Tighten bolt of each camshaft sprocket. Tightening torque: 110 Nm.
• Tighten idler sprocket bolt [3] . Tightening torque: 110 Nm.
• Remove:
  • Crankshaft timing pin [2] .
  • Camshaft locking tools [1] .
• Turn crankshaft four turns clockwise.
• Ensure crankshaft timing pin and camshaft locking tools can be fitted [1] & [2] .
• Tighten crankshaft pulley bolt. Tightening torque: 350 Nm.