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

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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

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

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.

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