How to Replace timing chain on Citroen Jumper 2.2HDi 2003

Citroen

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 & A3,00
Camshaft drive belt/chain, AC – C & A3,30
Camshaft drive belt/chain – R & I3,70
Camshaft drive belt/chain, AC – R & I4,00

Valve timing procedures


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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Bent Valves
Timing Tools?
Misconception
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Bent Valves

What happens when your chain or belt breaks. 

The timing of course becomes way off. Your crankshaft will always spin making the pistons move up and down. However the valves will remain in the position they were in when the belt or chain stopped working. 

Half of the valves will be stuck open and in the way of the pistons. Not all engines, but most. The piston out of valve time will smash right into the open valve and bend the, The only way to fix that is to remove the head and place those valves. 

If you think your valves might have been damaged.

Remove all the spark plugs, valve covers. With both valves in the closed position insert a compression tester hose in place of the spark plug and inject air into the hose and see if the cylinder can hold air. If both valve are closed and air can not be held, chances are you have bent valves.   

 

Timing Tools?

Do you need special tools to time your engine? Not always, on all my post I'll indicate that in each post if you do or not. 

But what are these special tools? Normally you would just line up some marks on the cam and crank gears and simply be done with it. However when these tools are needed they are very very important. 

The last one I did was a 2013 Range Rover 2.0 Turbo with dual cams. There were not timing marks at all. 

There is a small threaded plug on the back of the engine that I removed to insert a special threaded pin that would rest up against the weight of the crankshaft to prevent for DTC of the #1 piston. No further clockwise rotation would be possible. At that point I installed the supplied crankshaft lock by removing the starter. 

Then you line up the back of both camshafts to a notch in each camshafts to each other that a flat tool connects to each cam so they are in line with each other. But first you would make sure both intake and exhaust valves are closed DTC of the cams. 

And the last tool was to lineup the crankshaft position sensor. 

 

Misconception

The most important thing in any major engine work is to rotate the engine by hand at least two complete rotations. And do it easy and slow and with the spark plugs removed. 

Why remove the spark plugs? you may ask. Simple, with the plugs in place you'll be creating compression, making the engine harder to turn by hand and perhaps giving you the misconception of valves hitting the pistons or is it compression.  

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