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    Peugeot, Boxer 2,2 HDI Distribución

    Uploaded by

    Manuel Castellón
    The document lists the tools needed and provides step-by-step instructions for dismounting and mounting the timing chain on a Peugeot Boxer 2.2 HDI engine. It details removing components, using locking tools on the flywheel, camshaft, and chain tensioner, and turning the crankshaft to specific marks before removing parts. Reassembly instructions include installing the chain and gears, checking camshaft timing, and applying sealant when mounting the chain cover.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Peugeot, Boxer 2,2 HDI Distribución

    Uploaded by

    Manuel Castellón
    1K views7 pages
    The document lists the tools needed and provides step-by-step instructions for dismounting and mounting the timing chain on a Peugeot Boxer 2.2 HDI engine. It details removing components, using locking tools on the flywheel, camshaft, and chain tensioner, and turning the crankshaft to specific marks before removing parts. Reassembly instructions include installing the chain and gears, checking camshaft timing, and applying sealant when mounting the chain cover.

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    © © All Rights Reserved

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    The document lists the tools needed and provides step-by-step instructions for dismounting and mounting the timing chain on a Peugeot Boxer 2.2 HDI engine. It details removing components, using locking tools on the flywheel, camshaft, and chain tensioner, and turning the crankshaft to specific marks before removing parts. Reassembly instructions include installing the chain and gears, checking camshaft timing, and applying sealant when mounting the chain cover.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    1K views7 pages

    Peugeot, Boxer 2,2 HDI Distribución

    Uploaded by

    Manuel Castellón
    The document lists the tools needed and provides step-by-step instructions for dismounting and mounting the timing chain on a Peugeot Boxer 2.2 HDI engine. It details removing components, using locking tools on the flywheel, camshaft, and chain tensioner, and turning the crankshaft to specific marks before removing parts. Reassembly instructions include installing the chain and gears, checking camshaft timing, and applying sealant when mounting the chain cover.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 7

    Tolerance Data 2009.

    2 Peugeot, Boxer 2,2 HDI

    Tools

    1. “0198-A” = Flywheel locking tool.


    2. ”0198-B2” = Camshaft locking tool/rod.
    3. “0198-J” = Chain tensioner locking tool.
    4. ”0198-G” = Centring gauge for chain cover.
    5. ”0198-D" = Special tool for dismounting/mounting of crankshaft oil seal.
    6. ”0198-2A” = Tool for rotating crank.

    1. “0198-A” = Flywheel locking tool.


    2. ”0198-B2” = Camshaft locking tool/rod.
    3. “0198-J” = Chain tensioner locking tool.
    4. ”0198-G” = Centring gauge for chain cover.
    5. ”0198-D" = Special tool for dismounting/mounting of crankshaft oil seal.
    6. ”0198-2A” = Tool for rotating crank.
    Tolerance Data 2009.2 Peugeot, Boxer 2,2 HDI

    Dismount 1

    1. Switch off ignition and wait at least 15 minutes before removing chassis cable.
    2. Remove :
     the right front wheel.
     the bottom plate.
     the right inner fender.
     the front bumper.
     the right headlamp.
     the multi-belt.
    3. Dismount air filter housing.
    Tolerance Data 2009.2 Peugeot, Boxer 2,2 HDI

    Dismount 2

    1. Dismount one of the crank bolts.


    2. Mount tool "0198-2A" on crankshaft pulley / vibration damper.
    3. Dismount crank position sensor.
    4. Turn the engine clockwise to the marks.
    5. Fix locking tool “0198-A” in flywheel.
    6. Remove :
     tool "0198-2A"
     crankshaft pulley / vibration damper.

    1. Dismount one of the crank bolts.


    2. Mount tool "0198-2A" on crankshaft pulley / vibration damper.
    3. Dismount crank position sensor.
    4. Turn the engine clockwise to the marks.
    5. Fix locking tool “0198-A” in flywheel.
    6. Remove :
     tool "0198-2A"
     crankshaft pulley / vibration damper.
    Tolerance Data 2009.2 Peugeot, Boxer 2,2 HDI

    Dismount 3

    1. Attach the engine fixing.


    2. Dismount :
     upper engine suspension.
     lower engine suspension.
    3. Use tool ”0198-D” to dismount the crankshaft oil seal, turn 90° counterclockwise.

    1. Attach the engine fixing.


    2. Dismount :
     upper engine suspension.
     lower engine suspension.
    3. Use tool ”0198-D” to dismount the crankshaft oil seal, turn 90° counterclockwise.
    Tolerance Data 2009.2 Peugeot, Boxer 2,2 HDI

    Dismount 4

    1. Remove the chain cover.


    2. Fix locking tool “0198-B2” through the camshaft gear.
    3. Lock hydraulic chain tensioner with tool "0198-J".
    4. Dismount chain tensioner.
    5. Remove :
     guide rail.
     locking tool “0198-B2”.
     the chain together with the camshaft gear.

    1. Remove the chain cover.


    2. Fix locking tool “0198-B2” through the camshaft gear.
    3. Lock hydraulic chain tensioner with tool "0198-J".
    4. Dismount chain tensioner.
    5. Remove :
     guide rail.
     locking tool “0198-B2”.
     the chain together with the camshaft gear.
    Tolerance Data 2009.2 Peugeot, Boxer 2,2 HDI

    Mounting 1

    1. Install the chain and the chain gear together.


    2. Fix locking tool “0198-B2” through the camshaft gear.
    3. Install timing chain slack guide, tighten 16 Nm.
    4. Mount chain tensioner, tighten the bolts 16 Nm.
    5. Check that the small bolts are positioned centrally in their holes.
    6. Tighten the small cam wheel bolts 33 Nm.
    7. Remove :
     locking tool “0198-J” from the chain tensioner.
     locking tool “0198-B2”.
    8. Control of camshaft timing.

    1. Install the chain and the chain gear together.


    2. Fix locking tool “0198-B2” through the camshaft gear.
    3. Install timing chain slack guide, tighten 16 Nm.
    4. Mount chain tensioner, tighten the bolts 16 Nm.
    5. Check that the small bolts are positioned centrally in their holes.
    6. Tighten the small cam wheel bolts 33 Nm.
    7. Remove :
     locking tool “0198-J” from the chain tensioner.
     locking tool “0198-B2”.
    8. Control of camshaft timing.
    Tolerance Data 2009.2 Peugeot, Boxer 2,2 HDI

    Mounting 2

    1. Apply a bead of sealant onto the sealing surface of the timing chain cover.
    2. Use ”0198-G” to center the timing chain cover.
    3. Mount chain cover, tighten the bolts 12 Nm.
    4. Use tool ”0198-D” to mount the crankshaft oil seal, turn 90° clockwise.
    5. The remainder is assembled in opposite order.

    1. Apply a bead of sealant onto the sealing surface of the timing chain cover.
    2. Use ”0198-G” to center the timing chain cover.
    3. Mount chain cover, tighten the bolts 12 Nm.
    4. Use tool ”0198-D” to mount the crankshaft oil seal, turn 90° clockwise.
    5. The remainder is assembled in opposite order.

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