Page 1/5

PEUGEOT Boxer I 310 2.5 D DJ5/W2 (T9A)

1993 - 2002

Timing belt: removal/installation

Warnings and recommendations
Unless otherwise advised by the manufacturer, the following procedures are recommended:
Always fit a new timing belt after removal
Coolant pump renewal is recommended after timing belt removal
Check the tensioner and idler pulleys; renew if necessary
Never turn the engine in the direction opposite to that of normal operation
Check the belt(s) for cracks, fraying, wear and oil contamination
Note: The engine must be cold before timing belt adjustment
Note: Avoid bending, torsion or traction
General
Before disconnecting the battery cable, check the audio system security code

Removal
Disconnect the battery
Remove the front right wheel
Remove the engine covers
Remove the ancillary drive belt
Remove the engine control unit
Remove the ancillary drive belt pulley
Remove the timing belt upper cover
Remove the crankshaft pulley
Remove the timing belt lower cover
Turn the crankshaft to TDC for cylinder 1
Fit the crankshaft locking pin 7004-TJ / 7014-TJ

©HaynesPro B.V. Powered by Stakis Technik

 Page 2/5

PEUGEOT Boxer I 310 2.5 D DJ5/W2 (T9A)

1993 - 2002

Timing belt: removal/installation

Warnings and recommendations
Unless otherwise advised by the manufacturer, the following procedures are recommended:
Always fit a new timing belt after removal
Coolant pump renewal is recommended after timing belt removal
Check the tensioner and idler pulleys; renew if necessary
Never turn the engine in the direction opposite to that of normal operation
Check the belt(s) for cracks, fraying, wear and oil contamination
Note: The engine must be cold before timing belt adjustment
Note: Avoid bending, torsion or traction
General
Before disconnecting the battery cable, check the audio system security code

Fit the camshaft locking pin 5711-T / 5711-TA

Removal
Fit the injection pump locking pin 5711-T / 5711-TB
Disconnect the battery
Support the engine
Remove the front right wheel
Remove the engine supports
Remove the engine covers
Loosen the tensioner
Remove the ancillary drive belt
Remove the timing belt
Remove the engine control unit
Installation
Remove the ancillary drive belt pulley
Loosen the camshaft gearwheel outer bolts
Remove the timing belt upper cover
Remove the crankshaft pulley
Remove the timing belt lower cover
Turn the crankshaft to TDC for cylinder 1
Fit the crankshaft locking pin 7004-TJ / 7014-TJ

©HaynesPro B.V. Powered by Stakis Technik

 Page 3/5

PEUGEOT Boxer I 310 2.5 D DJ5/W2 (T9A)

1993 - 2002

Timing belt: removal/installation

Warnings and recommendations
Unless otherwise advised by the manufacturer, the following procedures are recommended:
Always fit a new timing belt after removal
Coolant pump renewal is recommended after timing belt removal
Check the tensioner and idler pulleys; renew if necessary
Never turn the engine in the direction opposite to that of normal operation
Check the belt(s) for cracks, fraying, wear and oil contamination
Note: The engine must be cold before timing belt adjustment
Note: Avoid bending, torsion or traction
General
Before disconnecting the battery cable, check the audio system security code

1/6 of a turn
Loosen the injection pump gearwheel
1/6 of a turn
Turn the camshaft gearwheel clockwise to its stop
Turn the injection pump gearwheel clockwise to its stop
Fit the timing belt a -> b -> c -> d ->
e

Removal
Disconnect the battery
Remove the front right wheel
Remove the engine covers
Remove the ancillary drive belt
Remove the engine control unit
Remove the ancillary drive belt pulley
Remove
Turn the the timinguntil
tensioner belt the
upper cover
special tool reads: 107 SEEM
Remove the crankshaft pulley
Remove the timing belt lower cover
Turn the crankshaft to TDC for cylinder 1
Fit the crankshaft locking pin 7004-TJ / 7014-TJ

©HaynesPro B.V. Powered by Stakis Technik

 Page 4/5

PEUGEOT Boxer I 310 2.5 D DJ5/W2 (T9A)

1993 - 2002

Timing belt: removal/installation

Warnings and recommendations
Unless otherwise advised by the manufacturer, the following procedures are recommended:
Always fit a new timing belt after removal
Coolant pump renewal is recommended after timing belt removal
Check the tensioner and idler pulleys; renew if necessary
Never turn the engine in the direction opposite to that of normal operation
Check the belt(s) for cracks, fraying, wear and oil contamination
Note: The engine must be cold before timing belt adjustment
Note: Avoid bending, torsion or traction
General
Before disconnecting the battery cable, check the audio system security code

Used belt: 80 SEEM

Use a special tool: 5711-TE
Tighten the tensioner 45 Nm
Remove the special tool SEEM
Tighten the camshaft gearwheel bolts 1: 10 Nm + 2: 25
Nm
Tighten the injection pump gearwheel 1: 10 Nm + 2: 25
Nm
Remove the locking pins
Turn the engine 2 rotations clockwise
Fit the crankshaft locking pin
Loosen the camshaft gearwheel outer bolts
Tighten the camshaft gearwheel bolts lightly until there is no play
Loosen the camshaft gearwheel outer bolts
1/6 of a turn
Removal
Loosen the injection pump gearwheel
Disconnect the battery
Tighten the injection pump gearwheel bolts lightly until there is no play
Remove the front right wheel
Loosen the injection pump gearwheel
Remove the engine covers
1/6 of a turn
Remove the ancillary drive belt
Fit the camshaft locking pin
Remove the engine control unit
Fit the injection pump locking pin
Remove the ancillary drive belt pulley
Fit the tensioning tool SEEM
Remove the timing belt upper cover
Turn the tensioner until the special tool reads: 58 SEEM
Remove the crankshaft pulley
Used belt: 51 SEEM
Remove the timing belt lower cover
Tighten the tensioner 45 Nm
Turn the crankshaft to TDC for cylinder 1
Remove the special tools
Fit the crankshaft locking pin 7004-TJ / 7014-TJ
Turn the engine 2 rotations clockwise
Fit the locking pins to check the timing
Note: Repeat the procedure if the special tools do not fit properly
Torque settings

©HaynesPro B.V. Powered by Stakis Technik

 Page 5/5

PEUGEOT Boxer I 310 2.5 D DJ5/W2 (T9A)

1993 - 2002

Timing belt: removal/installation

Crankshaft
Warningspulley:
and recommendations 25 Nm
Unless otherwise advised by the manufacturer, the following procedures are recommended:
Always fit a new timing belt after removal
Coolant pump renewal is recommended after timing belt removal
Check the tensioner and idler pulleys; renew if necessary
Never turn the engine in the direction opposite to that of normal operation
Check the belt(s) for cracks, fraying, wear and oil contamination
Note: The engine must be cold before timing belt adjustment
Note: Avoid bending, torsion or traction
General
Before disconnecting the battery cable, check the audio system security code

Removal
Disconnect the battery
Remove the front right wheel
Remove the engine covers
Remove the ancillary drive belt
Remove the engine control unit
Remove the ancillary drive belt pulley
Remove the timing belt upper cover
Remove the crankshaft pulley
Remove the timing belt lower cover
Turn the crankshaft to TDC for cylinder 1
Fit the crankshaft locking pin 7004-TJ / 7014-TJ

©HaynesPro B.V. Powered by Stakis Technik