2003 2.2 hdi

[V8Sam]

Hello peeps, long time no speak! (Been hassle free untill this week )

I have a 2003 Peugeot boxer with a 2.2 hdi.

Water pump gave up recently and was using water every 100 miles or so, new pump time thought I would change all the belts whilst I was there as it has been 6 years.

Completed the job

Turned over by hand no with interference
Started and it ran and I wanted to take it on a nice long test run.

About 30 miles in it started making a loud 'puffing' type noise. Sounds like it's pushing back through the intake?

how ever still runs and turns over by hand with no issues. Idles fine No warning lights on dash.

I suspect the timing may have jumped a tooth? So it's now ever so slightly out?

So my questions are, is there a specific way to tension these engines that I may have missed? Causing it to jump?

OR

I may have re timed it ever so slightly out

If not how are they timed from scratch? So I can start again from fresh and get it bang on.

Or does anyone have any other ideas? (I'll get a video of it running later so you can see for yourself)

Thanks

[mickthemaverick]

Hopefully you'll find what you need at this link: https://timingbeltreplace.com/how-to-re ... 2hdi-2003/

[V8Sam]

What's the tensioner tool all about it those instructions?

Never seen it heard of that before?!

[wheeler]

It's a SEEM gauge, that's the official way to tension them, very rarely used in real life. Pretty easy to tension this belt without any fancy tools.
When you changed it did you set everything with locking pins? When you tensioned it did you slacken the 13mm bolts (number 9 in the 1st diagram in the link) on the camshaft pulley to allow it to 'float' when tensioning?
Are you sure its not injector blow by that's casing the noise? This can be a puffing/chuffing noise.

You should be able to check the valve timing without a full strip down, just take the top cover off & pin the flywheel & camshaft.

[V8Sam]

Yeah set with locking pins, all thou when I released tensioner the top pin (which was a drill bit) fell out, must not if been in properly, I put it back in though and marks only moved the smallest it increments (mainly as I had the 3 middle bolts undone)

But this is what's making me feel like it slipped out of time.


When I get a chance I'm going to take the belt back off and make sure the timing holes align perfectly.

I assume I don this by locating the timing hole in the fly wheel and locking it.

Then the camshaft pulley hole should also be perfectly aligned.

It it isn't is it a case should I just move by hand the camshaft pulley with the belt off untill it lines up correctly with the locking hole? Then slide the correct size lock (drill bit) in there? then re fit belt as normal?


I didn't use a tensioning tool or anything, I put then tensioner in, rotated it anti clock wise, placed a pry bar between pulley and engine to keep it in place then did the bolt up, then checked for.90⁰ turn in belt on longest part (cam to pump)

I feel I may i have over tightening it though?