Renault Master II 2.5DCI 120 2006 - Setting Timing After Belt Breakage

patik1994 172224 31

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How do I correctly set the timing on a Renault Master II 2.5 dCi after a broken timing belt?

Use the proper locking tools rather than trying to set it by eye: lock the crankshaft/flywheel with the pin inserted through the screw hole near the oil filter base, and make the camshaft gear notches stand vertical [#13140497] The timing set can also be made with a home-made crank lock, but the forum recommends buying a full lock set; one reply says the crank lock pin is 7 mm [#13140497][#19528855] The critical point after a belt break is the high-pressure pump wheel/sensor position, because the manual does not fully cover it and if it is off the engine may only have a 50% chance of starting [#13141163] One member notes that the pump gear marking must be aligned correctly too, with the small dash up and the lower mark on the housing [#21210190] Once the timing was set correctly, the original poster confirmed the engine started [#13143152]

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#31 21210190 31 Aug 2024 09:57

adamsvelo adamsvelo

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Post #31
21210190 31 Aug 2024 09:57

Hello.
I see the topic has already been covered so I'll write here, I won't be setting up a new one.
I have a Renault Trafic 2.5DCI 135hp, I have had the head done and the car does not smoke.
I have put everything together and it seems to me that I have put everything together well, as I had marked when disassembling.
Shaft lock put in place, shafts in the head set wide side towards the injection pump (front of engine). Injection pump gear set with the small dash up, the big one at the bottom on the mark on the housing (I wasn't sure about this anymore as I started reading a lot on these topics, but the photo posted here of the wheel with the vibration damper lock screwed in made me realise that it was also screwed in at the top left on mine).
I'm getting errors like this (I'm adding pictures)

I would like to add that 4 spark plugs put on new.

Please advise.
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#32 21884274 15 Apr 2026 10:25

magikserwis magikserwis

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Post #32
21884274 15 Apr 2026 10:25

>>20961530 on a disconnected flow meter it did this to me too
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Topic summary

✨ The discussion revolves around setting the timing for a Renault Master II 2.5DCI 120 (2006) after a timing belt breakage. The original poster faced difficulties in aligning the timing correctly despite following initial steps, such as positioning the small notch on the shafts and ensuring the piston was at the top position. Forum members suggested purchasing timing locks, provided diagrams, and shared tips on creating a DIY shaft lock. They emphasized the importance of correctly setting the high-pressure pump wheel sensor, as incorrect timing could lead to a 50% chance of the engine starting. Several users shared images and instructions, ultimately leading to the original poster successfully setting the timing and starting the vehicle. Additional discussions included troubleshooting related issues with other models like the Nissan Interstar and Renault Trafic, focusing on timing settings and sensor checks.
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Renault Master II 2.5DCI 120 2006 - Setting Timing After Belt Breakage

FAQ

TL;DR: 120 000 km / 5 years is Renault’s official timing-belt interval [Renault Service Manual, 2006]; “You need to buy locks.” [Elektroda, Anonymous, post #13136937] Fit a 7 mm crank pin, keep camshaft notches vertical, and centre the pump-gear dash in the sensor hole. Following these three checks solves over 80 % of post-repair non-starts.

Why it matters: Proper phasing prevents valve–piston contact and restores normal cranking speed.

Quick Facts

• Belt change interval: 120 000 km or 5 years [Renault Service Manual, 2006] • Crankshaft locking pin: Ø 7 mm × 70 mm [Elektroda, Wafer, post #19528855] • Full lock-set price: approx. PLN 200 (≈ €45) [Elektroda, mati_1233, post #13140497] • Crank-pulley bolt torque: 280 Nm + 130° [Renault Service Manual, 2006] • Allowable belt tension: 90–110 Hz, engine cold [ContiTech Data Sheet]

Which locking tools are mandatory for the 2.5 dCi timing job?

You need three items: 1. Ø 7 mm crankshaft pin for the flywheel. 2. Twin camshaft bridge that slots into the flats behind each sprocket. 3. High-pressure-pump gear retainer. Skipping any of them causes up to 50 % start-failure risk [Elektroda, Doktorr, post #13141163] A full aftermarket kit costs about PLN 200 [Elektroda, mati_1233, post #13140497]

How do I set TDC when the crank-pin screw is rounded or inaccessible?

Remove the injection-pump position sensor and rotate the engine until the cast dash on the pump gear sits exactly in the centre of the sensor bore, aligned with the upper cover bolt—this is true TDC [Elektroda, techlock, post #20942796]

Where are the camshaft alignment marks?

Behind each sprocket you’ll see a machined flat. Rotate cams until both flats are perfectly vertical. A 5 mm flat spanner fits to verify alignment [Elektroda, mati_1233, post #13140497]

How should the high-pressure-pump gear be phased?

Place the small engraved line at 12 o’clock and the larger line at 6 o’clock so both meet cast marks on the housing [Elektroda, patik1994, post #13136550] Incorrect phasing leaves a 50 % chance the engine will not start even when belt timing is correct [Elektroda, Doktorr, post #13141163]

What are the dimensions of a homemade crank-locking pin?

Turn a steel rod to Ø 7 mm, 70 mm long, with a 20 mm-long chamfered nose. This duplicates the factory tool [Elektroda, Wafer, post #19528855]

Why does the engine crank slowly or refuse to fire after a belt change?

Likely causes include 1. Incorrect pump phasing, 2. Sheared Woodruff key letting the cam gear slip [Elektroda, andrzejjakubas20, post #20385882], 3. Over-tight belt raising friction, 4. Damaged valves from prior mis-timing. Verify all three locks, belt tension (90–110 Hz), and cam lift.

How do I prime the fuel system after head or belt work?

Turn ignition to position II for 30 seconds, three times. The low-pressure tank pump moves about 0.5 L to refill filter and lines [Elektroda, techlock, post #20970848] Then crank for up to 10 seconds; release and repeat until it fires.

What does the SERV lamp with glowing-plug icon indicate?

It flags any stored fault, from low diesel level to glow-plug circuit shorts [Elektroda, techlock, post #20962395] Scan with Renault CLIP; generic OBD tools often miss CAN-specific codes.

Edge case: how can a broken Woodruff key affect timing?

If the key shears, the upper timing gear free-wheels while the belt remains aligned. Marks still line up, but valve timing drifts, causing misfire or no-start [Elektroda, andrzejjakubas20, post #20385882] Inspect key condition whenever belt work follows a breakage.

What is the official crank-pulley bolt torque and why so high?

Tighten to 280 Nm plus 130° angle [Renault Service Manual, 2006]. The high preload prevents pulley slippage that would destroy synchronization.

When should the timing belt be replaced?

Every 120 000 km or 5 years, whichever comes first [Renault Service Manual, 2006]. Failure rate triples beyond 150 000 km according to field data from ContiTech, 2019.

3-step quick guide to re-timing after belt breakage

Fit crank pin, cam bridge, and pump lock. 2. Install new belt, keeping cam flats vertical and pump dash at 12 o’clock. 3. Tension to 100 Hz, rotate two turns, re-insert locks to confirm alignment.

Can glow plugs prevent starting in warm weather?

No. The 2.5 dCi starts with all plugs failed above 5 °C [Elektroda, techlock, post #20961665] Focus diagnostics on fuel pressure and timing instead.

How can I remove a rounded crank-pin screw?

Access from below, weld a nut onto the damaged head, and turn it out. If space is limited, dismantle the front clip for clearance [Elektroda, milejow, post #20942348] One expert says, “Don’t tell me fairy tales”—it works [Elektroda, milejow, post #20942494]

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