AS4740 Diesel & Petrol engine Setting/locking tool Kit Associated tool: AS4741 Front Panel Support Guide Set

Transcription

1 AS Diese & Petro engine Setting/ocking too Kit Associated too: Front Pane Support Guide Set Appications: V W GROUP Diese (1.7 & 1.9D/SDi/TDi) & Petro ( ) engines in AUDI 80 A3 S3 A4 A6 TT Cabrioet SEAT Ibiza Cordoba Arosa Leon Inca Toedo Ahambra SKODA Fabia Feicia Octavia Superb VOLKSWAGEN Lupo Poo/Cassic Caddy Gof Bora Beete Passat Touran Sharan Transporter IMPORTANT: Aways refer to the vehice manufacturer s service instructions, or proprietary manua, to estabish the current procedures and data. Product Information Sets detai appications and use of the toos with any genera instructions provided as a guide ony. Refer to the Appication Charts on the foowing page(s) for specific mode information Additiona AS toos required: Front Pane Support Guide Set Camshaft Sprocket Hoding Too Kit contents/spares item Part Number Description 1 AS4115A-1 Camshaft Setting Pate 2 AS4749 Camshaft Setting Pate 3 AS3054V3 Injection Pump Locking Pin 4 AS44440V2 Injection Pump Locking Pin 5 AS4444 Tensioner Adjuster 6 AS4633 Tensioner Adjuster 7 AS4440T1 Tensioner Retainer 8 AS4593-E1 Tensioner Lock Pin 9 AS4809 Tensioner Retainer 10 AS4440V1 Fan Retaining Bot -- AS-84 Case + Insert To free Internationa Fax /10

2 AS Diese and Petro Engine Setting/Locking Too Kit for VAG modes covers a comprehensive range of VAG - D, SDi and TDi dieses (1.7 & 1.9) and a range of standard 1.6 to 2.0 petro engines, incuding 1.8/1.8T Chain in Head engines - refer to Appication Charts for specific mode/engine appications. Diese Engine Injection Pump Locking Pins Refer to Appication Charts for mode/engine appications Diese Engine Camshaft Setting Pates Refer to Appication Charts for mode/engine appications 3 AS4440V2 1 AS AS4749 AS4115A-1 and AS4749 Camshaft Setting Pates Camshaft Setting Pates are used to accuratey aign a datum sot, ocated in the end of the camshaft, with the top face of the camshaft housing, to hod the camshaft at the TDC position. AS4115A-1 Pate has extended right anges at each end to aow it to rest on the sides of the cam housing. Remove the camshaft cover and timing bet cover and turn the engine in the norma direction of rotation unti the setting pate can be inserted into the machined sot in the end of the camshaft. When fitting the setting pate, feeer gauges of equa thickness can be inserted on either side of the pate unti free pay has been eiminated. AS4749 Setting Pate is for specified 1.9 diese engines where the camshaft can be set in timed position without removing the cam cover. The vacuum pump (exhauster) is removed giving access to the sot in the end of the camshaft. The vacuum pump retaining bot hoes are used to attach the two AS4749 bots and pate. AS3054V3 and AS4440V2 Injection Pump Locking Pins Locking pins are designed to pass through datum hoes in the sprockets into fixed hoes on the engine. AS3054V3 is the arger diameter of the two ocking pins in the kit and is used on engines having One Piece Injection Pump Sprockets. AS4440V2 Pin is used when 2 - Part Sprockets are fitted, (Sprockets with three retaining bots securing a front sprocket to a rear mounting). IMPORTANT: Do NOT use Camshaft Setting Pates or Locking Pins to hod the camshaft/injection pump in position whist reeasing or re-tightening the sprocket bot. Pates and Pins are for retention of timing position ony. Use Sprocket Hoding Too AST4844 to counterhod sprockets. Diese and Petro Engines Timing Bet Tensioner Adjusters Refer to Appication Charts for mode/engine appications 4 AS4444 and AS4633 Tensioner Adjusters AS4444 and AS4633 Adjusters are used on a very wide range of V W diese and petro engines, in a of the Group s marques, to adjust timing bet tension. The tensioner cam has two hoes into which the two pegs of the Adjuster ocate to aow the tensioner to be turned and provide tension adjustment for the timing bet. 2/10 To free Internationa Fax

3 Petro Engine 1.8/1.8T Automatic Bet Tensioner and Chain in Head vave timing Refer to Appication Charts for mode/engine appications This V W range of 1.8 and 1.8 Turbo twin cam petro engines, introduced around 1997 (dependant upon V W Group marques), have a timing bet connecting the crankshaft to exhaust camshaft, and a timing chain situated inside the cyinder head, driving the inet camshaft from the exhaust camshaft. Timing Bet Repacement Timing bet repacement is straightforward. The punger of the automatic tensioner must be compressed and retained by a pin to aow the bet to be removed. Position the crankshaft at TDC Check that the marks on the crankshaft puey and camshaft front sprocket aign correcty with their timing marks. Support the engine, as the R-H engine mounting bracket must be removed, aong with the crankshaft puey and timing covers. Prior to any dis-assemby, the crankshaft must be positioned at TDC No1. cyinder and the mark on the front camshaft sprocket must be aigned with the mark on the cyinder head cover. Mark with paint if necessary, the position of the chain inks reative to the arrows on the camshaft rear bearing caps. The distance between arrows shoud be 16 roers on the chain. The head cover and timing bet can then be removed. 16 roers 7 5 AS4440T1 and AS4593-1E Tensioner Toos Insert Tensioner Retainer AS4440T1 into the tensioner and tighten sufficienty to depress the punger and to aign the hoes in the punger with the hoe in the tensioner housing. Lock the punger in position by inserting Pin AS4593-1E When fitting a new bet, ensure it is taut on the non-tensioned side. Appy tension by removing the Locking Pin. Remove AS4440T1 Retainer. Vave Timing Chain in Head Remove the camshaft front sprocket, using a counter-hoding too such as, to retain sprocket whist reeasing the bot. The notches on the camshaft must be aigned with the arrows on the bearing caps. Fit Chain Tensioner Retainer AS4809 to reease tension off the chain WARNING: Do not over-tighten Retainer as damage to the tensioner can resut. IMPORTANT: When refitting a chain, aign the paint marks with the notch/arrows. A new chain must be fitted so that the distance between the timing marks (the arrows on bearing caps/notches on camshafts) shoud be 16 roers on the chain. Note however that the ink being ocated onto the exhaust camshaft is sighty offset from the notch on the camshaft see diagram. AS4440V1 Retaining Bot On Audi A4 and A6 atest 1.6 and 1.8 petro engines, timing bet renewa requires the viscous fan couping to be reeased. For this to be achieved it must first be ocked in position using AS4440V1 and reeased with a suitabe aen key. 6 AS4809 Chain Tensioner Retainer Remova and refitting of the vave gear, camshafts, timing chain etc. wi require setting of the vave timing. To free Internationa Fax /10

4 Associated Toos In addition to the specia timing toos in Kit AS, it is recommended you aso have avaiabe:- Front End Support Guide Set Camshaft Sprocket Hoding Too see Appication Charts for modes/engines requiring these additiona toos 9 Camshaft Sprocket Hoding Too Associated Too not in kit 8 Front End Support Guide Set Associated Too not in kit Lock Carrier Service Position Amost a V W Group modes have the faciity of extending the front pane of the vehice to provide increased access space in the engine compartment to carry out various service appications. On a number of modes, Audi A4, A6, A8, Vokswagen Passat, for exampe, moving the front end out to Service Position is part of the timing bet repacement procedure. Remove the front pane bots, fit the appropriate Support Guides and side the pane forward. Re-fit the upper bots to hod pane in position. Many engine timing procedures require the camshaft to be set in position and the camshaft sprocket or gear reeased to turn freey on its shaft, to reaign engine timing correcty. provides a safe and correct means of counter-hoding the sprocket whist reeasing and tightening the camshaft nut/bot, without damage to the sprocket or to timing toos fitted to the engine. It can aso be used for turning the camshaft and diese injection pump sprockets for timing aignment. IMPORTANT: Do NOT use Camshaft Setting Pates or Locking Pins to hod the camshaft/injection pump in position whist reeasing or re-tightening the sprocket bot. Pates and Pins are for retention of timing position ony. Use Sprocket Hoding Too to counterhod sprockets. Inter-changeabe Location Pins comes compete with 4 pairs of Location Pins, a different sizes and diameters to suit the wide range of camshaft sprockets and gears you wi encounter on VAG engines. 4/10 To free Internationa Fax

5 AS Appication Chart DIESEL ENGINES 1.7 & 1.9D/SDi/TDi Use toos from AS Kit:- AS Camshaft Setting Pate AS3054V3 Injection Pump Locking Pin AS4444 Tensioner Adjuster AS4749 Camshaft Setting Pate AS4440V2 Injection Pump Locking Pin AS4633 Tensioner Adjuster Additiona AST toos required:- Front End Support Guide Set AST4844 Camshaft Sprocket Hoding Too DIESEL ENGINES Modes (Year) / engine codes Camshaft Pates AUDI D Turbo (91-94), 1.9TDi (91-96) 1Z/AAZ A3 1.9TDi (96-03) AGR/AHF/ALH/ASV A4 1.9TDi (95-01) 1Z/AHU/AFF/AFN/AVG 1.9TDi (98-01) AHH Cabrioet 1.9TDi (95-00) 1Z/AHU A6 1.9TDi (94-02) 1Z/AHU/AFN/AVG SEAT Arosa 1.7SDi (98-05) AKU Ibiza/Cordoba 1.7SDi (98-99) AKW 1.9D (93-99) 1Y 1.9D Turbo (93-97) AAZ 1.9SDi (96-99) AEY (99-02) AGP/AQM (02-06) ASY 1.9TDi (96-99) 1Z/AFN/AHU (99-02) AGR/ALH/ASV Leon 1.9SDi (00-05) (AGP/AQM 1.9TDi (99-05) AGR/AHF/ALH/ASV Toedo 1.9D (94-99) 1Y 1.9D Turbo (94-99) AAZ 1.9TDi (95-99) 1Z/AFN/AHU/AAZ (99-05) AGR/AHF/ALH/ASV To free Internationa Fax AS4440V1 Additiona AST Toos Required AS 5/10

6 DIESEL ENGINES Modes (Year) / engine codes SEAT Ahambra 1.9TDi (96-00) 1Z/AFN/AHU/AVG Inca 1.9D (96-04) 1Y 1.9SDi (96-04) AEY (00-04) AYQ SKODA Fabia 1.9SDi (99-06) ASY Feicia 1.9D (95-01) AEF Octavia 1.9SDi (97-05) AGP/AQM 1.9TDi (96-06) AGR/AHF/ALH/ASV VOLKSWAGEN Lupo 1.7SDi (98-05) AKU Poo / Poo Cassic 1.7D (96-00) AHG/AKU 1.7SDi (96-00) AHB/AKW 1.9D (95-02) 1Y/AEF 1.9SDi (96-02) AEY/AGD/ASX (99-02) AQM/AGP (02-06) ASY 1.9TDi (97-02) AFN/AHU/ALE/ (99-02) AGR/ALH/ASV Gof/Bora 1.9D (94-96) 1Y 1.9D Turbo (94-98) AAZ 1.9SDi (95-98) AEY/AEF (97-05) AGP/AQM 1.9TDi (93-03) 1Z/AHU/AFN/ALE/AVG/AAZ (97-05) AGR/AHF/ALH/ASV Passat 1.9TDi (96-00) AFN/AHH 2 Part Pump Sprocket Singe Piece Sprocket (97-00) AHU/AVG Camshaft Pates AS4440V1 Additiona AST Toos Required 6/10

7 DIESEL ENGINES Modes (Year) / engine codes VOLKSWAGE Camshaft Pates Beete 1.9TDi (98-02) AGR/ALH Sharan 1.9TDi (95-00) 1Z/AHU/AFN/AVG Caddy 1.7SDi (96-00) AHB/AKW 1.9D (96-01) 1Y/AEF 1.9SDi (96-00) AEY (98-04) AQM/AYQ 1.9TDi (96-00) AFN/AHU/ALE (99-03) ALH/ASV Transporter 1.9D (90-96) 1X 2 Part Pump Sprocket Singe Piece Sprocket 1.9D Turbo (92-03) ABL 2 Part Pump Sprocket Singe Piece Sprocket More AST Engine Setting/Locking Too Kits covering VAG Diese Engines 2.5TDi V6 Diese Engine Setting/Locking Too Kit - use AS /2.5TDi Diese Engine Setting/Locking Too Kit- use AS , 1.4, 1.9, 2.0TDi Pumpe Düse Diese Engine Setting/Locking Too Kit- use AS4840 To free Internationa Fax AST4440V1 Additiona AST Toos Required 7/10

8 AS Appication Chart PETROL ENGINES 1.6 to 2.0 Use toos from AS Kit:- AS4444 Tensioner Adjuster AS4440T1 Tensioner Retainer AS4809 Tensioner Retainer (Chain in Head) AS4633 Tensioner Adjuster AS4593-1E Tensioner Lock Pin AS4440V1 Retaining Bot Additiona AST toos required:- Front End Support Guide Set Camshaft Sprocket Hoding Too PETROL ENGINES Modes (Year) / engine codes Camshaft Pates AS4440V1 AUDI (92-96) ABM/ADA 2.0 (91-96) ABK/ABT/ACE A3 1.6 (96-06) AEH/AKL/APF/AVU/BFQ/BGU 1.8 (96-03) AGN/APG 1.8 Turbo (96-03) AGU/AJQ/APP/AQA ARX/ARY/ARZ/AUM/AUQ/AMK 2.0FSi (03-06) AXW S3 1.8 Turbo (99-03) AMK/APY/BAM A4 1.6 (95-97) ADP (96-06) AHL/ALZ/ANA/ARM 1.8 (95-01) ADR/APT/ARG 1.8 Turbo (95-99) AEB/AJL/ANB/APU (99-01) AEB/AJL/ANB/APU (2001) AWT Cabrioet 1.8 (97-00) ADR 2.0 (91-96) ABK/ACE A6 1.8 (95-97) ADR (97-02) AJP 1.8 Turbo (97-99) AEB/AJL/ANB/APU (99-05) AEB/AJL/ANB/APU 2.0 (94-97) AAE/ABK/ACE TT 1.8 (98-05) AJQ/APP/APX/ARY/AUM/ AUQ/BAM To free Internationa Fax Additiona AST Toos Required AS 8/10

9 PETROL ENGINES Modes (Year) / engine codes SEAT Ibiza / Cordoba 1.6 (96-02) AFT/AEH/AKL/ APF/AUR 1.8 (93-99) ABS/ADZ v. (94-97) ADL 1.8 Turbo (99-02) AQX/AYP Leon 1.6 (99-05) AEH/AKL 1.8 (99-05) AGN/APG/APT 1.8 Turbo (99-05) AJQ/APP/ARY/AUQ 1.8 CupraR (02-05) AMK Toedo 1.6 (94-99) 1F/AFT (99-05) AEH/AKL 1.8 (94-97) ABS/ADZ (99-05) AGN/APG/APT 1.8 Turbo (02-05) ARY/AUQ 2.0 (94-99) 2E/AGG v. (94-99) ABF Ahambra 1.8 Turbo (97-06) AJH/AWC 2.0 (96-06) ADY/ATM Inca 1.6 (95-04) 1F SKODA Octavia 1.6 (97-05) AEH/AKL/AVU 1.8 Turbo (96-00) AGN (98-05) AGU/ARX/ARZ/AUM 1.8 TurboRS (00-06) AUQ 2.0 (99-05) AEG/APK/AQY/AZH/Azj Superb 2.0 (02-06) AZM VOLKSWAGEN Poo / Cassic 1.6 (95-02) AFT/AKS (99-02) AEH/AKL/APF Camshaft Pates ADY ATM AS4440V1 Additiona AST Toos Required ast 9/10

10 PETROL ENGINES Modes (Year) / engine codes Camshaft Pates VOLKSWAGEN continued Gof / Bora 1.6 (94-98) AEK/AFT/AKS (98-05) AKS (97-05) AEH/AKL/APF/AVU/BFQ/BGU 1.8 Turbo (97-03) AGN (97-04) AGU/AQA/ARZ/AUM/AUQ 2.0 (98-02) APK/AQY/AZH/AZJ/BEH (99-02) ATU/AWF/AWG v. (92-97) ABF 2.0FSi (04-06) AXW Beete 1.6 (00-06) AYD/BFS 1.8 Turbo (99-06) AVC/AWU 2.0 (98-06) AQY/AZJ Passat 1.6 (96-05) ADP/AHL/ANA/ARM/ALZ 1.8 (96-00) ADR/APT/ARG 1.8 Turbo (96-00) AEB/ANB/APU 2.0 (01-05) AZM Touran 1.6 (03-06) BGU 2.0FSi (03-06) AXW Sharan 1.8 Turbo (97-06) AJH/AWC 2.0 (95-00) ADY/AKT (00-06) ATM Caddy 1.6 (95-00) AFT (03-06) BGU Transporter 2.0 (90-03) AAC (04-06) AXA More AST Engine Setting/Locking Too Kits covering VAG Petro Engines V6 Petro Engine Setting/Locking Toos - use AS4401/AS4402/AS /1.6 16v (Bet) Petro Engine Setting/Locking Too Kit - use AS /1.6FSi (Chain) Petro Engine Setting/Locking Too Kit - use AS V8 Petro Engine Setting/Locking Too Kit - use AS v-12v Petro Engine Setting/Locking Too Kit - use AS4810 To free Internationa Fax AS4440V1 Additiona AST Toos Required AS 10/10