master engine timing tool set | 2009 volkswagen audi group - machine … · 2010-12-10 · valve...
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Master Engine Timing Tool Set | 2009Volkswagen Audi Group
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4864
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• Disconnectthebatteryearthleads(checkradiocodeisavailable)
• Removesparkorglowplugstomaketheengineturneasier
• Donotusecleaningfluidsonbelts,sprocketsorrollers
• Alwaysmakeanoteoftherouteoftheauxiliarydrivebeltbeforeremoval
• Turntheengineinthenormaldirection(clockwiseunlessstatedotherwise)
• Donotturnthecamshaft,crankshaftordieselinjectionpumponcethetimingchain/belthasbeenremoved(unlessspecificallystated)
• Donotusethetimingchain/belttolocktheenginewhenslackeningortighteningcrankshaftpulleybolts
• Markthedirectionofthechain/beltbeforeremoving
• Itisalwaysrecommendedtoturntheengineslowly,byhandandtore-checkthecamshaftandcrankshafttimingpositions.
• CrankshaftsandCamshaftsmayonlybeturnedwiththechaindrivemechanismfullyinstalled.
• Donotturncrankshaftviacamshaftorothergears
• Removesparkorglowplugstomaketheengineturneasier
• Checkthedieselinjectionpumptimingafterreplacingthechain
• Observealltighteningtorques
ALWAYS REFER TO A REPUTABLE MANUFACTURERS WORKSHOP MANUAL
Safety Precautions – Please Read
2 7
Introduction
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4864Master Engine Timing Tool Set | 2009 Volkswagen Audi Group
including: the latest FSi/TFSi engines.
Special Tool
Special Tools
Crankshaft Locking Tool
C395CrankshaftPulleyBoltAdaptor
ThistoolisrequiredtoenablethecrankshafttobeturnedonmostAudichaindrivenFSienginesplus2.7/3.0TDienginesfittedtoA4/A6QuattroandQ7.
C345 Camshaft Locking Tools
Designedtocorrectlyalignthecamshaftstoachievethecorrectvalvetimingposition.Itisimportanttofitthetoolcorrectly,andwhereapplicabletheorientationismarkedonthetool.
Ifthetoolscannotbecorrectlyfittedthevalvetimingisincorrectandthetensionmustbereleasedandthecorrectalignmentprocedurethenfollowed.
C356 Camshaft Alignment Tool
ToolFisfittedbetweentheslotslocatedbetweeneachcamlobe.Thistoolissecuredinpositionasarrowed,using2xM6Boltsprovided.Thecorrectcamshaftpositioncanonlybeachievedfollowingtheremovaloftensiontothechain.
C357 Crankshaft Locking Tool
CrankshaftLockingToolachoicemustbecorrectlymadefromtwotosetthecrankshafttimingpositionduringbothremovalandreplacementofthetimingbelt.Thesetoolsarenotinterchangeable.
ThecrankshaftisfirstturnedtoTDConNo1cylinder,checkingthetimingmarksonthecamshaftsprockethubsarealigned.
Slidethecorrecttoolintopositionensuringthatthetriangularmark/arrowonthetoolalignswiththetimingmarkonthecrankshaftsprocket.
Plan Layout General Information
4 5
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This master timing tool kit has been specifically compiled to give a comprehensive range of engine timing locking tools for Cam belts, chains and gears.
Alwaysrefertothevehiclemanufacturer’sservicemanualorasuitableproprietaryinstructionbook.
TheToolConnectionLimitedrecommendandendorsetheuseoftheAutodataTimingBelts,ChainsandGearsinstructionsandapplicationsbooks.
BothbooksareavailablethroughyourLaserToolsdistributor:
PartNo3601 Autodata|Timing Belts
PartNo3626 Autodata|Timing Chains and Gears
Orforaoneoffapplicationchapterandinstructionsonaspecificenginegoto:
http://www.autodata-online.com/uk/timingbelt.asp
Applications
OurapplicationsdataissuppliedbyAutodataandweareabletosupplythisdatatoyouinapdfformat.
ThisapplicationlistisenclosedintheattachedCDlistingwhichtoolisrequiredforeachenginecode.
Ifthisisaspecifickitforagroupofenginecodestheapplicationlisthasbeensuppliedshowingthemainvehiclesthiskitisdesignedforanddoesnotlisteverymodeleachpinfits.
Ifthisisamasterkitthenallvehiclesareincluded.
The data is the copyright of The Tool Connection and should not be reproduced.
Languages
OntheenclosedCDyouwillalsofindthisdocumentinthefollowinglanguages:
English Dutch French German Portuguese Spanish
WARNING
Incorrect or out of phase engine timing can result in damage to the valves.
The Tool Connection cannot be held responsible for any damage caused by using these tools in anyway.
ComponentCode LayoutID OEMRef Description
C226 M T10170 DTiAdaptor
C157 N T10050 CrankshaftSprocketAlignmentTool
C304 O T10100 CrankshaftSprocketAlignmentTool
C158 P HTSetcrewM5x60
C159 Q M5x55StudandNuts
C160 R T20046 TensionerLockingPin
C161 S 3369 SupportGuide
C335 T T10252 CamshaftAlignmentTool
C348 U 3366 ChainTensionerRetainer
C337 V T10092 ChainTensionerRetainer
C282 W T10115 TensionerPin
C395 X T40058 CrankshaftPulleyBoltAdaptor
C283 Y T10060/A TensionerPin
C162 Z T20038/3418 CamshaftAlignment/LockingTool
C345 AA T10171 CamshaftAlignmentTool
C356 AB T40070 CamshaftAlignmentTool
C357 AC T40069 CrankshaftLockingTool
C358 AD T40071T10020 TimingChainTensionerLockingPin
6 3
General Guidance Notes Plan Layout
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ComponentCode LayoutID OEMRef Description
C203 A MatraV159 TensionWrench
C204 B U30009/3387/T10004
TensionWrench
C441 C T10020 TensionWrench
C043 D 3242 CrankshaftLockingPin
C044 E 3458 CamshaftAlignmentPlates
C059 F ShimSet
C061 G U20003/2064 InjectionPumpTimingPin15,4mm.Dia.
C070 H U40021/2065A CamshaftSettingBracket
C216 I T20102/3359 InjectionPumpTimingPin6mm.Dia.
C095 J T10008 TensionerSettingTool
C096 K T10016/T10074 CamshaftAlignment/LockingTool
C127 L VAS6079 DialTestIndicator
• WhenfittingCamshaftsetting/lockingplates,feelergauges/shimsofequalthicknesscanbeinsertedundereithersideoftheplateuntilallfreeplayhasbeeneliminated.Thecamshaftisnowlockedinitstimingpositionandserviceworkcannowbecarriedout.
Tensioning Tools
Thetensionofthechainisvitallyimportantandmustbesetusingthetensioner.Ifanautomatictensionerisfitteditshouldnotbetamperedwith.Manuallytensionedchainsmustbetensionertothemanufacturer’sspecification.
Foramanualtensionersee:
CambeltsTensionGauge 3899
TensioningGuageForCambelts 4212
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Valve Timing
ValvetimingisessentialtotheefficientperformanceofthePetrolorDieselengine.Thevalvesareopenedandclosedbythecamshaft(s)whicharedrivenbythecambelt,chainorgearsfromthecrankshaft.
Crankshaft Locking Tools
• TheCrankshaftTDCLocationPinisdesignedtoscrewintothecylinderblockandtoprovideastopforthecrankshafttobepositionedagainsttosettheTDCposition.
• Turntheengineinthenormaldirectionofrotationuntilthetimingmarkontheinjectionpumpsprocketlinesupwiththecastlugonthetimingcover.
• RemovetheplugfromthecylinderblockaccessholeandscrewintheTDClocationpin.
• Slowlyturnthecrankshaftclockwiseuntilthewebmakescontactwiththeendofthepin.Number1cylinderisnowsetatTDConignitionstroke.
Camshaft Setting/Locking Tools
• Camshaftsetting/lockingtoolsareusedtoaccuratelyalignadatumslot,locatedintheendofthecamshaft,withthetopfaceofthecamshafthousingtoholdthecamshaftatthe(TDC)TopDeadCentreposition.
• Followtheservicemanualinstructionstoremovethecamshaftcoverandtimingchaincovers.
• Turnengineinthenormaldirectionofrotationuntilthecamshaftsetting/lockingplatecanbeinsertedintothemachinedslotintheendofthecamshaft.