master engine timing tool set | 2009 volkswagen audi group - machine … · 2010-12-10 · valve...

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

D

H

L

P O

K G

C

AE

I

M

N

J

F

B

R

V

Z

ADAC

Z

U

Q

S

W

AA

AB

X

T

F

R

Y

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.