AST4388A. Diesel & Petrol Engine Setting/Locking Tool Kit. Applications: 1/7. AUTO SERVICE TOOLS Auto Service Tools Limited, 2002

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1 AST Diesel & Petrol Engine Setting/Locking Tool Kit IMPORTANT: Always refer to the vehicle manufacturer s service instructions, or proprietary manual, to establish the current procedures and data. Product Information Sets detail applications and use of the tools with any general instructions provided as a guide only. Applications: CITROËN / PEUGEOT Diesel (TUD/) and Petrol (TU/XU) engines in CITROËN AX BX ZX Visa Saxo Xsara Xantia XM Synergie/Evasion Berlingo C15 Dispatch/Jumpy Relay/Jumper FIAT Ulysse Scudo Ducato FSO Caro LDV 200 Pilot NISSAN Micra PEUGEOT Partner Expert Boxer J5/Talbot Express ROVER Metro /418 TATA Loadbeta TUD/ Diesel engines and TU/XU Petrol engines Refer to the Application chart on the following page(s) for specific model information Additional AST Tools required - see Application Charts AST4394 Sprocket Holding Tool } Flywheel Holding AST4358 Tools (Crank Pulley AST4306 removal) Injection Pump Sprocket Remover AST4373 EPIC Injection Pump Timing Pin 1/7 1

2 C8 C1 C2 C3 C4 M8 T5 T1 AST4362 P1 P2 P3 P4 C5 P5 T4 P8 C6 AST4363 P6 P7 Kit contents/spares AST4360C1 Injection Pump Locking Pin AST4360C2 Injection Pump Locking Pin AST4360C3 Balance Shaft Locking Pins (Pair) AST4360C4 Injection Pump Locking Pin AST4360C5 Camshaft Locking Pin AST4360C6 Flywheel TDC Locking Pin AST4360C8 Flywheel TDC Locking Pin WARNING: Locking Pins must NOT be used to counter-hold the crank or camshaft for removing/releasing pulleys or sprockets. They are for retention of engine timing position only. Use appropriate Flywheel Holding Tool for crankshaft or AST4394 Holding Tool to counter-hold sprockets. AST4360M8 Locking Bolts (3 off) AST4360P1 Crank/Cam Locking Pin AST4360P2 Camshaft Locking Pins (Pair) AST4360P3 Camshaft Locking Pin AST4360P4 Crank/Cam Locking Pin AST4360P5 Camshaft Locking Pins (Pair) AST4360P6 Crank/Cam Locking Pin AST4360P7 Crankshaft Locking Pin AST4360P8 Short Flywheel Locking Pin Tensioner Adjustment Tools AST4360T1 Retaining Pin (Roller) AST4360T4 Tensioner Tool (Dynamic Roller) AST4360T5 Retaining Pin AST4362 Tensioner Adjuster AST4363 Tensioner Adjuster AST4388/84 Case + Insert AST4394 Sprocket Holding Tool - Additional tool - not included in kit. 2/7 2

3 AST Application Chart Models/engines PSA Diesel, inc. direct injection engines Citroën AX 1.4D(-94), ZX 1.4D TUD3(K9A) engines AX 1.5D(94-), Saxo 1.5D, ZX 1.5D TUD5(VJY/VJZ) engines Visa 17D, BX 1.7D/TD/1.9D(-93), ZX 1.8D/1.9D(91-)/1.8TD/1.9TD(92-), Xsara 1.9D/TD, Xantia 1.9D/TD(93-), Synergie/Evasion 1.9TD, C15D 1.8D, Berlingo 1.8D/1.9D, Dispatch/Jumpy 1.9D/TD, Relay/Jumper 1.9D/TD 7(A9A)/7TE 9AY(DJY)/9A+AU(D9B) 9TE+TFY(DHX)/9TFL(D8B) 9UTF(D8C)/9BTF(DHX) engines (9BTF has Electronic Controlled Pump) Xantia 2.1TD(95-), XM 2.1/TD/XM 2.2D Synergie/Evasion 2.1TD, Dispatch/Jumpy 2.1 DT 11A/11ATE/11BTE (P8A/P8B/P8C/P9A/PHZ) engines (11BTE has EPIC Inj. Pump-see AST4373) XM 2.5TD, Relay/Jumper 2.5D/TD(94-), Relay/Jumper 2.5TDi DIRECT INJECTION DKATE(THY)/DJ5(T9A)/DJ5T(T8A-THZ) DJ5TED(THX) engines Fiat Ducato 1.9D/TD/Ulysse 1.9TD/2.1TD, Scudo 1.9D/TD 9TF/D8B/D9B/DHX/DJY engine FSO Caro 1.9D(94-) 9 engine LDV D, Pilot 1.9D(94-) 9A engine Nissan Micra 1.5D VJZ engine AST Kit Tools Camshaft, Injection Pump, Balance Shaft, Crank/Flywheel TDC Lock Tensioner Adjustment Timing Adj. AST AST AST AST C1 C2 C3 C4 C5 C6 C8 M8 P4 P8 T1 T Additional AST Tool required Spr. Hold Flywheel Hold (Crank Pulley removal) Pump Sprocket Removal 7 (-94) 9AU (Relay) 9TF 7 (A9A) 9A 9TE (Xsara) 9BTF 11BTE (Xantia) Aux. Belt Aux. Belt 11BTE AST4358 (9BTF) AST4358 (9BTF Xantia/XM) DJ5T DJ5 TED 3/7 3

4 AST Application Chart Models/engines PSA Diesel, incl. Di. engines (continued.) Peugeot D(-94) TUD3(K9A) engines D(94-) TUD5(VJY/VJZ) engines D/TD/1.9D, D/1.9D(-89), D/TD(93-), D/TD/1.9D(-93), TD/1.9D/TD(92-), TD, TD, J5/Talbot Express 1.9D(-94), Partner 1.8D/1.9D, Expert 1.9D/TD, Boxer 1.9D/TD 7(A9A)/7TE 9AY(DJY)/9A+AU(D9B) 9TE+TFY(DHX)/9TFL(D8B) 9UTF(D8C)/9BTF(DHX) engines (9BTF has Electronic Controlled Pump) TD(95-), D/TD, TD 11A/11ATE/11BTE (P8A/P8B/P8C/P9A/PHZ) engines (11BTE has EPIC Inj. Pump-see AST4373) TD, Boxer 2.5D/TD(95-), Boxer 2.5TDi DIRECT INJECTION DKATE(THY)/DJ5(T9A)/DJ5T(T8A+THY) DJ5TED(THX) engines Rover Metro 1.4D(-94) TUD3(K9A) engine 115D(95-) TUD5(VJY) engine 218SD/418D Turbo 7TE/9A engines TATA Loadbeta 1.9D(94-) 9(483DL 43/44) engine AST Kit Tools Camshaft, Injection Pump, Balance Shaft, Crank/Flywheel TDC Lock Tensioner Adjustment Timing Adj. AST AST AST AST C1 C2 C3 C4 C5 C6 C8 M8 P4 P8 T1 T Additional AST Tool required Spr. Hold Flywheel Hold (Crank Pulley removal) Pump Sprocket Removal 11BTE DJ5T DJ5 TED AST4306 4/7 4

5 AST Application Chart Models/engines PSA Petrol, including twin cam engines Citroën AX 1.0/1.1/1.4, AX GTi, Saxo 1.0/1.1/1.4/1.6, C15 1.0/1.1/1.4, BX 1.1/.14(-93), ZX 1.1/1.4/1.6, Berlingo 1.1/1.4, Xsara 1.4/1.6 TU9-1.0 / TU1-1.1 / TU3-1.4 / TU5JP-1.6 (CDY/CDZ/HDY/HDZ/KDX/KDY/KFW/KFX/KFZ/NFZ) engines Saxo v, Xsara v. TU5J4/L3(NFX/NFU) TWIN CAM engines Visa 1.6 GTi, ZX 1.6/1.9, BX 1.6/1.9 XU5(B1E/B6D) / XU9(D6A/D6B) engines (WITH SLIDING TENSIONER -92) ZX 1.6/1.8/1.9/2.0, Xsara 1.8, BX 1.6/1.9(92-),Xantia 1.6/1.8/2.0, XM 2.0/Turbo, Synergie 2.0/Turbo, Berlingo 1.8, Relay/Jumper 2.0 XU5(BDY/BDZ/BFZ) / XU7(L6A/LFX/LFZ) / XU9(D6A/D6B/D6D/DDZ/DKZ/DFZ) XU10J2(RFU/RGX/RGY/RFZ/RFX/RFW/RDZ) engines (WITH ECCENTRIC TENSIONER) Xsara v, Xantia v, ZX v. XU7JP4(LFY) TWIN CAM engines BX GTi 16v(-92), ZX v, Xsara v., Xantia v, XM v XU9J4(D6C) / XU10J4(RFY/RFV/R6E/RFS) TWIN CAM engines Fiat Ulysse 1.8/2.0/Turbo, Ducato 2.0 LFW/RFU/RGX/RFW engines Peugeot /1.1/1.4/1.6, /1.1/1.4, /1.4/1.6 (98-) /1.4/1.6, , /1.4(-93) Partner 1.1/1.4, (-94) TU9-1.0 / TU1-1.1 / TU3-1.4 / TU5JP-1.6 (CDY/CDZ/HDY/HDZ/KDX/KDY/KFW/KFX/KFZ/NFZ) engines v(96-), v., v. TU5J4/L3(NFX/NFU) TWIN CAM engines /1.9, /1.9, /1.9, /1.9 XU5(B1E/B6D) / XU9(D6A/D6B) engines (WITH SLIDING TENSIONER-92) /1.9(92-), /2.0, /1.9(92-), /1.8/1.9/2.0(92-), /1.8/2.0, , /2.0/Turbo, Boxer 2.0, Partner 1.8 XU5(BDY/BDZ/BFZ) / XU7(L6A/LFX/LFZ) / XU9(D6A/D6B/D6D/DDZ/DKZ/DFZ) XU10J2(RFU/RGX/RGY/RFZ/RFX/RFW/RDZ) engines (WITH ECCENTRIC TENSIONER) v, v XU7JP4(LFY) TWIN CAM engines v, 309 GTi 16v(-94), 405 Mi 16(-94), v, v, v, v. XU9J4(D6C) / XU10J4(RFY/RFV/R6E/RFS) TWIN CAM engines AST Kit Tools Twin Camshaft, Crank/Flywheel TDC Lock Tensioner Spr. Hold AST AST P1 P2 P3 P4 P5 P6 P7 P8 T Additional AST Tool required Flywheel Hold (Crank Pulley removal) RFY/ RFV/ D6C R6E/RFS Early XU7/9 (-93) AST4358 (XU7) AST4358 (Xsara) (D6C/RFY) AST4358 (RFS) except 206 Early XU7/9 (-93) AST4358 (XU7) (99-) AST4358 RFY/RFT/ RFV/ D6C R6E/RFS (D6C/RFY) AST4358 (RFV/RFS) 5/7 5

6 The huge range of PSA TU/XU petrol and TUD/ diesel engines require a comprehensive selection of setting/locking pins and tensioner tools for timing belt replacement/renewal and AST provides these tools in one kit. Both petrol and diesel applications are covered including the 1.6, 1.8 and 2.0 twin cam engines and direct injection engines. In addition to the essential difficult access flywheel pins, specific dimentional pairs and single application pins are included, as well as a range of tensioner locking and adjusting tools. Citroen/Peugeot engines have access holes through pulleys/sprockets and fixed datum holes on the engine to allow the camshaft, injection pump and crank to be locked in their timed positions by use of correctly sized locking pins - refer to Application Charts. AST4360C6, AST4360C8, AST4360P8 Flywheel TDC Locking Pins ( Difficult Access Pins) This series of 3 shaped locking pins are designed to provide access to the flywheel datum hole enabling the engine to be locked at TDC. Often, access to the datum hole is restricted by a component ie. starter motor etc. and therefore the specific pin shapes are essential to overcome difficult access. For 7, 9AU/9TF, 11, DJ/DK Use AST4360C6 For 7, 9A, 9TE, 9BTF, 11BTE Use AST4360C8 For TUD3/5 diesel and TU1/3/5/9 petrol Use AST4360P8 NOTE: Engine types are fitted over a number of models. For engine references to vehicle model - refer to Application Charts. AST4360C1, AST4360C2, AST4360C3, AST4360C4, AST4360C5, AST4360M8 AST4360P1, AST4360P3, AST4360P4, AST4360P6, AST4360P7 Locking Pins - Camshaft, Injection Pump, Crankshaft, Balance Shafts IMPORTANT: Locking Pins must NOT be used to hold the crankshaft whist releasing or tightening the pulley bolt. Locking Pins are for retention of timing position only. Use appropriate Flywheel Holding tool - see Additional AST Tools required and Application Charts. IMPORTANT: To ensure accuracy of the timing position and access to the datum hole, it is essential to use the correct pins to suit each application. Tensioner Adjustment Tools AST4360T1, AST4360T4 and AST4360T5 Retaining Tools AST4362 and AST4363 Tensioner Adjusters AST4360T1 Retaining Pin is required when removing/replacing the timing belt on the DJ5TED Di engines. It is necessary to compress the automatic roller tensioner and lock it using AST4360T1 Retaining Pin. AST4360T4 Tensioner Tool (Dynamic Roller) is essential for use on the Auxiliary Belt tensioner, when air conditioning/power steering is installed. AST4360T5 Retaining Pin is used on later XU7JP4 (LFY) v. engines to retain dynamic tensioner. 6/7 6

7 Tensioner Adjustment Tools - continued Twin Cam Engine Timing Tools AST4362 and AST4363 are specialised wrenches for adjusting the timing belt tensioners. AST4362 provides access onto the square drive on belt tensioners on 11/DK/DJ engines. AST4363 carries out the similar function on TUD3, TUD5 diesels and TU1/2/3/9 and TU5J4 petrol engines. On early TU1/2/3/9 engines (-94), AST4363 can also be used with an appropriate weight to establish timing belt tension. For DJ5TED direct Inj. engine Use AST4360T1 For 9/11 engines (Aux. Belt Dyn. Roller) Use AST4360T4 For 11/DK/DJ engines Use AST4362 For TUD3/5 diesel and TU1/2/3/9 & TU5J4 petrol Use AST4363 For XU7JP4 (LFY) petrol Use AST4360T5 AST4360P2, AST4360P3, AST4360P4 and AST4360P5 Locking Pins There are a number of Citroën/Peugeot 16v twin cam engines and these use locking pins to retain the engine timing position during belt renewal. These pins enter through access holes in each of the camshaft sprockets into fixed datum holes behind. NOTE: Later engine cam sprockets have slotted bolt holes to allow movement as part of assembly/tensioning procedure. For XU9J4(D6C)/ XU10J4(RFY) v Use AST4360P2(Pair) + AST4360P4 for Crank For TU5J4/LE v Use AST4360P3 + P4 + AST4360P8 for Flywheel For XU7JP4(LFY) / XU10J4 (RFV/R6E/RFS) 1.8/2.0 16v Use AST4360P5 (Pair) + AST4360P4 for Crank Additional AST Tools required - not included in AST Kit - see Application Charts for models/ application details Injection Pump Remover AST4394 Sprocket Holding Tool AST4358 AST4373 EPIC Injection Pump Timing Pin Citroën/Peugeot - Flywheel Holding Tools (Crank Pulley removal) 7/7 7 07/25/02, 9:44 AM