AST5045 Timing Chain Service Tool Set

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1 AST5045 Timing Chain Service Tool Set Applications: BMW.8,.0,.5, 3.0 and BMW Mini / Citroën - Peugeot.4 and.6 Petrol engines (Chain) in: BMW 8i E87 (04-07) 0i E87 (04-07) 36i E46 (0-05) 36ti Compact E46 (0-05) 38i E46 (0-07) 38ti Compact E46 (0-05) 38i E90 (05-08) 30i E90 (05-08) 50i E60 (04-08) Z4..0 E85 (04-08) X3.0i E83 (05-08) Engines N4/N46 B8 B8A B0 B0A B0B 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. Additional AST Tools required: AST4939 Handle for use with AST508 Holding Tool. NOTE: A Camshaft Setting Plate(s) and Flywheel Locking Pin will be required from the appropriate Setting/Locking Tool Kit associated with the engine - see application chart - page 6i E8/E87 (03-08) 36i E46/E90 (0-08) 36Ci E46 (0-06) 36ti E46 (0-05) 8i E8 (07-08) 30i E8/E87 (05-08) 35iS E8 (07-08) 33i E90/9/9/93 (04-08) 35i/xi E90/9/9/93 (04-08) 38i/xi E90/9/9/93 (04-08) 330i/xi E90/9/9/93 (04-08) 335i/xi E90/9/9/93 (05-08) 53i/Li E60/6 (04-08) 55i/Li/xi E60/6 (04-08) 58i/xi E60/6 (06-08) 530i/Li/xi E60/E6 (05-08) 535ixi E60/E6 (06-08) 630i E63/64 (04-08) 730i/Li E65/66 (04-08) X3.5/3.0 E83 (06-08) X5 3.0 E70 (06-08) Z4.5/3.0 E85/86 (05-08) N40/N45/N45T B6 N5/N5/N5K/N53/N54 Valvetronic N53/N54 Direct Injection Non - Valvetronic Set contents / spares Item Part Number Description AST506 Balancer Shaft Alignment Tool AST507 Balancer Shaft Alignment Tool 3 AST508 Crankshaft Gear Holding Tool 4 AST509 Crankshaft Gear Holding Tool Support 5 AST443 Chain Tensioner Pin AST Case + insert Limited, 009 BMW Mini: R55/R56 Cooper S (06-09) R55/R56 Cooper (06-09) R56 Mini One (07-09) N/N4 Peugeot: 07 (06-09) EP3(8FS)/EP6(5FW) 07CC (07-09) EP6DT(5FX) 308 (07-09) EP6DTS(5FY) Citroën: C4 Picasso (08-09) C4 (08-09) /

2 AST5045 Timing Chain Service Tool Set Removal of the Timing Chain assembly requires the use of the appropriate Camshaft Setting Plates and Flywheel Locking Pins (not in AST5045 kit) from the associated Engine Setting/Locking Tool Kits listed in the application chart. The service tools in this set are required when replacing the timing chain and other applications which involve the removal of the chain assembly on the models / engines detailed below:- Set contents AST506 Balancer Shaft Alignment Tool AST507 Balancer Shaft Alignment Tool AST508 Crankshaft Gear Holding Tool AST509 Crankshaft Gear Holding Tool Support AST443 Chain Tensioner Pin Application Chart Models engines AST506 AST507 AST508 AST509 AST443 Associated Tool Kits required for camshaft Setting Plate and Flywheel Locking Pin BMW 8i E87 N4/N46 Kit AST4800 0i E87 B8/B8A AST4805 Camshaft Setting Plate Assembly. 36i E46 B0/B0A AST480 Flywheel Locking Pin 36ti E46 B0B 38i E46 l l l l 38ti E46 38i E90 30i E90 50i E60 Z4..0 E85 X3.0i E83 6i E8/E87 N40/N45/N45T Kit AST i E46/E90 B6 l l l l AST4868 Camshaft Setting Plate Assembly. 36Ci E46 AST480 Flywheel Locking Pin 36ti E46 8i E8 N5/N5/ Kit AST i E8/E87 N5K/N53 /N54 AST500 Camshaft Setting Assembly 35iS E8 Valvetronic AST500 Flywheel Locking Pin 33i E90/9/9/93 35i/xi E90/9/9/93 N53/N54 38i/xi E90/9/9/93 Direct Injection 330i/xi E90/9/9/93 Non - Valvetronic 335i/xi E90/9/9/93 53i/Li E60/6 55i/Li/xi E60/6 l l l 58i/xi E60/6 530i/Li/xi E60/E6 535i/xi E60/E6 630i E63/64 730i/Li E65/66 X3.5/3.0 E83 X5 3.0 E70 Z4.5/3.0 E85/86 BMW Mini Kit AST5030 R55/R56 Cooper S N/N4 AST50 Flywheel Locking Pin. R55/R56 Cooper AST50 Exhaust Camshaft Setting Plate R56 Mini One (N/N4). l l AST503 Inlet Camshaft Setting Plate (N). AST504 Inlet Camshaft Setting Plate (NI4). PSA Kit AST5030 Peugeot EP3(8FS) AST50 Flywheel Locking Pin. 07CC EP6(5FW) AST50 Exhaust Camshaft Setting Plate 07 EP6DT(5FX) (EP3/EP6/EP6DT). 308 EP6DTS(5FY) l l AST503 Inlet Camshaft Setting Plate Citroën (EP3/EP6). C4 Picasso AST504 Inlet Camshaft Setting Plate C4 (EP6DT/DTS). / Limited, 009

AST506/AST507 Balancer Shaft Alignment Tools AST506 and AST507 are used to re-adjust the balancer shafts when replacing the timing chain.

AST508 is used in conjunction with AST4939 Handle assembly. (AST4939 Associated Tool - not in set) NOTE: On N5 and N5 engines the central bolt requires a torque of 00 Nm and +360.

the central bolt. AST443 Tensioner Pin AST443 is used for locking the chain tensioner in position when removing the tensioner on the N5 and N5 engines.

3 AST506/AST507 Balancer Shaft Alignment Tools AST506 and AST507 are used to re-adjust the balancer shafts when replacing the timing chain. AST508 / AST509 Crankshaft Gear Holding Tool and Support AST508 is used to counter-hold the crankshaft when releasing / tightening the central bolt. AST508 is used in conjunction with AST4939 Handle assembly. (AST4939 Associated Tool - not in set) NOTE: On N5 and N5 engines the central bolt requires a torque of 00 Nm and As it is difficult to hold Tool AST508 steady whilst applying such a high torque/angle specification, support Tool AST509 is provided to assist retention of the AST508 Holding Tool whilst tightening the central bolt. AST443 Tensioner Pin AST443 is used for locking the chain tensioner in position when removing the tensioner on the N5 and N5 engines. It is also used to lock the drive belt tensioner when removing the alternator drive belt, when replacing the timing chain on the N40 N4 N45 N46 engines. Removal of the Timing Chain - all listed engines It will be necessary to remove the cylinder head cover, all spark plugs, the chain tensioner, belt tensioner and vibration damper. NOTE: Illustration shows N5 engine Select the appropriate Camshaft Setting Tool from the relevant Timing Kit (refer to application chart). Refer to the individual Kit instructions and position the Camshaft Setting Tools onto the camshaft. If Setting Tools are already in position from earlier applications do not remove. 3 With the engine positioned at TDC No. cylinder, select the appropriate Flywheel Locking Pin from the relevant Timing Kit (refer to application chart) and insert it through the datum hole, which is located underneath the starter motor, and into the timing hole in the flywheel. NOTE: The datum hole can be difficult to locate and may be constricted by dirt / corrosion. Position AST508 Crankshaft Gear Holding Tool on the hub of the vibration damper and release the central bolt, removing with the hub. Important: It is advisable not to rely on the Flywheel Locking Pin and Camshaft Setting Plate Assembly to counter-hold when loosening the central bolt. When releasing the central bolt, hold using a second person the Crankshaft Gear Holding Tool and slacken a quarter turn to approximately 60 Nm. The flywheel pin may now be used as the counter-hold to continue to release the central bolt. Limited, 009 3/

4 Release of Bearing Pins on Chain Guide Rails 7 4 Pic 4. N/N4 chain guide rail bearing pin positions 8 Pics 7 & 8 N5/N5 chain guide rail bearing pin positions 5 6 Pics 5 & 6 N40/N4/N45/N46 chain guide rail bearing pin positions 4/ ALL Engines: Open sealing plugs and release the pins of the chain guide rails Auto Service Tools Limited, 009

VANOS Unit(s) - all engines NOTE: On some engines VANOS units are fitted on the Inlet only 0 Slacken the centre bolts of the VANOS Units.

It is recommended to counter-hold against camshaft rotation at the hexagon at the rear of the camshafts.

If VANOS units are fitted to both Inlet and Exhaust camshafts, first detach the exhaust VANOS unit followed by the inlet VANOS unit.

the crankshaft, as incorrect assembly will result in engine damage. Release screw of chain guide.

3 4 Prior to installing the chain assembly, pull timing chain () upwards until the crankshaft sprocket wheel () engages in the chain guide

5 VANOS Unit(s) - all engines NOTE: On some engines VANOS units are fitted on the Inlet only 0 Slacken the centre bolts of the VANOS Units. (N5 Engine shown for illustration purposes) WARNING: These bolts are likely to be tight. It is recommended to counter-hold against camshaft rotation at the hexagon at the rear of the camshafts. It is advisable not to rely on the Flywheel Locking Pin and Camshaft Setting Assembly to counter-hold when loosening these bolts. If VANOS units are fitted to both Inlet and Exhaust camshafts, first detach the exhaust VANOS unit followed by the inlet VANOS unit. Removal of Timing Chain Assembly - all engines 3 IMPORTANT: Note the installation direction of the crankshaft sprocket wheel in relation to the crankshaft, as incorrect assembly will result in engine damage. Release screw of chain guide. Remove the timing chain module with timing chain and camshaft sprocket wheel upwards in the direction of arrow shown on picture. 3 4 Prior to installing the chain assembly, pull timing chain () upwards until the crankshaft sprocket wheel () engages in the chain guide rail (3). The chain () and crankshaft sprocket wheel () MUST BE installed as an assembly. To keep the chain assembly together place a rubber band around the two guide rails. Insert the timing chain assembly, ensuring that the timing chain remains in this position to prevent the chain getting jammed. Limited, 009 5/

After fitment of the new chain and whilst the central bolt is slackened the balancing shafts can be rotated by hand.

5 Sprocket wheel of timing chain Sprocket wheel of oil pump Sprocket wheel of oil pump 4 Guide rail 3 8 On some newer versions the balancer shafts are aligned using AST507 Aligner.

Installation (Tightening the central bolt) N/N4/N40/N4/N45/N46 engines WARNING: Tighten the crankshaft central bolt to an initial torque of 60 Nm; the Flywheel Locking Pin may be used to counter-hold

The sprocket wheel for the oil pump is positioned BEHIND the sprocket wheel for the timing chain.

6 After fitment of the new chain and whilst the central bolt is slackened the balancing shafts can be rotated by hand. Rotate the balancer shafts until AST506 can be inserted from the INLET side and ensure it locates fully on each shaft. The tool is designed to align the shafts to each other. 5 Sprocket wheel of timing chain Sprocket wheel of oil pump Sprocket wheel of oil pump 4 Guide rail 3 8 On some newer versions the balancer shafts are aligned using AST507 Aligner. Slide AST507 () under balancing shafts () on contact faces (3) as far as pins on AST507 will allow (4). Secure balancer shafts and remove AST507 Aligner. Installation (Tightening the central bolt) N/N4/N40/N4/N45/N46 engines WARNING: Tighten the crankshaft central bolt to an initial torque of 60 Nm; the Flywheel Locking Pin may be used to counter-hold but to this initial torque of 60Nm only. Sprocket wheel on timing chain Hub 6 Note: The installation positions of each sprocket wheel in relation to the guide rail and the hub. The sprocket wheel for the oil pump is positioned BEHIND the sprocket wheel for the timing chain. Install the timing chain and sprocket wheel assembly, insert the hub and secure to the crankshaft using a new central bolt, do not tighten down. Balancer Shafts / Timing Chain Assembly on N40 N4 N45 N46 Engines 9 NOTE: Picture shows an N Engine N N4 - After applying the initial tightening torque of 60Nm tighten the crankshaft pulley central bolt to its final tightening torque of 50Nm + 00 N40 N4 N45 N46 - After applying the initial tightening torque of 60Nm tighten the crankshaft pulley central bolt to its final tightening torque of 300Nm. 7 6/ WARNING: The Flywheel TDC Locking Pin MUST NOT be used to counter hold the crankshaft when tightening the crankshaft pulley central bolt to its final tightening torque. Auto Service Tools Limited, 009

N5 N5 Engines 0 WARNING: Tighten the crankshaft central bolt to an initial torque of 60 Nm; the Flywheel Locking Pin may be used to counter-hold but to this initial torque of 60Nm only.

7 N5 N5 Engines 0 WARNING: Tighten the crankshaft central bolt to an initial torque of 60 Nm; the Flywheel Locking Pin may be used to counter-hold but to this initial torque of 60Nm only. Remove the auxiliary belt tensioner from the engine and using the available threaded hole, screw in AST509 Crankshaft Gear Holding Tool Support () and position AST508 Crankshaft Gear Holding Tool (). After applying the initial tightening torque of 60Nm tighten the crankshaft pulley central bolt to its final tightening torque of 00Nm + 360, marking the central bolt and hub with paint as a starting point for torsion angle tightening. One complete turn of 360 is required. WARNING: The Flywheel TDC Locking Pin MUST NOT be used to counter hold the crankshaft when tightening the crankshaft pulley central bolt to its final tightening torque. Install the VANOS unit(s) Install the chain tensioner Crank engine twice Check Timing Assemble engine Refer to associated tool kit instructions for installation of VANOS units, chain tensioner }and checking timing. Limited, 009 7/

BMW N12 PSA 1.4 / 1.6 Chain. Engine timing tools. K 10558

BMW N12 PSA 1.4 / 1.6 Chain. Engine timing tools. K 10558 Engine timing tools BMW N12 PSA 1.4 / 1.6 Chain K 10558 www.kamasatools.com Plan Layout C A D A B Component Identification Ref OEM Ref BMW OEM Ref PSA Description A 11 9 540 0197-A3 B 11 9 540 0197-A1