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AST5219 Engine Support Bracket

AST5220Petrol Engine Setting/Locking Tool Kit

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AST5220.01

Item Part No. Description OE Ref.1 AST5021 Flywheel Setting Pin 11-9-590, 2 299 362, 0 496 709, 0197-BZ2 AST5221 Camshaft Setting Tool 11-7-440, 0197-A3 AST4803 Crankshaft Setting Tool 11-9-340, 0197-M- AST5220-84 Case + Insert -

Kit Contents / Spares:

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.

AST has a policy of continuous development & reserve the right to change product specification or appearance without prior notice.

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AST5218 Auxiliary Belt Tensioner Wrench

Applications:

BMW:1 (F20/F21) 3 (F30/F31)

MINI:Clubman (R55) Roadster (R59)Hatch (R56/R57) Countryman (R60)Coupe (R58) Paceman (R61)

CITROEN: PEUGEOT:DS4 208DS5 308C5 III RCZ

Engine codes:N13B16A EP6CDTR (5FG)N18B16A EP6CDTX (5FU)N18B16C EP6FDTR (5GN, 5GP)N18B16M0 EP6FDTX (5GR, 5GT)N18B16T0

Additional AST Tools required:

AST5018 Crankshaft Hub Holding Tool

Chain Tensioner Pre-Load Tool

©AST Tools Ltd, 2019 www.asttools.co.uk

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AST5220.01

AST5220Petrol Engine Setting/Locking Tool Kit

AST5018 Crankshaft Hub Holding Tool

The Crankshaft Timing Chain Sprocket locates onto the Crankshaft Hub.

To remove the Timing Chain from the engine the Crankshaft Hub must first be removed. AST5018 Crankshaft Hub Holding Tool, equivalent to OE reference 11-9-280, provides a secure method of counter holding the Hub while the central bolt is removed and installed. DO NOT use AST5021 Flywheel Locking Pin to counter hold the crankshaft hub.

AST5219 Engine Support Bracket

On some vehicle models, the engine mount bracket must be removed as part of the timing chain replacement procedure.

Use AST5219 Engine Support Bracket, equivalent to OE reference 11-9-630 / 0 496 016, in place of the engine mounting bracket, to support the engine when the mounting bracket is removed from the vehicle.

AST5218 Auxiliary Belt Tensioner Wrench

Removal and installation of the Auxiliary Belt can be carried out without having to disassemble a large amount of the vehicle. AST5218 Auxiliary Belt Tensioner Wrench, equivalent to OE reference 11-6-210, provides a quick and simple method of releasing the Auxiliary Belt Tensioner from beneath the vehicle.

Introduction

AST5220 covers engine setting / timing chain removal and installation procedures for N13, N18 and EP6 1.6L four cylinder, direct injection, twin VVT petrol engines installed in a variety of BMW, MINI and PSA models.

The N13/N18/EP6 engines covered by this set of tools are broadly similar to the earlier N12, N14, N16 and EP6 engines covered by kit AST5020. This range of engines feature direct injection, VANOS VVT on the Inlet and Exhaust camshafts and ‘Valvetronic’ intermediate camshaft system to vary the lift profile of the inlet valves.

©AST Tools Ltd, 2019 www.asttools.co.uk

Rotate the crankshaft in the normal direction of rotation using a socket or wrench at the crankshaft hub central bolt.

Remove the blanking plug and insert AST5021 Flywheel Locking Pin into the timing hole of the flywheel. The balancing holes in the flywheel can easily be mistaken for the timing hole.

To check that the pin has been inserted into the correct hole of the flywheel, check that all pistons are level in the 90-degree position.

Check the operation of the VANOS adjustment units by attempting to rotate the camshafts in the direction of engine rotation using a wrench on the hexagonal form of the camshaft.

If there is no fixed connection and the camshafts can be rotated by approximately 10-15 degrees, the adjustment units may need to be replaced.

Both camshafts have three machined surfaces to enable fitting of the camshaft setting plates.

Install AST5121 Camshaft Setting Tool to the Exhaust camshaft, ensuring that the tool is located on the cylinder head.

Install the Camshaft Setting Tool to the Inlet camshaft, ensuring that it is correctly located on the cylinder head and the Exhaust Camshaft Tool.

Retain the tool in position using the three bolts provided.

If it is not possible to correctly install the Flywheel Locking Pin and the Camshaft Setting Tool, the engine timing may require adjustment.

Remove the timing chain tensioner, the crankshaft hub and then remove the timing chain assembly.

Ensure that the engine is set in the correct timing position, with AST5021 Flywheel Locking Pin and AST5221 Camshaft Setting Tool installed. Using a wrench on the hexagonal part of the camshaft, loosen the camshaft sprocket bolts.

Remove and discard the camshaft central bolts, install new bolts finger tight only so that the adjustment units can rotate freely but not tilt.

Install the timing chain assembly on to the crankshaft and camshafts.

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AST5220.01

AST5220Petrol Engine Setting/Locking Tool Kit

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WARNING: Never rotate the crankshaft against the normal direction of rotation. It is important to ensure that the Flywheel Locking Pin is correctly located in the timing hole, this can be confirmed by checking that all pistons are level, in the 90 degree position. Access to the pistons is via the spark plug apertures.

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AST Tools Ltd. 68 Heming Road, Washford Industrial Estate, Redditch, Worcestershire, B98 0EA, England.

+44 (0)1527 522550 sales@asttools.co.uk www.asttools.co.uk © AST Tools Ltd, 2019

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AST5220.01

AST5220Petrol Engine Setting/Locking Tool KitAST5220Petrol Engine Setting/Locking Tool Kit

Insert AST4803 Tensioner Pre-Load Tool into the cylinder head. Screw in the adjusting screw of AST4803 by hand until it makes contact with the tensioner rail but does not apply pressure. Attach a suitable torque wrench to the adjusting screw of AST4803 and turn to pre-load the tensioner rail to 0.6Nm.

Remove and discard the camshaft sprocket bolts and replace with new bolts.

Tighten the central bolt of the exhaust camshaft to the specified torque, followed by the central bolt of the inlet camshaft.

Unscrew the adjustment screw of AST4803, remove the Tensioner pre-load tool and refit the timing chain tensioner.

Remove all timing tools from the engine. Rotate the crankshaft two full turns in the normal direction of rotation, returning to the engine timing position.

Install AST5021 Flywheel Locking Pin and AST5221 Camshaft Setting Tool to check the timing position.

If the Flywheel Locking Pin and Camshaft Setting Tool cannot be correctly installed, the engine timing will require adjustment.

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