Rover | 825 | AS4600 - Baum Tools

Applications:
AS4600
ROVER V6 2.0 & 2.5 Quad Cam Petrol
engines in
Petrol Engine V6
Setting/Locking
COMPLETE KIT
ROVER
825
45
75
LAND ROVER
Freelander
Associated Tool: AS4614
Crankshaft Pulley Holding Tool
Rover KV6 engines
Additional AS Tools required:
AS4614 Crankshaft Pulley Holding Tool
Engine Variants & Kit Options:
The Rover KV6 quad cam engine has evolved over a number of years,
and the original version in the Rover 825 uses a different timing tools
combination than the later engine variants in the Rover 45/75/L-R
Freelander models. However some of the timing tools are common to
all applications.
AS4600
AS4614
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.
Front Timing Belt
x2
4
1
The 2 x Main Kits can subsequently increase their application
coverage via
• AS4615 SUPPLEMENTARY SET - Increases AS4610 Kit (825)
to cover Rover 45/75 & L-R Freelander
• AS4616 SUPPLEMENTARY SET - Increases AS4605 Kit
(45/75/Freelander) to cover Rover 825
AS4600 COMPLETE Kit and AS4605 / AS4610 MAIN Kits use an
identical case and insert layout where space is provided to also accept
the tools from the SUPPLEMENTARY Sets - see Page 2 for Kit contents.
NOTE: All AST KV6 Kits cover replacement of both front
timing belt and rear cam belts.
3
2
5
x2
2.5 Engine
A COMPLETE KIT is available to cover all KV6 models/variants.
2 x MAIN KITS are also available - these cover only specific
models/engines.
• AS4600 COMPLETE Kit includes ALL tools covering ALL KV6
engine variants.
• AS4605 MAIN KIT comprises the tools for Rover 45/75 and
L-R Freelander 2.0 & 2.5 engines (99-)
• AS4610 MAIN KIT comprises the tools for Rover 825
2.5 variant (-99).
AS4600 Kit contents/spares
x2
Item
2.0 Engine
Front Timing Belt
1
AS4601
2
AS4602
Rear Camshaft Belts
3
6
8
7
Part Number
9
x2
AS4603
4
AS4604
5
AS4360T1
Rear Camshaft Belts
6
AS4606
7
AS4607
8
AS4608
9
AS4609
- AS4600/84
Description
Camshaft Locking Tool (2 per kit)
Camshaft Locking Adaptor (2 per kit)
SILVER (2.5 engine)
Camshaft Locking Adaptor (2 per kit)
GOLD (2.0 engine)
Crankshaft Locking Pin
Tensioner Locking Pin
Rear Cam Sprockets Setting Tool
Rear Cam Sprockets Setting Tool
Rear Cam Sprockets Spreader
Rear Cam Sprockets Guide Pin (2 per kit)
Case + Insert
Toll free 800-848-6657 International +1 941-927-1414 Fax +1 941-927-1612
1/6
4600
AS4600 Range - Kit Options / Applications
AS4605 Engine Setting/Locking MAIN KIT
Applications: Rover 45 & 75
Land Rover Freelander
2.0 & 2.5 KV6 engines (99-)
Front Timing Belt
2.5
x2
x2
Comprises: AS4601 Camshaft Locking Tool (2 off)
AS4602 Camshaft Locking Adaptor (2 off)
AS4603 Camshaft Locking Adaptor (2 off)
AS4360T1 Tensioner Locking Pin
AS4606 Rear Cam Sprockets Setting Tool
AS4608 Rear Cam Sprockets Spreader
AS4609 Rear Cam Sprockets Guide Pin (2 off)
2.0
x2
Rear Camshaft Belts
x2
AS4616 Engine Setting/Locking
SUPPLEMENTARY SET
Applications: Increases AS4605 Main Kit
to additionally cover Rover 825
Comprises: AS4604 Crankshaft Locking Pin
AS4607 Rear Cam Sprockets Setting Tool
AS4610 Engine Setting/Locking MAIN KIT
Applications: Rover 825
2.5 KV6 engine (96-99)
Front Timing Belt
Comprises: AS4601 Camshaft Locking Tool (2 off)
AS4602 Camshaft Locking Adaptor (2 off)
AS4360T1 Tensioner Locking Pin
AS4604 Crankshaft Locking Pin
AS4607 Rear Cam Sprockets Setting Tool
AS4608 Rear Cam Sprockets Spreader
AS4609 Rear Cam Sprockets Guide Pin (2 off)
x2
x2
Rear Camshaft Belts
x2
AS4615 Engine Setting/Locking
SUPPLEMENTARY SET
Applications: Increases AS4610 Main Kit to additionally cover Rover 45 / 75
and L-R Freelander
Comprises: AS603 Camshaft Locking Adaptor (2 off)
AS4606 Rear Cam Sprockets Setting Tool
2/6
4600
x2
Toll free 800-848-6657 International +1 941-927-1414 Fax +1 941-927-1612
AS4600 Rover KV6 Engine Setting/Locking
COMPLETE Kit
Comprises AS4601 Camshaft Locking Tool (2 off)
AS4602 Camshaft Locking Adaptor (2 off)
AS4603 Camshaft Locking Adaptor (2 off)
AS4604 Crankshaft Locking Pin
AS4606 Rear Cam Sprockets Setting Tool
AS4607 Rear Cam Sprockets Setting Tool
AS4608 Rear Cam Sprockets Spreader
AS4609 Rear Cam Sprockets Guide Pin (2 off)
AS4360T1 Tensioner Locking Pin
The AS4600 COMPLETE Kit includes all the engine timing belt
replacement tools for the 2.0 and 2.5 variants of the KV6 quad cam
engine and therefore covers applications on the Rover 825, 45, 75 and
Land Rover Freelander.
MAIN Kits AS4605 and AS4610 cover these applications as two
groups - either 45/75/L-R Freelander or 825 and each kit includes the
relevant timing tools from AS4600 Kit to fully cover that application see Engine Variants / Kit Options on first page.
45/75/L-R Freelander - align the white mark on the crank pulley
with the ‘SAFE’ arrow timing mark on the mounting plate, check that
the timing marks on the rear camshaft sprockets (L-H bank) are aligned
as the illustration below
475/75/L-R Freelander
It will be necessary to remove belt covers, auxiliary belt/tensioner,
alternator, PAS pump (move sideways, do not disconnect hoses), AC
compressor, mounting bracket etc., and drain engine oil. On automatic
transmission also remove dipstick
NOTE: The Rover KV6 engines have a front timing belt and two rear
camshaft belts and therefore replacement of all 3 belts are covered
by the tools in the Kits.
This Product Information details use of the tools required for belt
replacement as Section 1 - Front Timing Belt replacement
Section 2 - Rear Camshaft Belt replacement
Belt replacement procedures on all KV6 variants are basically the
same and this information covers all applications. Most tools are
common to all engines but where a tool is required for a specific
model/engine variant, it is detailed.
Section One - Front Timing Belt
It will be necessary to raise and support the front of the vehicle and
also support the engine.
Remove the right-hand front wheel, slash guard and rear cover of L-H
cylinder bank (to view camshaft position).
AS4614 Crankshaft Pulley Holding Tool - Associated
Tool, not in kits
Crankshaft Position
The crankshaft pulley must be removed in order to remove front timing
belt on 45, 75 and L-R Freelander - Use AS4614 Tool to counterhold the pulley whilst releasing the centre bolt.
The crankshaft timing position is established by turning the crankshaft
in a clockwise direction to 825 - achieve position 60° BTDC and checking that the hubs of the
rear camshaft sprockets (L-H bank) are positioned as the illustration
below.
AS4614 must also be used when installing the pulley.
Tensioner
45/75/L-R Freelander - remove the rubber blanking plug from
around the tensioner
The timing belt tensioner is turned clockwise to release tension and
is then removed.
WARNING: Do not loosen the allen screw which holds the
tensioner pulley.
825
Then insert AS4604 Crankshaft Locking Pin through the hole located
in the lower crankcase under L-H cylinders to ‘lock’ the crankshaft.
Toll free 800-848-6657 International +1 941-927-1414 Fax +1 941-927-1612
3/6
4600
AS4360T1 Tensioner Locking Pin
Using a vice, carefully compress the tensioner plunger until the holes
in the body and plunger align, and insert AS4360T1 Pin to keep
plunger depressed.
Remove the front timing belt.
WARNING: Do NOT rotate the crankshaft with the timing
belt removed.
Remove the front oil seals from both exhaust camshafts.
NOTE: Once the ‘pegs’ have been inserted it can be difficult to
align the spindle for insertion into the end of the camshaft. Use of
a drivebar in the square drive hole provided in the Locking Tool, will
assist alignment.
WARNING: Damage to camshafts can result if an attempt
is made to release or tighten sprocket bolts without these tools
being installed.
Remove and discard sprocket bolts and remove Locking Tools
AS4602
2.5 engines
AS4603
2.0 engines
AS4601
Camshaft Locking Tools Assembly
AS4601 Camshaft Locking Tools
used with
AS4602 Camshaft Locking Adaptors - 2.5 engines
or
AS4603 Camshaft Locking Adaptors- 2.0 engines
The appropriate Adaptor AS4602 (2.5 engine) or AS4603 (2.0
engine) is selected and fixed onto AS4601 Locking Tool to make a
Locking Tool Assembly.
These Locking Tool Assemblies are used to ‘lock’ the camshafts whilst
the front sprocket bolts are released or tightened.
NOTE: Two AS4601/02 or /03 Assemblies are required, one for
each front camshaft sprocket.
To ‘lock’ the camshaft the ‘pegs’ of the Camshaft Locking Adaptor are
inserted into the front sprocket hub and the Locking Tool spindle is
inserted into the end of the exhaust camshaft (location pin into slot
in camshaft).
4/6
4600
Remove front sprockets complete with hub assemblies.
Clean the sprockets and hubs and assemble back onto the camshafts.
Screw in new sprocket bolts to fingertight allowing the sprockets to
turn freely but not to tilt.
The AS4601/02 or /03 Camshaft Locking Tool Assemblies are now
refitted, however as the new belt will not pass over these tools once
they are installed, fit the new belt temporarily in position prior to fitting
the tools.
Fit both of the AT4601/02 or /03 Tool Assemblies to the front
camshaft sprocket hubs and into the ends of the exhaust camshafts.
Turn the sprockets fully clockwise and commence fitting the new
timing belt in an anti-clockwise direction starting at the crankshaft
gear.
WARNING: When fitting the belt over the front camshaft
sprockets turn each sprocket only the minimum amount
required to fit the belt into the sprocket teeth.
Turn the tensioner clockwise to rest against the belt and install the
tensioner unit, applying Loctite to the bolt threads.
Remove AS4360T1 Locking Pin to release the tensioner plunger.
45/75/L-R Freelander - Re-fit rubber blanking plug around
tensioner.
With the AS4601/02 or /03 Locking Tool Assemblies in place, tighten
the sprocket bolts to 27Nm + 90°.
Remove both Camshaft Locking Tool Assemblies and
825 - Remove AS4604 Crankshaft Locking Pin
Re-assemble engine components.
s
Toll free 800-848-6657 International +1 941-927-1414 Fax +1 941-927-1612
Section Two - Rear Camshaft Belts
IMPORTANT: The rear camshaft belt replacement procedure
applies to both the right-hand and left-hand belts, however
replacement should be carried out only on one belt at a time.
AS4607
AS4606
AS4606 and AS4607 Rear Cam Sprocket
Setting Tools
AS4606 - for Rover 45/75 & L-R Freelander
AS4607 - for Rover 825
Dependant upon the model/engine, fit either AS4606 or AS4607
Setting Tool to the rear cam sprockets
NOTE: Setting Tools must be fitted to sprockets using hand pressure
only.
Setting Tool and Guide Pins
Replacing a rear camshaft belt involves the removal of the bank of
two cam sprockets complete with existing belt, as an assembly, whilst
using a Setting Tool to maintain the relevant position and distance
between the two sprockets. Then, on the workbench, a new belt is
fitted over the two sprockets which are spread apart to tension the belt
and the Setting Tool re-fitted. Guide Pins are used to assist installation
of the whole assembly back onto the camshafts.
Release, remove and discard the sprocket bolts and remove the
sprockets, existing belt and Setting Tool as an assembly, from the
engine.
On the workbench, remove the belt from the sprockets and clean the
sprockets and hubs.
Assemble the hubs to the sprockets and place them on a flat surface
ready to reconstruct the assembly for re-fitting to the engine.
It will be necessary to raise and support the vehicle and to remove
R-H front wheel, splash guard, timing covers, air filter, inlet manifold
(upper), and rear engine bracket.
825
L-H Bank
L-H Bank
R-H Bank
R-H Bank
825
825 - Place the sprockets as above illustration noting flanged edges
and position/alignment of centre hubs
45/75/L-R Freelander
Turn the crankshaft in a clockwise direction to
825 - position the rear cam sprockets to be able to fit Setting Tool
AS4607 - see above illustration
45/75/L-R Freelander - align white timing marks on crank pulley
and ‘SAFE’ arrow on mounting plate and to align timing marks on rear
sprockets - see above illustration
45/75/L-R Freelander
45/75/L-R Freelander - Place sprockets as above illustration noting
position of locating lugs and timing marks.
Fit new belt around sprockets.
5/6
Toll free 800-848-6657 International +1 941-927-1414 Fax +1 941-927-1612
4600
AS4608 Spreader
AS4609 Rear Cam Sprocket Guide Pin (2 required)
AS4609 Guide Pins are fitted into the rear ends of each camshaft
to help install the rear cam sprocket/belt assembly onto the ends of
the camshafts.
Setting Tool
Slide the assembly over the Guide Pins.
AST4608 Rear Cam Sprockets Spreader
Fit AS4608 Sprocket Spreader between the sprockets and turn its
centre screw to expand the distance between the sprockets to a
position where AS4606 or AS4607 Setting Tool (dependant upon
engine), can be inserted to re-make the assembly ready to install on
the engine.
Once the cam sprocket/belt assembly is installed, remove the
AS4609 Guide Pins and fit new sprocket bolts.
Tighten sprocket bolts to 25Nm. + 90°.
Remove the AS4606 or AS4607 Setting Tool from the rear cam
sprockets and AS4601 from the front of the exhaust camshaft. Fit
new oil seal.
NOTE: Setting Tools must be fitted to sprockets using hand pressure
only.
Remove the AS4608 Spreader.
Refitting rear cam sprockets
Some alignment of the exhaust camshaft will be required when
installing the rear cam sprocket/belt assembly, and therefore it is
necessary to remove and discard the oil seals from the front of the
exhaust camshafts in order to fit AS4601 Locking Tools.
Exhaust camshaft alignment is achieved by fitting the Spindle of
AS4601 Locking Tool into the front of the exhaust camshaft (location
pin into slot in camshaft) and using it to carefully turn the camshaft
to align the drive slot in the camshaft rear to match the rear sprockets
during their installation.
NOTE: For this alignment application the ‘pegs’ of the Locking Tool
Assembly are not located into the camshaft sprocket hubs. Only the
spindle of AS4601 is used.
6/6
4600
More AST Timing Tools for Rover / Land Rover
Engine Setting/Locking Tool Kit Rover Twin Cam Petrol & L Series Diesels –
see AS4386
Diesel Engine Setting/Locking Tool Kit Rover /Land Rover 2.0d (BMW) –
see AS4555
Diesel Engine Setting/Locking Tool Kit Land Rover 2.5D/200/300Tdi –
see AS3243
Diesel Engine Setting/Locking Tool Kit Land Rover 2.5td (BMW) –
see AS4411
Toll free 800-848-6657 International +1 941-927-1414 Fax +1 941-927-1612
Download PDF