AST5105

Diesel Engine Setting/Locking Tool Kit

Applications:
2.0/2.2/2.4/3.2 TDCi/TDdi
Diesel (CHAIN) engines in:
CITROEN-PEUGEOT:
Boxer III Jumper III Relay III
FORD:
Mondeo Ranger Transit Transit Custom
FIAT:
Ducato
JAGUAR: LAND ROVER:
X-Type Defender
Kit Contents / Spares:
LDV: LTI: MAZDA:
Convoy TXII BT-50
2
Engine codes:
3 4
244DT
4HG
D0FA
D2FA
GBVAJ
GBVAJPF
QJBA
QJBB
1
4HH D2FB GBVAJQJ QJBC
4HJ
4HM
D3FA
D4FA
GBVAJQW
H9FA
QJBD
QVFA
6
4HU D5BA H9FB QW2R
4HV D6BA H9FD QWFA 5
ABFA DRF5 HEFA SAFA
CVF5 DRFA HJBA SAFB
CVFF DRFB HJBB SDBA
CVR5 DRFC HJBC SRFA
CVRA DRFF HJBE SRFB
CVRB DRFG JXFA SRFC 7 8
CYF5 DRR5 JXFC SRFD
CYFA DRRA N7BA SRFE Item Part No. Description OE Ref.
CYFB DRRB N7BB UHFA 303-1310, 303-1177,
CYFC F3FA P8FA UHR5 Crankshaft Pulley
1 AST5107 2.000.018.3400,
CYFF F4FA P8FB USR5 Holding Tool
2.000.001.000
CYFG FIFA PGFA USRA Camshaft Setting 6mm Drill, 0198.B2,
CYR5 FMBA PGFB USRB 2 AST4730F1
Pin Set 2.000.016.500, LDV167
CYRA FMBB PHFA UYR5
CYRB FXFA PHFC ZSD422 Crankshaft 303-1587, 0198.N,
3 AST5106
ZSD424 Setting Tool 2.000.018.700
Additional Tools Required: Chain Tensioner
4 AST4593-1D 0198.J
AST4939 Crankshaft Locking Pin
Pulley Hold Tool Handle Oil Pump
5 AST5109 303-705
Alignment Tool
Flywheel Locking
6 AST5108 303-254
Tool
Timing Chain
IMPORTANT: Always refer to the vehicle manufacturer’s 7 AST5131 303-682, LDV177
Cover Aligner
service instructions, or proprietary manual, to establish the current
procedures and data. Product Information Sets detail applications Crankshaft Seal
8 AST5132 303-679A, LDV170
and use of the tools with any general instructions provided as a Installer
guide only.
- AST5105-84 Case + Insert -
AST has a policy of continuous development & reserve the right to
change product specification or appearance without prior notice.
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 AST5105
Diesel Engine Setting/Locking Tool Kit

Introduction
AST5105 covers timing chain removal and installation procedures on all variants of the 2.0/2.2/2.4L four cylinder and 3.2L five cylinder
TDCi/TDdi DuraTorq ‘PUMA’ engines installed in a number of models 2000-2018. Engines with camshaft driven H.P. fuel pumps utilise the
same setting tools as engines with chain driven pumps, but the pump timing pin is not required as the pump is directly connected to the
camshaft.

For chain driven fuel pump removal and installation, see kit AST5195 H.P. Fuel Pump R+I kit.

1 2
CRANKSHAFT PULLEY REMOVAL CRANKSHAFT SEAL REMOVAL
Using AST5107 in conjunction with AST4939, rotate the crankshaft Assemble AST5131 to AST5132.
pulley to position.
Locate tool assembly into holes of crankshaft seal.
Remove the crankshaft pulley.
Rotate crankshaft seal in anti-clockwise direction to remove it from
AST5107 is also used to counter hold the crankshaft pulley when the timing chain cover.
tightening the retaining bolts the final torque figure.
Remove retaining screws and remove cover.

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 AST5105
Diesel Engine Setting/Locking Tool Kit

For engines with H.P. fuel pumps that are driven directly from the rear
of the camshaft, only use two setting pins through the camshafts.

3
CRANKSHAFT TIMING 5
Install AST5106 crankshaft setting tool on the nose of the
crankshaft, ensuring that the location peg is positioned in the recess TENSIONER LOCKING PIN
of the crankshaft. Secure the tool in position using one of the
crankshaft pulley bolts and a timing chain cover retaining screw. Compress the plunger of the timing chain tensioner, retain in position
using AST4593-1D locking pin.
Remove the camshaft timing chain guide rails and the timing chain.

IMPORTANT: Removal of the timing chain requires removal

of AST5106 crankshaft setting tool.
Ensure that the crankshaft is positioned correctly, with AST5106
fitted to the crankshaft and retained using a timing chain cover
screw, before installing the timing chain on to the sprockets.

6
TIMING CHAIN COVER ALIGNMENT +
CRANKSHAFT SEAL INSTALLATION
4 Locate AST5131 cover aligner fully in the recess of the timing chain
cover.
CAMSHAFT/H.P. PUMP SETTING PINS Apply a bead of sealant to the engine. Locate the timing chain cover
on engine, ensuring that AST5131 remains seated in the cover and
Ensure that the holes in the camshaft sprockets and H.P. pump
is located on the nose of the crankshaft.
sprocket are aligned with the holes in the engine.
Install timing chain cover retaining screws and tighten to the
Install camshaft setting pins through holes in camshaft sprockets
prescribed torque figure.
and through the hole in the H.P. fuel pump sprocket.
Remove AST5131 from timing chain cover.

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 AST5105
Diesel Engine Setting/Locking Tool Kit

The pump must be refitted in the correct position, sprocket teeth

aligned to the crankshaft sprocket, to prevent premature wear and
breakage of the oil pump drive chain.
Install AST5109 on the block, ensuring that the edges of the
alignment tool are contacting the face of the oil pump sprocket,
retain in position using one of the sump retaining screws and nut.
Remove the oil pump tensioner, the oil pump feed pipe, pump and
drive chain.

IMPORTANT: Do not remove AST5109 oil pump alignment

tool until the oil pump assembly has been refitted in the correct
position and the retaining screws have been tightened to their final
torque setting.

7
Assemble AST5131 and AST5132, locate the assembled tool into
the dimples of a new crankshaft seal.
Install the seal on the nose of the crankshaft, into the recess of the
timing chain cover.
Rotate the tool assembly in a clockwise direction to lock the seal
into the cover.
9
FLYWHEEL LOCKING TOOL - AST5108
AST5108 locates in the teeth of the flywheel to counter hold and
prevent rotation of the crankshaft, this tool can be used during a
number of operations and procedures such as flywheel, crankshaft
pulley or timing chain removal and installation.
Remove the starter motor, locate AST5109 in the teeth of the
flywheel and retain in position using the nut.

8
OIL PUMP ALIGNMENT
Removal and installation of the oil pump drive chain requires oil
pump to be removed from the engine.

AST. 68 Heming Road, Washford Industrial Estate, Redditch, Worcestershire, B98 0EA, England. Page 4/4
Tel: +44 (0)1527 522550 Email: sales@asttools.co.uk www.asttools.co.uk © AST, 2018 AST5105.01