AS4600

Petrol Engine V6 Setting/Locking COMPLETE KIT
Associated Tool: AS4614 Crankshaft Pulley Holding Tool

Applications:

ROVER V6 2.0 & 2.5 Quad Cam Petrol engines in ROVER 825 LAND ROVER Freelander

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. 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). 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

AS4600 AS4614

IMPORTANT: Always refer to the vehicle manufacturers 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
timing belt and rear cam belts. 5
AS4600 Kit contents/spares
Item Part Number Description
Front Timing Belt 1 ASASAS4603

2.5 Engine

2.0 Engine Rear Camshaft Belts 6
4 ASAS4360T1 Rear Camshaft Belts 6 ASASASAS4609 - AS4600/84
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
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

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)

Rear Camshaft Belts

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)
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)
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
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. 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.

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
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). Crankshaft Position 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 Crankshaft Pulley Holding Tool - Associated Tool, not in kits
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. 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.
Then insert AS4604 Crankshaft Locking Pin through the hole located in the lower crankcase under L-H cylinders to lock the crankshaft.
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 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.

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).
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. 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.
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.

825 L-H Bank L-H Bank

825 - Place the sprockets as above illustration noting flanged edges and position/alignment of centre hubs

R-H Bank 825

R-H Bank 45/75/L-R Freelander 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 - Place sprockets as above illustration noting position of locating lugs and timing marks. Fit new belt around sprockets.

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. Slide the assembly over the Guide Pins. 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.

Setting Tool

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. 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.
More AST Timing Tools for Rover / Land Rover
Engine Setting/Locking Tool Kit Rover Twin Cam Petrol & L Series Diesels Diesel Engine Setting/Locking Tool Kit Rover /Land Rover 2.0d (BMW) Diesel Engine Setting/Locking Tool Kit Land Rover 2.5D/200/300Tdi Diesel Engine Setting/Locking Tool Kit Land Rover 2.5td (BMW) see AS4386 see AS4555 see AS3243 see AS4411