NEO TOOLS 11-303 Timing Tool Kit Instruction Manual

1. Introduction

The NEO TOOLS 11-303 Timing Tool Kit is a specialized set of tools designed for the precise adjustment and locking of engine timing components on various Audi and Volkswagen (VAG) diesel engines. This kit is essential for tasks such as timing belt or chain replacement, cylinder head work, or any repair requiring the engine's timing to be accurately set and maintained.

Proper use of these tools ensures correct engine timing, which is critical for engine performance, fuel efficiency, and preventing internal engine damage. Always consult the vehicle manufacturer's specific repair manual for detailed procedures and torque specifications.

2. Safety Information

Working with automotive engines and specialized tools requires adherence to strict safety protocols. Failure to follow these guidelines can result in serious injury or damage to the vehicle.

• Always wear appropriate personal protective equipment (PPE), including safety glasses, gloves, and sturdy footwear.
• Ensure the vehicle is securely supported on jack stands or a lift before working underneath it. Never rely solely on a jack.
• Disconnect the vehicle's battery before performing any work on electrical components or when there is a risk of accidental engine cranking.
• Ensure the engine is cool before beginning work to avoid burns.
• Keep the work area clean, well-lit, and free of obstructions.
• Do not use damaged or modified tools.
• Always refer to the vehicle manufacturer's service manual for specific procedures, torque values, and safety warnings related to your vehicle model.
• If you are unsure about any procedure, seek assistance from a qualified automotive technician.

3. Package Contents

The NEO TOOLS 11-303 kit includes 10 specialized tools for engine timing. The primary components are designed to lock the crankshaft, camshafts, and high-pressure fuel pump in their correct timing positions.

Figure 3.1: Overview of the NEO TOOLS 11-303 Timing Tool Kit components.

This image displays all the individual tools included in the NEO TOOLS 11-303 kit, laid out for clear identification. It shows various pins, locking tools, and turning tools.

• Crankshaft Locking Pin (OEM 3242): Used to lock the crankshaft at Top Dead Center (TDC).
• High-Pressure Pump Locking Pin (OEM 3359): Secures the high-pressure fuel pump sprocket.
• Crankshaft Turning Tool (OEM T40049): Facilitates manual rotation of the crankshaft for timing adjustments.
• Crankshaft Pulley Holding Tool (OEM T40058): Prevents the crankshaft pulley from rotating during tightening or loosening of the central bolt.
• Camshaft Locking Pins (OEM T40060, T40061): Used to lock the camshafts in their timed position.
• Tensioner Pin (OEM T40062): Used to lock the timing belt/chain tensioner.
• Additional specialized pins and adapters for various engine configurations.

Figure 3.2: The NEO TOOLS 11-303 kit neatly organized within its durable storage case.

This image shows the complete tool kit securely housed in its custom-molded plastic case, demonstrating the organized storage for each component.

4. Compatibility

This timing tool kit is compatible with a wide range of Audi and Volkswagen vehicles equipped with specific diesel engines. Always verify the engine code of your vehicle against the list below and consult your vehicle's service manual for precise application details.

Compatible Engine Codes:

• 2.7TDI V6: BBP, BSG, CAMA, CAMB, CANA, CANC, CAND, CGKA, CGKB
• 3.0TDI V6: ASB, BKN, BKS, BMK, BMZ, BNG, BUG, BUN, CAPA, CARA, CARB, CASA, CASB, CASC, CATA, CCMA, CCWA, CCWB, CDYA, CDYB, CDYC, CEXA
• 4.0TDI V8: ASE

Example Compatible Vehicles:

• Audi:
  • A4 B7 Avant (8ED) (2004-2008) - various 1.9 TDI, 2.0 TDI, 2.5 TDI, 2.7 TDI, 3.0 TDI quattro, 3.0, 3.2 FSI quattro, S4 quattro, RS4 quattro engines
  • A4 B7 Saloon (8EC)
  • Q7 (4LB) (2006-2015) - 3.0 TDI, 4.2 TDI, 6.0 TDI engines
• Volkswagen:
  • Touareg II (7P5, 7P6) (2010-2018) - 3.0 TDI, 4.2 TDI engines
  • Phaeton (3D1, 3D2, 3D3, 3D4, 3D6, 3D7, 3D8, 3D9) (2002-2016) - 3.0 TDI, 4.2 V8, 5.0 V10 TDI engines

Figure 4.1: Detailed compatibility chart with engine codes and vehicle models.

This diagram provides a visual representation of the compatible Audi and Volkswagen models, along with a comprehensive list of engine codes that this timing tool kit supports.

5. Setup and Preparation

Before using the NEO TOOLS 11-303 kit, ensure proper preparation of the vehicle and work environment.

1. Vehicle Positioning: Park the vehicle on a level, stable surface. Engage the parking brake and block the wheels.
2. Access: Depending on the vehicle and engine, you may need to remove various components (e.g., engine covers, accessory belts, cooling fan, engine mounts) to gain access to the timing components.
3. Engine at TDC: Rotate the engine manually in the normal direction of rotation until the crankshaft is at Top Dead Center (TDC) for cylinder 1, or as specified by the vehicle's service manual for timing procedures. This is typically indicated by alignment marks on the crankshaft pulley and engine block, or by the crankshaft locking pin engaging its bore.
4. Consult Service Manual: Always refer to the specific vehicle manufacturer's service manual for the exact procedure to set the engine to its timing position and for the location of all locking points.

6. Operating Instructions

The following steps outline the general application of the timing tools. These are general guidelines; always follow your vehicle's specific repair manual for detailed, step-by-step instructions.

1. Locking the Crankshaft:

   Once the engine is at the correct timing position (often TDC for cylinder 1), insert the Crankshaft Locking Pin (OEM 3242) into its designated bore on the engine block and crankshaft. This prevents the crankshaft from rotating.

   

   Figure 6.1: Close-up of the Crankshaft Locking Pin (OEM 3242).

   This image provides a detailed view of the crankshaft locking pin, showing its design for precise fitment into the engine block and crankshaft.

2. Locking the Camshafts:

   Insert the Camshaft Locking Pins (OEM T40060, T40061) into the camshaft sprockets or camshafts themselves, as per the vehicle's manual. These pins ensure the camshafts are held in their correct timing position relative to the crankshaft.

   

   Figure 6.2: Close-up of a Camshaft Locking Tool.

   This image highlights one of the camshaft locking tools, demonstrating its specific shape designed to engage with the camshaft or sprocket.

3. Locking the High-Pressure Pump:

   If applicable to your engine, use the High-Pressure Pump Locking Pin (OEM 3359) to secure the high-pressure fuel pump sprocket in its timed position.
4. Using the Crankshaft Turning Tool:

   The Crankshaft Turning Tool (OEM T40049) can be used to carefully rotate the crankshaft to align timing marks or to bring the engine to the correct position for locking.

   

   Figure 6.3: Close-up of the Crankshaft Turning Tool (OEM T40049).

   This image shows the crankshaft turning tool, which is used to precisely rotate the engine's crankshaft during timing procedures.
5. Using the Crankshaft Pulley Holding Tool:

   The Crankshaft Pulley Holding Tool (OEM T40058) is used to counter-hold the crankshaft pulley when loosening or tightening the central crankshaft bolt, preventing engine rotation.

6. Timing Belt/Chain Replacement:

   With all components locked, you can proceed with the removal and installation of the timing belt or chain, tensioners, and idlers as per the vehicle's service manual. Use the Tensioner Pin (OEM T40062) to lock the tensioner if required.

7. Reassembly and Verification:

   After installing new timing components, remove all locking tools. Manually rotate the engine through at least two full revolutions (as specified by the manual) to ensure all timing marks align correctly and there is no interference. Re-check timing if necessary before reassembling the engine.

7. Maintenance and Storage

Proper maintenance and storage will extend the life of your NEO TOOLS 11-303 kit.

• Cleaning: After each use, wipe down all tools with a clean cloth to remove oil, grease, and dirt. A mild degreaser can be used if necessary.
• Lubrication: Apply a light coat of rust-preventative oil to any bare metal surfaces, especially on pins and threaded parts, before storage.
• Storage: Store the tools in their original durable plastic case in a dry, cool place, away from direct sunlight and corrosive chemicals. Ensure each tool is placed in its designated slot to prevent damage and loss.
• Inspection: Periodically inspect tools for any signs of wear, damage, or corrosion. Do not use damaged tools.

8. Troubleshooting

While this kit is designed for precision, issues can arise. Here are some common troubleshooting tips:

• Tool Does Not Fit:
  • Double-check the engine code and vehicle compatibility.
  • Ensure the engine is precisely at the correct timing position (e.g., TDC for cylinder 1). Slight misalignment will prevent tools from seating correctly.
  • Verify you are using the correct tool for the specific locking point.
• Engine Does Not Start After Timing Work:
  • Immediately stop attempting to start the engine.
  • Re-verify all timing marks and tool placements. It is highly likely the timing is off.
  • Consult the vehicle's service manual for diagnostic procedures. Incorrect timing can cause severe engine damage.
• Tools Seem Loose:
  • Ensure the tools are fully seated and engaged. Some tools may have a slight amount of play, but should not be excessively loose.
  • Verify the engine is in the exact position required for the tools to lock it securely.

For complex issues or if you are unsure, it is always recommended to consult a professional automotive technician.

9. Specifications

10. Warranty and Support

For information regarding product warranty, returns, or technical support, please refer to the official NEO TOOLS website or contact the retailer from whom the product was purchased. Keep your proof of purchase for warranty claims.

NEO TOOLS Official Website: neo-tools.com