© Auto Service Tools Limited, 2002

AUTO SERVICE TOOLS

AST4388A

Diesel & Petrol EngineSetting/Locking Tool Kit

Applications:

CITROËN / PEUGEOT Diesel (TUD/XUD) and Petrol (TU/XU) engines in

CITROËN

AX BX ZXVisa Saxo XsaraXantia XM Synergie/EvasionBerlingo C15 Dispatch/JumpyRelay/Jumper

FIAT

Ulysse Scudo Ducato

FSO

Caro

LDV

200 Pilot

NISSAN

Micra

PEUGEOT

106 205 206305 306 307309 405 406 605 806 Partner Expert Boxer J5/Talbot Express

ROVERMetro 115 218/418

TATA

Loadbeta

1/7

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.

Additional AST Tools required- see Application ChartsAST4394 Sprocket Holding Tool

AST3398 Flywheel Holding

AST4358 Tools

AST4359 (Crank Pulley

AST4306 removal)

AST4377 Injection Pump Sprocket Remover

AST4373 ‘EPIC’ Injection Pump Timing Pin

Refer to the Application chart on the following page(s) for

specific model information

4388A

TUD/XUD Diesel engines and TU/XU Petrol engines

}

3381.indd 07/25/02, 9:43 AM1

© Auto Service Tools Limited, 2002

AUTO SERVICE TOOLS2/74388A

Kit contents/sparesAST4360C1 Injection Pump Locking Pin

AST4360C2 Injection Pump Locking Pin

AST4360C3 Balance Shaft Locking Pins (Pair)

AST4360C4 Injection Pump Locking Pin

AST4360C5 Camshaft Locking Pin

AST4360C6 Flywheel TDC Locking Pin

AST4360C8 Flywheel TDC Locking Pin

AST4360M8 Locking Bolts (3 off)

AST4360P1 Crank/Cam Locking Pin

AST4360P2 Camshaft Locking Pins (Pair)

AST4360P3 Camshaft Locking Pin

AST4360P4 Crank/Cam Locking Pin

AST4360P5 Camshaft Locking Pins (Pair)

AST4360P6 Crank/Cam Locking Pin

AST4360P7 Crankshaft Locking Pin

AST4360P8 Short Flywheel Locking Pin

Tensioner Adjustment ToolsAST4360T1 Retaining Pin (Roller)

AST4360T4 Tensioner Tool (Dynamic Roller)

AST4360T5 Retaining Pin

AST4362 Tensioner Adjuster

AST4363 Tensioner Adjuster

AST4388/84 Case + Insert

WARNING: Locking Pins must NOT be used to counter-hold the crank or camshaft for removing/releasing pulleys or sprockets. They are for retention of engine timing position only. Use appropriate Flywheel Holding Tool for crankshaft or AST4394 Holding Tool to counter-hold sprockets.

AST4394 Sprocket Holding Tool - Additional tool - not included in kit.

C1

C3

C4

C5

T4

P8

C6

M8

T1 P1

P2

P3

P4

P5

P6

P7

T5

C2

C8AST4362

AST4363

3381.indd 07/25/02, 9:43 AM2

Mod

els/

engi

nes

PS

A D

iese

l, inc.

dir

ect

inje

ctio

n e

ngin

es

AS

T4388A

Kit

Too

ls

Cam

shaf

t, In

ject

ion

Pum

p, B

alan

ce S

haft

,C

rank

/Fly

whe

el T

DC

Loc

kTe

nsio

ner

Adj

ustm

ent

AS

T A

ST

AS

T A

ST

C

1 C

2 C

3 C

4 C

5 C

6 C

8 M

8 P

4 P

8 T1

T4

43

62

4363

43

73

4394

Cit

roën

AX

1.4

D(-

94

), Z

X 1

.4D

TUD

3(K

9A)

engi

nes

AX

1.5

D(9

4-)

, S

axo

1.5

D,

ZX

1.5

DTU

D5(

VJY

/VJZ

) en

gine

s

Vis

a 1

7D

, B

X 1

.7D

/TD

/1.9

D(-

93

),ZX

1.8

D/1

.9D

(91

-)/1

.8TD

/1.9

TD

(92

-),

Xsa

ra 1

.9D

/TD

, X

anti

a 1

.9D

/TD

(93

-),

Syn

ergie

/Eva

sion

1.9

TD

, C

15

D 1

.8D

,B

erlingo

1.8

D/1

.9D

, D

ispatc

h/J

um

py

1.9

D/T

D,

Rel

ay/

Jum

per

1.9

D/T

DXU

D7(

A9A

)/XU

D7T

EXU

D9A

Y(D

JY)/

XUD

9A+

AU

(D9B

)XU

D9T

E+TF

Y(D

HX)

/XU

D9T

FL(D

8B)

XUD

9UTF

(D8C

)/XU

D9B

TF(D

HX)

eng

ines

(XU

D9B

TF h

as E

lect

roni

c C

ontr

olle

d Pu

mp)

Xanti

a 2

.1TD

(95

-),

XM

2.1

/TD

/XM

2.2

DS

yner

gie

/Eva

sion

2.1

TD

, D

ispatc

h/J

um

py

2.1

DT

XUD

11A

/XU

D11

ATE

/XU

D11

BTE

(P8A

/P8B

/P8C

/P9A

/PH

Z) e

ngin

es(X

UD

11B

TE h

as ‘E

PIC

’ Inj

. Pum

p-se

e A

ST4

373)

XM

2.5

TD

, R

elay/

Jum

per

2.5

D/T

D(9

4-)

,R

elay/

Jum

per

2.5

TD

i D

IREC

T I

NJE

CTIO

ND

KA

TE(T

HY)

/DJ5

(T9A

)/D

J5T(

T8A

-TH

Z)D

J5TE

D(T

HX)

eng

ines

Fia

tD

uca

to 1

.9D

/TD

/Uly

sse

1.9

TD

/2.1

TD

, S

cudo

1.9

D/T

DXU

D9T

F/D

8B/D

9B/D

HX/

DJY

eng

ine

FS

OC

aro

1.9

D(9

4-)

XUD

9 en

gine

LD

V200 1

.9D

, P

ilot

1.9

D(9

4-)

XUD

9A e

ngin

e

Nis

san

Mic

ra 1

.5D

VJZ

eng

ine

Tim

ing

Adj

.

●

●

●

●

● ●

●

●

●

●

XUD

●

●

11B

TE

(X

antia

)

●

DJ5

T

●

●

●

D

J5

● ●

TED

●

●

●

●

●

Spr

. H

old

●

●

●

XUD

7 (-

94)

XUD

9AU

(Rel

ay)

XUD

9TF

XUD

7(A

9A)

XUD

9A XUD

9TE

(Xsa

ra)

XUD

9BTF

AS

T4388A

Applica

tion

Chart

© A

uto

Serv

ice T

oo

ls L

imited

, 2002

AU

TO

SER

VIC

E T

OO

LS

Addit

ional A

ST T

ool re

quir

ed Pum

p S

proc

ket

Rem

oval

Flyw

heel

Hol

d (C

rank

Pul

ley

rem

oval

)

AS

T435

9

AS

T437

7

AS

T339

8

AS

T435

8

(XU

D9B

TF)

AS

T437

7

AS

T437

7

AS

T339

8A

ST4

377

AS

T339

8A

ST4

377

AS

T339

8A

ST4

377

AS

T435

9

AS

T339

8

AS

T435

8(X

UD

9BTF

Xant

ia/X

M)

Aux

.

Bel

t

Aux

.

Bel

t

●

● ●

●

●

3/7

4388

A

XUD

11B

TE

●

●

●

●

3381.indd 07/25/02, 9:43 AM3

Mod

els/

engi

nes

PS

A D

iese

l, in

cl. D

i. e

ngin

es (c

ontin

ued.

)

●

●

● ●

●

● ●

●

●

●

●

DJ5

T

●

●

●

D

J5

● ●

TED

●

●

●

●

●

●

●

●

Peu

geo

t1

06

1.4

D(-

94

)TU

D3(

K9A

) en

gine

s

10

6 1

.5D

(94

-)TU

D5(

VJY

/VJZ

) en

gine

s

205 1

.8D

/TD

/1.9

D, 305 1

.8D

/1.9

D(-

89),

306 1

.9D

/TD

(93-)

, 309 1

.8D

/TD

/1.9

D(-

93),

405 1

.8TD

/1.9

D/T

D(9

2-)

, 406 1

.9TD

,806 1

.9TD

, J5

/Talb

ot E

xpre

ss 1

.9D

(-94),

Part

ner

1.8

D/1

.9D

, Exp

ert

1.9

D/T

D,

Box

er 1

.9D

/TD

XUD

7(A

9A)/

XUD

7TE

XUD

9AY(

DJY

)/XU

D9A

+A

U(D

9B)

XUD

9TE+

TFY(

DH

X)/X

UD

9TFL

(D8B

)XU

D9U

TF(D

8C)/

XUD

9BTF

(DH

X) e

ngin

es(X

UD

9BTF

has

Ele

ctro

nic

Con

trol

led

Pum

p)

406 2

.1TD

(95-)

, 605 2

.1D

/TD

, 806 2

.1TD

XUD

11A

/XU

D11

ATE

/XU

D11

BTE

(P8A

/P8B

/P8C

/P9A

/PH

Z) e

ngin

es(X

UD

11B

TE h

as ‘E

PIC

’ Inj

. Pum

p-se

e A

ST4

373)

605 2

.5TD

, B

oxer

2.5

D/T

D(9

5-)

,B

oxer

2.5

TD

i D

IREC

T I

NJE

CTIO

ND

KA

TE(T

HY)

/DJ5

(T9A

)/D

J5T(

T8A

+TH

Y)

DJ5

TED

(TH

X) e

ngin

es

Rov

erM

etro

1.4

D(-

94

)TU

D3(

K9A

) en

gine

11

5D

(95

-)TU

D5(

VJY

) en

gine

218S

D/4

18D

Turb

oXU

D7T

E/XU

D9A

eng

ines

TATA

Loadbet

a 1

.9D

(94-)

XUD

9(48

3DL

43/4

4) e

ngin

e

●

●

●

●

AS

T438

8A

Applica

tion

Chart

© A

uto

Serv

ice T

oo

ls L

imited

, 2002

AU

TO

SER

VIC

E T

OO

LS

AS

T437

7

AS

T435

9

AS

T339

8A

ST4

377

AS

T339

8A

ST4

377

AS

T437

7

AS

T435

9

●

●

●

A

ST4

306

AS

T437

7

AS

T437

7

4/7

4388

A

●

●

●

●

XUD

●

11B

TE

●

●

●

●

AS

T4388A

Kit

Too

ls

Cam

shaf

t, In

ject

ion

Pum

p, B

alan

ce S

haft

,C

rank

/Fly

whe

el T

DC

Loc

kTe

nsio

ner

Adj

ustm

ent

AS

T A

ST

AS

T A

ST

C

1 C

2 C

3 C

4 C

5 C

6 C

8 M

8 P

4 P

8 T1

T4

43

62

4363

43

73

4394

Tim

ing

Adj

.S

pr.

Hol

d

Addit

ional A

ST T

ool re

quir

ed Pum

p S

proc

ket

Rem

oval

Flyw

heel

Hol

d (C

rank

Pul

ley

rem

oval

)

3381.indd 07/25/02, 9:43 AM4

Mod

els/

engi

nes

PS

A P

etro

l, incl

udin

g t

win

cam

engin

es

AS

T4388A

Kit

Too

ls

Twin

Cam

shaf

t,C

rank

/Fly

whe

el T

DC

Loc

kTe

nsio

ner

Spr

. Hol

d

A

ST

AS

T

P1

P2

P3

P4

P5

P6

P7

P8

T5

4363

43

94

Cit

roën

AX

1.0

/1.1

/1.4

, A

X G

Ti, S

axo

1.0

/1.1

/1.4

/1.6

, C

15 1

.0/1

.1/1

.4, B

X 1

.1/.

14(-

93),

ZX

1.1

/1.4

/1.6

, B

erlingo

1.1

/1.4

, X

sara

1.4

/1.6

TU9-

1.0

/ TU

1-1.

1 /

TU3-

1.4

/ TU

5JP-

1.6

(CD

Y/C

DZ/

HD

Y/H

DZ/

KD

X/K

DY/

KFW

/KFX

/KFZ

/NFZ

) en

gine

s

Saxo

1.6

16v,

Xsa

ra 1

.6 1

6v.

TU5J

4/L3

(NFX

/NFU

) TW

IN C

AM

eng

ines

Vis

a 1

.6 G

Ti, Z

X 1

.6/1

.9, B

X 1

.6/1

.9XU

5(B

1E/B

6D)

/ XU

9(D

6A/D

6B)

engi

nes

(WIT

H S

LID

ING

TEN

SIO

NER

-92

)

ZX

1.6

/1.8

/1.9

/2.0

, X

sara

1.8

, B

X 1

.6/1

.9(9

2-)

,Xanti

a 1

.6/1

.8/2

.0, X

M 2

.0/T

urb

o,S

yner

gie

2.0

/Turb

o, B

erlingo

1.8

, R

elay/

Jum

per

2.0

XU5(

BD

Y/B

DZ/

BFZ

) /

XU7(

L6A

/LFX

/LFZ

) /

XU9(

D6A

/D6B

/D6D

/DD

Z/D

KZ/

DFZ

)XU

10J2

(RFU

/RG

X/R

GY/

RFZ

/RFX

/RFW

/RD

Z) e

ngin

es (

WIT

H E

CC

ENTR

IC T

ENS

ION

ER)

Xsa

ra 1

.8 1

6v,

Xanti

a 1

.8 1

6v,

ZX

1.8

16v.

XU7J

P4(

LFY)

TW

IN C

AM

eng

ines

BX

GTi 16v(

-92),

ZX

2.0

16v,

Xsa

ra 2

.0 1

6v.

, X

anti

a 2

.0 1

6v,

XM

2.0

16v

XU9J

4(D

6C)

/ XU

10J4

(RFY

/RFV

/R6E

/RFS

) TW

IN C

AM

eng

ines

Fia

tU

lyss

e 1.8

/2.0

/Turb

o, D

uca

to 2

.0LF

W/R

FU/R

GX/

RFW

eng

ines

Peu

geo

t106 1

.0/1

.1/1

.4/1

.6, 205 1

.0/1

.1/1

.4, 206 1

.1/1

.4/1

.6 (

98-)

306 1

.1/1

.4/1

.6, 307 1

.4,

309 1

.1/1

.4(-

93)

Part

ner

1.1

/1.4

, 405 1

.4(-

94)

TU9-

1.0

/ TU

1-1.

1 /

TU3-

1.4

/ TU

5JP-

1.6

(CD

Y/C

DZ/

HD

Y/H

DZ/

KD

X/K

DY/

KFW

/KFX

/KFZ

/NFZ

) en

gine

s

106 1

.6 1

6v(

96-)

, 206 1

.6 1

6v.

, 307 1

.6 1

6v.

TU5J

4/L3

(NFX

/NFU

) TW

IN C

AM

eng

ines

205 1

.6/1

.9, 305 1

.6/1

.9, 309 1

.6/1

.9, 405 1

.6/1

.9XU

5(B

1E/B

6D)

/ XU

9(D

6A/D

6B)

engi

nes

(WIT

H S

LID

ING

TEN

SIO

NER

-92)

205 1

.6/1

.9(9

2-)

, 306 1

.8/2

.0, 309 1

.6/1

.9(9

2-)

, 405 1

.6/1

.8/1

.9/2

.0(9

2-)

,406 1

.6/1

.8/2

.0, 605 2

.0, 806 1

.8/2

.0/T

urb

o, B

oxer

2.0

, P

art

ner

1.8

XU5(

BD

Y/B

DZ/

BFZ

) /

XU7(

L6A

/LFX

/LFZ

) /

XU9(

D6A

/D6B

/D6D

/DD

Z/D

KZ/

DFZ

)XU

10J2

(RFU

/RG

X/R

GY/

RFZ

/RFX

/RFW

/RD

Z) e

ngin

es (

WIT

H E

CC

ENTR

IC T

ENS

ION

ER)

306 1

.8 1

6v,

406 1

.8 1

6v

XU7J

P4(

LFY)

TW

IN C

AM

eng

ines

306 2

.0 1

6v, 3

09 G

Ti 1

6v(-

94),

405

Mi 1

6(-9

4), 4

05 2

.0 1

6v, 4

06 2

.0 1

6v, 6

05 2

.0 1

6v, 8

06 2

.0 1

6v.

XU9J

4(D

6C)

/ XU

10J4

(RFY

/RFV

/R6E

/RFS

) TW

IN C

AM

eng

ines

●

●

●

●

●

●

●

●

●

●

●

● ●

Earl

y ●

XU7/

9

(-

93)

● ●

R

FY/

●

R

FV/

D6C

R6E

/RFS

●

●

●

●

● ●

●

●

●

●

● ●

Earl

y

●

XU

7/9

(-

93)

● ●

RFY

/RFT

/

RFV

/

D6C

●

R

6E/R

FS

AS

T4388A

Applica

tion

Chart

Add

itio

nal A

ST

Tool

req

uire

d

Flyw

heel

Hol

d (C

rank

Pul

ley

rem

oval

)

© A

uto

Serv

ice T

oo

ls L

imited

, 2002

AU

TO

SER

VIC

E T

OO

LS

AS

T339

8

AS

T435

8 (X

U7)

AS

T339

8A

ST4

358

(Xsa

ra)

AS

T339

8 (D

6C/R

FY)

AS

T435

8 (R

FS)

AS

T339

8

AS

T339

8

AS

T339

8

AS

T435

8 (X

U7)

AS

T435

8

AS

T339

8 (D

6C/R

FY)

AS

T435

8 (R

FV/R

FS)

exce

pt

206

●

●

(99-

)

5/7

4388

A

3381.indd 07/25/02, 9:43 AM5

© Auto Service Tools Limited, 2002

AUTO SERVICE TOOLS

The huge range of PSA TU/XU petrol and TUD/XUD diesel engines

require a comprehensive selection of setting/locking pins and

tensioner tools for timing belt replacement/renewal and AST4388A

provides these tools in one kit.

Both petrol and diesel applications are covered including the 1.6, 1.8

and 2.0 twin cam engines and direct injection engines.

In addition to the essential ‘difficult access’ flywheel pins, specific

dimentional pairs and single application pins are included, as well as

a range of tensioner locking and adjusting tools.

AST4360C6, AST4360C8, AST4360P8Flywheel TDC Locking Pins(‘Difficult Access’ Pins)

This series of 3 ‘shaped’ locking pins are designed to provide access

to the flywheel datum hole enabling the engine to be locked at TDC.

Often, access to the datum hole is restricted by a component ie.

starter motor etc. and therefore the specific pin shapes are essential

to overcome difficult access.

For XUD7, XUD9AU/9TF, XUD11, DJ/DK Use AST4360C6

For XUD7, 9A, 9TE, 9BTF, 11BTE Use AST4360C8

For TUD3/5 diesel and

TU1/3/5/9 petrol Use AST4360P8

NOTE: Engine types are fitted over a number of models. For engine

references to vehicle model - refer to Application Charts.

AST4360C1, AST4360C2, AST4360C3, AST4360C4, AST4360C5, AST4360M8AST4360P1, AST4360P3, AST4360P4, AST4360P6, AST4360P7Locking Pins - Camshaft, Injection Pump,Crankshaft, Balance Shafts

IMPORTANT: Locking Pins must NOT be used to hold the

crankshaft whist releasing or tightening the pulley bolt. Locking Pins

are for retention of timing position only.

Use appropriate Flywheel Holding tool - see “Additional AST Tools

required” and Application Charts.

Citroen/Peugeot engines have access holes through pulleys/sprockets

and fixed datum holes on the engine to allow the camshaft, injection

pump and crank to be ‘locked’ in their timed positions by use of

correctly sized locking pins - refer to Application Charts.

IMPORTANT: To ensure accuracy of the timing position and

access to the datum hole, it is essential to use the correct pins to

suit each application.

Tensioner Adjustment Tools

AST4360T1, AST4360T4 and AST4360T5 Retaining ToolsAST4362 and AST4363 Tensioner Adjusters

AST4360T1 Retaining Pin is required when removing/replacing the

timing belt on the DJ5TED Di engines.

It is necessary to compress the automatic roller tensioner and lock it

using AST4360T1 Retaining Pin.

AST4360T4 Tensioner Tool (Dynamic Roller) is essential for use

on the Auxiliary Belt tensioner, when air conditioning/power steering

is installed.

AST4360T5 Retaining Pin is used on later XU7JP4 (LFY) 1.8 16v.

engines to retain dynamic tensioner.

6/74388A

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© Auto Service Tools Limited, 2002

AUTO SERVICE TOOLS 7/74388A

Tensioner Adjustment Tools - continued

AST4362 and AST4363 are specialised wrenches for adjusting the

timing belt tensioners.

AST4362 provides access onto the square drive on belt tensioners on

XUD11/DK/DJ engines.

AST4363 carries out the similar function on TUD3, TUD5 diesels and

TU1/2/3/9 and TU5J4 petrol engines.

On early TU1/2/3/9 engines (-94), AST4363 can also be used with an

appropriate weight to establish timing belt tension.

For DJ5TED direct Inj. engine Use AST4360T1

For XUD9/XUD11 engines

(Aux. Belt Dyn. Roller) Use AST4360T4

For XUD11/DK/DJ engines Use AST4362

For TUD3/5 diesel and

TU1/2/3/9 & TU5J4 petrol Use AST4363

For XU7JP4 (LFY) petrol Use AST4360T5

AST4360P2, AST4360P3, AST4360P4 and AST4360P5 Locking Pins

There are a number of Citroën/Peugeot 16v twin cam engines and

these use locking pins to retain the engine timing position during

belt renewal. These pins enter through access holes in each of the

camshaft sprockets into fixed datum holes behind.

NOTE: Later engine cam sprockets have slotted bolt holes to allow

movement as part of assembly/tensioning procedure.

For XU9J4(D6C)/ XU10J4(RFY) 2.0 16v Use AST4360P2(Pair) +

AST4360P4 for Crank

For TU5J4/LE 1.6 16v Use AST4360P3 + P4 +

AST4360P8 for Flywheel

For XU7JP4(LFY) / XU10J4 (RFV/R6E/RFS) 1.8/2.0 16v Use AST4360P5 (Pair) +

AST4360P4 for Crank

Additional AST Tools required - not included in AST4388A Kit - see Application Charts for models/application details

Twin Cam Engine Timing Tools

AST4394 Sprocket Holding Tool

Citroën/Peugeot - Flywheel Holding Tools (Crank Pulley removal)

AST4377 Injection Pump Remover

AST4373 ‘EPIC’ Injection Pump Timing Pin

AST3398 AST4358 AST4359

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