VS5035 Applications - CCW

VS5035 Applications - CCW
Instructions for:
DIESEL ENGINE SETTING/LOCKING KIT VOLKSWAGEN 2.5TDi - PUMP DüSE GEAR DRIVE
MODEL No:
VS5035
Thank you for purchasing a Sealey product. Manufactured to a high standard this product will, if used according to these instructions and properly
maintained, give you years of trouble free performance.
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS AND CAUTIONS.
USE THE PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE DAMAGE
AND/OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.
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SAFETY INSTRUCTIONS
WARNING! Ensure Health and Safety, local authority and general workshop practice regulations are adhered to when using tools.
DO NOT use tools if damaged.
Maintain tools in good and clean condition for best and safest performance.
Ensure that a vehicle which has been jacked up is
adequately supported with axle stands.
Wear approved eye protection. A full range of personal safety equipment is available from your Sealey dealer.
Wear suitable clothing to avoid snagging. DO NOT wear
jewellery and tie back long hair.
DO NOT attempt to start engine or move vehicle whilst in gear with locking devices fitted.
Always display warning notification on steering wheel when locking engine components.
Account for all tools, locking bolts, pins and parts being used and do not leave them in or near the engine.
WARNING! Incorrect or out of phase camshaft timing can result in contact between valve head and piston crown causing damage to the engine.
IMPORTANT: These instructions are provided as a guide only. Always refer to the vehicle manufacturer’s service instructions, or a proprietary manual, to establish the current procedure and data.
Applications:
VW GROUP 2.5 TDi Pump Düse Diesel engine (GEAR) in:
VOLKSWAGEN:
Transporter
Touareg
Multivan
03-08
03-08
04-08
AXD, AXE, BAC, BLJ, BLK, BNZ, BPC, BPD and
BPE engines.
2.contents & applications
Suitable for timing gear drive engines where the camshaft,
crankshaft and auxiliary shafts are all linked by a series of
inter-meshed cogs.
Kit contents
Item
Part Number Description
1
2
3
4
5
6
-
VS5031
Crankshaft TDC Position Tool
VS5032Crankshaft Locking Tool
VS5033Camshaft Locking Tool
VS5034Camshaft Gear Clamp
VS5036
Eccentric Pin Holding Tool
VS5037Camshaft Gear Adjuster
VS5035-84Case + Insert
Original Language Version
VS5035
Issue No: 1 - 08/07/10
3.instructions
Introduced in 2003, the 2,5L TDi Pump Düse engines utilise
a helical-toothed spur gear set that drives the camshaft and
all engine auxiliaries from the crankshaft. The engine fan is
electrically driven.
NOTE: The tools in this timing kit are used in a specific
sequence, and it will save time and make selection of the
correct tools easier if the operator reads and becomes familiar
with the timing procedure beforehand.
3.1. Checking the Valve Timing.
IMPORTANT: To check the valve timing, the crankshaft is
positioned at TDC at cylinder number 1.
fig.2
3.1.2. VS5032 Crankshaft Locking Tool.
VS5032 Locks the crankshaft in position with number 1 cylinder at TDC.
Fit VS5032 Crankshaft Locking Tool onto the crankshaft, at the same time engaging the clamp pin through the engine mounting in the cylinder block using the stepped pin (fig.2).
NOTE: When the engine is removed from the vehicle, or the engine mounting is removed, the alternative straight pin is positioned directly into the cylinder block.
fig.1
3.1.1. VS5031 Crankshaft TDC Position Tool.
VS5031 is used to rotate the crankshaft to the timed position.
Position VS5031 Crankshaft TDC Position Tool onto the crankshaft (fig.1); turn the crankshaft in the direction of engine rotation aligning the marks on VS5031 and the sealing flange.
NOTE: The Crankshaft Locking Tool locates onto the crankshaft in only one position.
The crankshaft is now timed in the correct position with number 1 cylinder at TDC.
fig.3
Remove VS5031 Position Tool
3.1.3. Attach the Crankshaft Locking Tool onto the crankshaft with the screw provided (fig.3).
NOTE: The Crankshaft Locking Tool fits in only one position on the crankshaft. If it is not possible to fit the Locking Tool, re-fit VS5031 and turn the crankshaft one revolution, in the direction of engine rotation, until the marks on VS5031 and the sealing flange align again.
Original Language Version
VS5035
Issue No: 1 - 08/07/10
fig.6
3.2.2. Position the crankshaft at TDC for cylinder number 1.
fig.4
3.1.4. VS5033 Camshaft Locking Tool.
VS5032 is used to accurately align a datum slot, located in the end of the camshaft with a datum hole in the cylinder head, to hold the camshaft at the TDC position.
Fit the VS5033 Camshaft Locking Tool in position (fig.4).
Position VS5031 Crankshaft TDC Position Tool onto the crankshaft (fig.6); turn the crankshaft in the direction of engine rotation aligning the marks on VS5031 and the sealing flange.
NOTE: The Crankshaft Locking Tool fits in only one position on the crankshaft.
The crankshaft is now timed in the correct position with number 1 cylinder at TDC.
fig.7
fig.5
3.2.3. VS5034 Camshaft Gear Clamp
3.1.5.Check the position of the camshaft gear.
The timing is correct when the marking arrow on the sender wheel is aligned with the upper edge of the cylinder head sealing surface as in fig.5.
If the marking arrow does not align, adjustment of the valve timing will be necessary.
3.2.
Adjusting the Valve Timing.
When adjusting the valve timing, removing and installing the cylinder head, removing and installing the camshafts, it is necessary to remove the camshaft drive gear
3.2.1.Removing camshaft drive gear
It will be necessary to remove the acoustic cover, cylinder head cover and the tandem pump.
VS5034 Camshaft Gear Clamp is used to support the
camshaft gear to allow the camshaft gear fixing bolt to be removed.
3.2.4.Remove the outer bearing cap and position VS5034 Camshaft Gear Clamp onto the camshaft gear and tighten the four bolts to 40 Nm (fig.7).
3.2.5. Loosen the fixing bolt of the camshaft gear and remove with the tandem pump shaft.
3.2.6.Release the four bolts securing the Camshaft Gear Clamp and remove VS5034.
3.2.7.Remove the camshaft gear from the camshaft.
3.2.8.Unbolt the sealing cover from the eccentric pin, removing the securing bolt and pulling the eccentric pin out.
Original Language Version
VS5035
Issue No: 1 - 08/07/10
3.2.9.Remove the camshaft drive gear.
IMPORTANT: Care must be taken when removing the camshaft drive gear and the compensating link.
3.3. Installing Camshaft Drive Gear.
fig.9
3.3.3.Fit VS5032 Crankshaft Locking Tool onto the crankshaft at the same time engaging the clamp pin through the engine mounting on the cylinder block using the stepped pin (fig.2).
fig.8
3.3.1.
Position VS5031 Crankshaft TDC Position Tool onto the crankshaft (fig.8); turn the crankshaft in the direction of engine rotation aligning the marks on VS5031 and the sealing flange.
NOTE: The Crankshaft Locking Tool fits in only one
position on the crankshaft.
NOTE: When the engine is removed from the vehicle, or the engine mounting is removed, the alternative straight pin is positioned directly into the cylinder block.
3.3.4. Attach the Crankshaft Locking Tool onto the crankshaft with the screw provided.
NOTE: The Crankshaft Locking Tool fits in only one position on the crankshaft. If it is not possible to fit the Locking Tool, re-fit VS5031 and turn the crankshaft one revolution, in the direction of engine rotation, until the marks on VS5031 and the sealing flange align again.
The crankshaft is now timed in the correct position with number 1 cylinder at TDC.
3.3.2.Remove VS5031 Position Tool.
fig.10
3.3.5. Fit VS5033 Camshaft Locking Tool in position (fig.10).
Original Language Version
VS5035
Issue No: 1 - 08/07/10
fig.11
3.3.6. Install the camshaft drive gear (fig11.1) onto the guide sleeve (fig.11.2) ensuring all surfaces of the guide sleeve are oiled.
fig.13
3.3.7. Install the disc (fig.11.3) engaging the lugs in the grooves of the guide sleeve (fig.11.2).
3.3.8. Install the drive gear (fig.11.1) with disc (fig.11.3) and the guide sleeve (fig.11.2) on the compensating link plate
(fig.11.4).
3.3.9. Guide the link plate (fig.13.4) and the camshaft drive gear (fig.13.1) into the gear cavity from above.
Refit the outer bearing cap and tighten hand tight.
2
5
6
4
fig.12
WARNING: The marks on the guide sleeve (fig.12.2) and the link plate (fig.12.4) must align.
fig.14
3.3.10. VS5036 Eccentric Pin Holding Tool
Install the eccentric pin (fig.14.5), oiling all surfaces, ensuring that the marking on the eccentric pin (fig.14.5) is vertical and uppermost; with the marking on the link plate
(fig.14.1) aligning with the sealing surface of the cylinder head.
Original Language Version
VS5035
Issue No: 1 - 08/07/10
fig.17
3.3.16. Position the camshaft gear wheel onto the camshaft ensuring that the marking arrow on the sender wheel aligns with the upper edge of the cylinder head sealing surface
(fig.17).
fig.15
fig.15
3.3.11. VS5036 is used to turn and hold the eccentric pin in the installed position whilst securing with a new bolt (fig.15).
3.3.17.Using a new bolt secure the camshaft gear wheel and the tandem pump shaft, tighten bolt finger tight. At this point the camshaft gear wheel can still turn.
NOTE: Lubricate the gear wheel teeth with engine oil prior to installation.
fig.16
3.3.12. Install a new securing bolt (fig.12.6) for the eccentric pin (fig.12.5) and tighten by hand, then unscrew back approximately one thread pitch.
fig.18
3.3.13. Position VS5036 Eccentric Pin Holding Tool with a torque wrench into the holes of the eccentric, turning the eccentric pin carefully anti-clockwise and tighten to 50Ncm
3.3.18. VS5037 Camshaft Gear Adjuster.
3.3.14. Whilst holding the eccentric pin in this position, tighten new securing bolt to 20Nm +90°. Remove the outer bearing cap.
3.3.15. Install the outer bearing cap using sealant and tighten with new bolts to 8Nm + 90°.
VS5037 is used to eliminate play in the gear train before tightening the camshaft gear securing bolt.
Position VS5037 Camshaft Gear Adjuster onto the camshaft gear and tighten the three bolts to 70Nm to clamp the adjuster onto the camshaft gear (fig.18).
Original Language Version
VS5035
Issue No: 1 - 08/07/10
fig.19
3.3.19.Using a suitable torque wrench in the square drive of the Camshaft Gear Adjuster, exert a force of 80 Nm in the opposite direction of engine rotation to remove play from the gear train (fig.19).
Whilst maintaining this force, tighten the camshaft gear securing bolt to 50 Nm.
NOTE: Tightening this camshaft gear securing bolt will require the assistance of a second mechanic.
3.3.20.Remove the Camshaft Gear Adjuster.
fig.21
3.3.24.Using VS5031 Crankshaft TDC Positioning Tool (fig.21), rotate the engine in direction of engine rotation twice until the crankshaft is set again to TDC No.1 cylinder.
3.3.25.Refit VS5032 Crankshaft Locking Tool and VS5033
Camshaft Locking Tool to check the timing position as described in Checking valve timing.
3.3.26.Remove all tools.
fig.20
3.3.21.Position VS5034 Camshaft Gear Clamp onto the camshaft gear and tighten the four bolts to 40Nm.
NOTE: Ensure that the clamp plate fits fully onto the surface of the cylinder head with no gap (fig.20).
3.3.22.Tighten camshaft gear securing bolt to 150 Nm + 90°
Remove all tools.
3.3.23.Install the tandem pump, cylinder head cover and acoustic cover.
NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.
IMPORTANT: No liability is accepted for incorrect use of this equipment.
WARRANTY: Guarantee is 12 months from purchase date, proof of which will be required for any claim.
INFORMATION: For a copy of our latest catalogue and promotions call us on 01284 757525 and leave your full name and address, including postcode.
Sole UK Distributor, Sealey Group,
Kempson Way, Suffolk Business Park,
Bury St. Edmunds, Suffolk
IP32 7AR
01284 757500
01284 703534
Original Language Version
Web
email
www.sealey.co.uk
[email protected]
VS5035
Issue No: 1 - 08/07/10
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