Sealey Diesel Engine Setting/Locking Tool Kit User Manual

VS1011
DIESEL ENGINE SETTING/LOCKING TOOL KIT FOR FORD, MAZDA,
AUDI, SEAT, VOLKSWAGEN & VOLVO.
STANDARD PARTS
1
2
3
4
5
6
7
8
-
VS101/1
VS101/2
VS101/3
VS101/4
VS101/5
VS101/6
VS101/7
VS115/01
VS1011/84
CAM SETTING PLATE
CRANKSHAFT TDC LOCATION PIN
6.0 LOCKING PINS (2)
9.5 LOCKING PIN
15.4 LOCKING PIN
8.25 LOCKING PIN
12.7 LOCKING PIN
CAM SETTING PLATE
CASE + INSERT
INTRODUCTION
1.
APPLICATION & ASSOCIATED TOOLS
APPLICATION:
VS1011 kit is designed to lock the crankshaft, camshaft and injection pump at
their datum positions on a wide range of Ford, Mazda, VW, Audi, Seat, and Volvo
diesel engines.
FORD, MAZDA, VW, AUDI, SEAT, VOLVO (See charts below)
ASSOCIATED TOOLS
Bosch Rotary Diesel Injection Pump Timing Tool - M8/M12 Service Ports . . . . . . . . . . . . . . . . .VS107 & VS108
Bosch Rotary Diesel Injection Pump Timing Tool - M10 Service Ports . . . . . . . . . . . . . . . . . . . .VS1070
CAV/Rotodiesel Injection Pump Timing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VS110
APPLICATION CHART
FORD
Fiesta 1.6D, Escort 1.6D, Orion 1.6D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VS101/1 + VS101/2
Fiesta 1.8D, Mondeo 1.8TD, Escort 1.8D/TD, (-96), Sierra 1.8TD, P100 1.8TD . . . . . . . . . . . . .VS101/2 + VS101/3 + VS101/4
Note: CAV inj. Pump - 6.0 Pin/Bosch inj. Pump - 9.5 Pin
Fiesta 1.8D, Escort 1.8D/TD, Mondeo 1.8 TD (96-) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VS115/01 + VS101/2
Galaxy 1.9TD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VS101/1 + VS101/5
Transit 2.4D (-86) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VS101/6
Transit 2.5 DI/Turbo (84-)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VS101/3 + VS101/6 + VS101/7 + VS101/4
Note: CAV inj. Pump - 6.0 Pin/Bosch inj. Pump - 9.5 Pin
AUDI
A4 1.9TDi, 80 1.9D/Turbo D, 80 1.9TDi, 100 5D, 100D/CD, 100D Turbo . . . . . . . . . . . . . . . . . .VS101/1 + VS101/5
100 2.5TD/TDi, A6 2.5 TDi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VS101/1
MAZDA
121 1.8D (95-) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VS101/2 + VS101/3 + VS101/4
SEAT
Terra 1.3D/1.4D, Ibiza 1.9D/Turbo
Cordoba 1.9D/Turbo, Toledo 1.9D/TD, Alambra 1.9TDi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VS101/1 + VS101/5
VOLKSWAGEN
Polo 1.3D/1.4D/1.9SDi (AGD), Polo Classic 1.7 SDi/1.9SDi (AEY)
Golf/Jetta/Caddy 1.5D/1.6D/Turbo, Caddy 1.7SDi/1.9SDi (AEY)
Golf/Vento 1.9TD/TDi (-94), 1.9SDi, Passat/Santana D/Turbo, Passat TD/TDi
Sharan 1.9TDi, Transporter 1.6D/1,7D/1.9D/Turbo (-94), 2.4D (-95)
LT 2.4D/Turbo D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VS101/1 + VS101/5
Transporter 1.9TD/LT 2.5TDi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VS101/1
VOLVO
240/Turbo, 740D/Turbo, 760D/Turbo, 940D/Turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VS101/1 + VS101/5
VS1011 - 0869 -(1)- 200599
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7
3
3
3
3
3
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3.
SAFETY INSTRUCTIONS
WARNING! Ensure all health and safety, local authority, and general workshop practice regulations are strictly adhered to when using tools.
DO NOT use tools if damaged.
Maintain tools in good and clean condition for best and safest performance.
If required, ensure the vehicle to be worked on is adequately supported with axle stands, ramps and chocks.
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.
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 the valve head and the piston crown causing
possible damage to the engine. Incorrect injection pump timing may cause excessive smoke emissions, poor starting and low output of power.
IMPORTANT: Always refer to the vehicle manufacturer’s service instructions, or proprietary manual to establish the current procedure and data.
These instructions for use are provided as a guide only .
4.
INSTRUCTIONS FOR USE
p WARNING! Ensure you have read and understood Section 3 safety instructions before commencing.
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4.2. VS101/1, VS115/01 Camshaft Setting/Locking Plates - (see applications).
Camshaft setting/locking plates are used to accurately align a datum slot located in the end of the camshaft, with the top face of the camshaft
housing to hold the camshaft at the TDC position.
1.
Follow the service manual instructions to remove the camshaft cover and timing belt cover.
3.
If required, feeler gauges of equal thickness can be inserted on either side of the plate until all free play has been eliminated. The camshaft is
now locked in its timing position and service work can now be carried out.
2.
Turn engine in normal direction of rotation until camshaft setting/locking plate can be inserted into machined slot in the end of the camshaft.
VS101/1
VS115/01
4.3. VS101/2 Crankshaft TDC Location Pin - Ford, Mazda. (see applications).
VS101/2 is designed to screw into the cylinder block and provide a stop for the crank to be positioned against
in order to set the TDC position.
1.
Turn engine in the normal direction of rotation until the timing mark on the injection pump
sprocket lines up with the cast lug on the timing cover. Remove the plug from the cylinder block
access hole and screw in VS101/2 Location Pin. Slowly turn the crankshaft clockwise until
contact is made with the pin. Number 1 cylinder is now set at TDC on ignition stroke.
VS101/2
4.4. VS101/3, VS101/4, VS101/5, VS101/6, VS101/7 Locking Pins - (see applications).
Locking pins are designed to pass through datum holes in timing belt pulleys into fixed timing holes on the engine. These can be used at the injection
pump pulley, the camshaft sprocket or the flywheel. Follow the service manual instructions to remove the engine timing cover where necessary.
1.
2.
Insert the locking pin through the timing pulley or fixed timing hole.
Rotate the engine slowly in the normal direction of rotation until the point at which the pulley timing holes and the engine timing holes are aligned.
The locking pins can now be engaged to lock the engine in the correct timing position.
IMPORTANT When the service application allows for injection pump timing on the vehicle
check the pump timing using the appropriate Sealey Pump Timing Tool after belt
replacement.
VS101/3
VS101/7
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 product. WARRANTY: Guarantee is 12 months from purchase date, proof of which will be required
for any claim. INFORMATION: Call us for a copy of our latest catalogue on 01284 757525 and leave your full name and address including your postcode.
Sole UK Distributor
Sealey Group,
Bury St. Edmunds, Suffolk.
01284 757500
01284 703534
E-mail: [email protected]
VS1011 - 0869 -(1)- 200599
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