Sealey VS5125 Manuale utente
INSTRUCTIONS FOR:
SETTING AND LOCKING KIT - VAG
1.8TFSI - 2.0TFSI PETROL CHAIN DRIVE
MODEL No: VS5125
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS & 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. KEEP THESE INSTRUCTIONS SAFE FOR FUTURE USE.
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.
1. SAFETY
2. INTRODUCTION
3. CONTENTS
Refer to
instruction
manual
Wear eye
protection
WARNING! Wear approved eye protection. Wear appropriate
Personal Protective Equipment. A full range of Personal Protective
Equipment is available from your Sealey dealer.
WARNING! Ensure that Health & Safety, Local Authority
Regulations and general workshop practice Regulations are
adhered to when using tools.
DO NOT use tools if damaged.
Maintain tools to ensure that they are in an adequate condition for
safe use and optimum performance.
Ensure that a vehicle that has been raised by a jack is adequately
supported. Use axle stands.
Wear suitable clothing to avoid snagging. DO NOT wear jewellery.
Tie back long hair.
Account for all tools, parts and components being used. DO NOT
leave these in or near the engine. Return tools to suitable storage
after use.
These Instructions are provided as a guide only.
Always refer to the vehicle manufactures’ service instructions or a
proprietary manual to establish the correct procedure and data.
WARNING! The warnings, cautions and instructions in this manual
cannot cover all possible conditions and situations. The
Operator/ user must apply caution and common sense (good
practical sense).
WARNING! Incorrect or out of phase camshaft timing can result in
contact between the valve head and the piston crown.
This will cause damage to the engine.
Setting and locking kit that ts a wide range of VAG group 1.8 & 2.0 petrol engines. Includes essential tooling required to remove the camshaft
adjuster valves and a useful crankshaft pulley holding tool. Some applications and repair operations will require additional tooling.
Item Part No. Description OE Refs. Associated Tools Description
1 VS5125-01 Crankshaft Pulley Holding Tool T10355 AK9634M Mini Dial Gauge
2 VS5125-02 Crankshaft Spacer Bush T10368 VSE2515 Petrol TDC Position Tool
3 VS5125-03 Camshaft Control Valve Tool T10352 VSE5852 Service Position Front End Support Guide Set
4 VS5125-04 Camshaft Control Valve Tool T10352/1
5 VS5125-05 Camshaft Control Valve Tool
6 VS5125-06 Camshaft Locking Tool T20208
7 VS5125-07 Chain Tensioner Locking Pin T40011
8 VS5125-08 Auxillary Belt Tensioner Locking Pin T40267
VS5125 Issue: 3 - 22/03/17
Original Language Version
© Jack Sealey Limited
4. APPLICATIONS
5. INSTRUCTIONS
Models:
Audi:
A3/A3 Sportback (8PA/8P1) (07-13)
A3/A3 Sportback (8VA/8V1) (12-14)
A3 Saloon (8VS) (13-15)
A3 Cabriolet (8V7) (13-15)
A3 Cabriolet (8P7) (08-13)
A4 (8K2/8K5) (07-15)
A4 Quattro (8K2/8K5) (08-15)
A4 Quattro (8KH) (09-15)
A4 Allroad (8KH) (09-15)
A5 Sportback (8TA) (09-17)
A5 Coupe/Cabriolet (8F7/8T3) (07-15)
A6 (4G2/4G5) (12-14)
TT (8J3/8J9) (08-17)
Q3 (8UB) (11-15)
Q5 (8RB) (08-15)
Seat:
Leon (1P1) (09-17)
Toledo (5P2) (09-09)
Exeo (R32/3R5) (10-13)
Altea (5P1/5P5/5P8) (06-15)
Altea Freetrack (5P1/5P5/5P8) (09-15)
Alhambra (710) (10-15)
Skoda:
Octavia II (1Z3/5) (07-13)
Octavia III (5E3/5E5) (13-17)
Superb II (3T4/5) (08-15)
Yeti (5L7) (09-13)
Volkswagen:
Jetta (1K2) (05-11)
Passat (3C2/3C5) (07-11)
Passat (362/365) (11-17)
Passat Alltrack (365) (12-15)
Passat CC (357) (08-12)
EOS (1F7/1F8) (08-15)
Transporter T5 (7H/7J/7E/7F) (11-15)
Amarok (2HX/S1B) (10-16)
Beetle/Maggiolino (5C1/5C7) (13-15)
CC (358) (12-15)
Golf V (1K1) (09-13)
Golf VI (AJ5) Estate (09-13)
Golf VII (5G1) (13-16)
Scirocco (137) (08-14)
Golf VI (1K1) Cabriolet (12-14)
Golf VII (517) (12-15)
Tiguan (5N1/5N2) (07-15)
Sharan (11-15)
Engines:
1.8 TFSI: 1.8 TSI: 2.0 TFSI:
BYT CDAA CAWA
BZB CDAB CAWB
CABA CJSA CBFA
CABB CJSB CCTA
CABD CCZA
CDHA CCZB
CDHB CCZC
CJEB CCZD
CDNB
CDNC
CDND
CESA
CETA
CFKA
CFPA
CHHA
CHHB
CJKA
CJKB
CNCB
CNCD
CPLA
CPSA
CYNB
5.1. Engine Timing Check
5.1.1. Remove the cover and the bumper from the front of the
vehicle. Fit the appropriate support guide pins, see VSE5852
Service Position Front End Support Guide Set.
5.1.2. Detach and move the front panel to its service position to
allow access to crankshaft pulley and the timing chain covers.
5.1.3. Detach the oil dipstick tube and remove the inlet camshaft
solenoid control valve from the upper timing chain cover.
5.1.4. Remove the upper timing chain cover.
Original Language Version
© Jack Sealey Limited VS5125 Issue: 3 - 22/03/17
5.1.5. Identify the crankshaft timing mark on the lower timing chain
cover, positioned at approximately 4 o’clock relative to the
crankshaft pulley. Locate the timing notch in the outer
diameter of the crankshaft pulley.
NOTE: It may be difcult to see the timing mark on the lower timing
chain cover if there is a build up of dirt. Care must be taken
not to confuse the timing mark with other markings on the
timing chain cover.
5.1.9. With the crankshaft at TDC position on No.1 cylinder the
timing marks on the camshaft sprockets should be towards
the top.
5.1.10. If the marks are not at the top of the sprockets, rotate the
crankshaft one full turn in the normal direction of rotation,
returning to piston TDC position. Check that the marks are at
the top of the sprockets.
5.1.6. Using VS5125-01 Crankshaft Pulley Holding Tool, rotate the
engine in the normal direction of rotation until the mark on the
crankshaft pulley is aligned with the mark on the lower timing
chain cover.
5.1.7. If the crankshaft is moved beyond TDC position, rotate it back
to approximately 45º before TDC and repeat the crankshaft
positioning procedure.
5.1.11. To check that the camshaft timing is correct, take a
measurement from the timing mark of the inlet camshaft
sprocket to the far side of the rib on the upper chain guide.
This distance should be 61-64mm.
5.1.12. Take a second measurement from the timing mark of the inlet
camshaft sprocket to the timing mark of the exhaust camshaft
sprocket. This distance should be 124-126mm.
NOTE: If the engine timing is out of position by one tooth/one chain
link, this is approximately equal to 6mm deviation in
measurement.
5.1.13. If the crankshaft is set at TDC position and either of the
camshaft position measurements are incorrect, engine timing
will need to be adjusted.
5.1.8. If it is not possible to accurately locate the crankshaft timing
mark on the timing chain cover use a suitable TDC
positioning tool, such as VSE2515+AK2515, in the spark plug
aperture of no.1 cylinder to ensure that the crankshaft is in
the correct position.
Original Language Version
© Jack Sealey Limited VS5125 Issue: 3 - 22/03/17
5.2. Engine Timing Adjustment
5.2.1. Engine timing adjustment requires the removal and retting of
the camshaft timing chain. Therefore, the following procedure
is applicable to timing chain replacement as well as engine
timing adjustment.
5.2.5. Rotate the auxiliary belt tensioner in an anti-clockwise
direction to release tension from the belt. Retain the tensioner
in position using VS5125-08 Auxillary Belt Tensioner Locking
Pin and remove the auxiliary belt.
Remove the auxiliary belt tensioner and the auxiliary belt idler
pulley.
5.2.2. Using the appropriate tool from VS5125-03, -04 or- 05,
Camshaft Control Valve Tools, remove the control valve from
the Inlet camshaft.
5.2.3. Remove the retaining bolt and washer from the exhaust
camshaft.
5.2.4. Remove the bearing saddle.
WARNING! The control valve has a LEFT HAND THREAD.
Rotate the tool in a clockwise direction to remove the valve.
IMPORTANT: A gauze filter and ball bearing are located at
the rear of the bearing saddle. Take care not to allow these or
any other components to fall into the chain drive assembly or
the engine sump when removing or fitting the bearing saddle.
NOTE:
An inspection of the camshaft
diameters and the bores of the
bearing saddle can be performed at
this point. A technical product infor-
mation notice (TPI) was issued by
VW group regarding of failure of the
gauze lter & ball bearing assembly,
leading to blocked oil-ways and
damaged bearing saddle &
camshafts.
Original Language Version
© Jack Sealey Limited VS5125 Issue: 3 - 22/03/17
5.2.6. Using VS5125-01 as a counterhold, release the central bolt of
the crankshaft pulley. DO NOT remove the crankshaft pulley
at this stage.
5.2.9. Detach and remove the oil dipstick guide tube.
5.2.7. Ensure that the crankshaft timing marks are aligned, or that
the needle of the dial gauge (AK9634M) is in the correct
position, with the engine at TDC position on No.1 cylinder.
Remove the crankshaft pulley central bolt and the crankshaft
pulley.
5.2.8. Fit VS5125-02 Crankshaft Spacer Bush onto the crankshaft
pulley central bolt. Ret the bolt, nger tight only at this stage,
to retain the crankshaft sprocket on the crankshaft. Ensure
that the crankshaft remains in the correct timing position
throughout.
5.2.10. Remove the bolts that retain the lower timing chain cover.
Using a suitable lever, remove the lower timing chain cover
starting at points 1 and 2. Take care not to damage the
sealing face of the cylinder block or the timing chain cover
when removing it from the engine.
▲ IMPORTANT! When the crankshaft pulley central bolt is
removed, the crankshaft sprocket is not positively retained
on the crankshaft. DO NOT disturb the engine timing or the
chain drive when the bolt is removed.
Original Language Version
© Jack Sealey Limited VS5125 Issue: 3 - 22/03/17
5.2.11. Compress the oil pump drive chain tensioner and retain in
position using VS5125-07 Chain Tensioner Locking Pin.
5.2.13. Check for elongation of the timing chain. If the timing chain
has maximum permitted elongation then it MUST be
replaced.
5.2.12. Remove the oil pump drive chain tensioner and detach the
pump drive chain from the crankshaft sprocket.
5.2.14. Lift the retaining clip and non-return block of the timing chain
tensioner. Fully compress the tensioner plunger and retain in
position using VS5125-07 Chain Tensioner Locking Pin.
NOTE: When the timing chain tensioner is compressed and
chain tension is relieved, the inlet camshaft may rotate in the
direction of engine rotation due to valve spring pressure.
Original Language Version
© Jack Sealey Limited VS5125 Issue: 3 - 22/03/17
5.2.15. Remove the tensioner rail and guide rail for the timing chain.
5.2.16. Remove the timing chain.
NOTE: If the chain is to be retted, note the direction of
rotation before removal.
5.2.17. If the balance shaft timing chain is to be adjusted or replaced,
refer to section: 5.3. “Balance Shaft Timing Chain”.
5.2.19 Using a spanner on the camshaft, rotate the inlet camshaft
until the camshaft timing mark is aligned with the cut-out in
VS5125-06 Camshaft Locking Tool. Lock the camshaft in
position using the locking wedge of VS5126-06. Repeat
this process for the exhaust camshaft.
5.2.20. With the camshafts locked in position, t the timing chain onto
the camshaft sprockets, ensuring that two of the coloured
links of the chain are aligned with the timing marks of the
sprockets.
5.2.18. Fit VS5125-06 Camshaft Locking Tool on the camshafts,
retain in position using one of the bolts from the bearing
saddle. Ensure that the locking wedges are positioned
between the sprockets and that the camshafts are free to
rotate.
Original Language Version
© Jack Sealey Limited VS5125 Issue: 3 - 22/03/17
5.2.21. Fit the timing chain tensioner rail and the chain guide rail,
ensuring that the third coloured link is aligned with the mark
on the crankshaft sprocket. Tighten the bolts of the timing
chain tensioner rail and guide rail to 20Nm.
5.2.26. Ret the oil pump drive chain and chain tensioner, ensuring
that the chain is correctly located in the teeth of the
crankshaft sprocket and oil pump. Tighten the oil pump
chain tensioner bolt to 20Nm. Remove VS5125-07 Chain
Tensioner Locking Pin to apply tension to the chain.
5.2.23. Remove VS5125-06 Camshaft Locking Tool. Small movement
of the camshafts may occur when the tool is removed. Ret
the bearing saddle, nger tight only at this stage, ensuring
that the retaining pin is located in the timing chain guide rail
and that the gauze lter assembly is in position.
5.2.24. Ret the exhaust camshaft retaining washer, nger tight only
at this stage, using a new bolt.
5.2.25. Check that slack within the chain has been removed and that
the three coloured chain links are aligned with the timing
marks of the camshaft and crankshaft sprockets.
5.2.22. Remove VS5125-07 Chain Tensioner Locking Pin to apply
tension to the chain. Ensure that the non-return block and
retaining clip are tted to the tensioner and operating
correctly, it should not be possible to fully compress the
tensioner.
Original Language Version
© Jack Sealey Limited
5.2.27. Ensure that the sealing surfaces of the cylinder block and the
lower timing chain cover are clean and free from oil or used
sealant.
VS5125 Issue: 3 - 22/03/17
5.2.29. Fit the chain cover retaining bolts, tightening to an initial
torque of 8Nm, in the sequence shown (1 - 15). Repeat the
sequence, tightening the retaining bolts a fur ther 45º to
achieve the nal torque setting.
5.2.28. Apply a 2-3mm bead of sealant to the sealing face of the
lower timing chain cover. Fit the timing chain cover to the
engine, locating on the dowel pins that protrude from the
block.
5.2.30. Remove the crankshaft pulley central bolt and VS5125-02
spacer bush.
5.2.31 Fit a new crankshaft pulley central bolt and ret the
crankshaft pulley, nger tight only at this stage. Ensure that
the spline of the pulley is fully located in the spline of the
crankshaft.
5.2.32. Check engine timing, refer to section “Engine Timing –
Check” 5.1.
5.2.33. Using VS5125-01 Crankshaft Pulley Holding Tool as a
counterhold, tighten the crankshaft pulley central bolt to a
nal torque of 150Nm + 90º.
▲ IMPORTANT! The cover must be tted within 5 minutes of
applying the sealant. DO NOT apply more sealant than
specied, excess sealant can damage engine components.
▲ IMPORTANT! A new bolt must be tted. The used
crankshaft pulley bolt must be discarded.
Original Language Version
© Jack Sealey Limited
5.2.34. Tighten the bolts of the bearing housing to 9Nm.
5.2.35. Tighten the exhaust camshaft retaining bolt to 8Nm + 90º
(1.8 engine), or 20Nm + 90º (2.0 engine). Tighten the inlet camshaft
control valve to 35Nm.
5.2.36. Remove VSE2515 TDC Positioning Tool, ret the spark plug
and coil pack.
5.2.37. Ret the upper timing chain cover, tighten the bolts to 9Nm in
the sequence shown (1-5).
5.2.38. Ret the dipstick guide tube and the solenoid control valve,
tightening the bolts to 9Nm.
5.2.39. Ret the auxiliary belt drive tensioner (40Nm) and idler pulley
(20Nm), then ret the auxiliary belt.
5.2.40. Remove VS5125-08 Auxiliary Belt Tensioner Locking Pin to
apply tension to the belt.
5.2.41. Reassemble engine components and vehicle front end panel.
WARNING! The control valve has a LEFT HAND THREAD.
Rotate the tool in an anti-clockwise direction to tighten the
valve.
VS5125 Issue: 3 - 22/03/17
5.3.3. Remove the timing chain tensioner and the balance shaft
chain tensioner.
5.3.4. Remove the balance shaft tensioner rail, followed by the
upper guide rail and nally the lower guide rail.
5.3.5. Remove the balance shaft timing chain.
5.3. Balance Shaft Timing Chain
5.3.1. In order to remove the balance shaft chain or adjust the
timing of the balance shafts, the timing chain must be
removed.
5.3.2. To remove the engine timing chain refer to section 5.2.
“Engine timing – Adjustment”. With the engine timing chain
removed, proceed as follows.
5.3.6. Align the timing mark (dot) of the inlet side balance shaft
sprocket with the mark of the idler sprocket.
5.3.7. Fit the balance shaft chain on to the inlet side balance shaft
idler, aligning the coloured chain link with the mark on the
sprocket at the 1 o’clock position.
5.3.8. Fit the balance shaft chain on to the exhaust side balance
shaft, aligning the mark on the shaft sprocket with the
coloured link of the chain. This mark is approximately at the
12 o’clock position.
5.3.9. Fit the balance shaft chain onto the crankshaft sprocket.
VS5125 Issue: 2 - 16/06/16
Original Language Version
© Jack Sealey Limited
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