Sealey VSE5863 User manual

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.
Original Language Version VSE5863 Issue:3 - 17/06/16
© Jack Sealey Limited
INSTRUCTIONS FOR:
DIESEL ENGINE SETTING/LOCKING KIT
FORD /JAGUAR 2.2D/3.2 TDCI - CHAIN DRIVE
MODEL NO: VSE5863
1. SAFETY
2. INTRODUCTION
3. CONTENTS
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.
DO NOT attempt to start or move a vehicle whilst in gear and with timing devices fitted.
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.
When not in use, store in a safe, dry childproof place.
Keep children and unauthorised persons away from the work area.
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 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).
When timing an engine, always prevent the engine from being turned over. Use a notice and / or inhibit the engine.
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.
Refer to
instruction
manual
Wear eye
protection
Suitable for Ford 2.2TDCi Puma Duratorq chain drive diesel engines. Includes useful holding wrench for locating the crankshaft pulley correctly
to allow for tting of the TDC sensor.
Item Part No. Description OE Number
1. VSE5863.01 Flywheel Locking Pin 303-698
2. VSE5863.02 Crankshaft Holding Tool 303-1310
3. VSE5863.03 Camshaft Locking Pins (2 in kit) 303-732

4. APPLICATIONS
5. INSTRUCTIONS
Make:
Ford
Models:
Transit 2.2 TDCi (06-16)
Ranger (11-16)
Engines:
2.2 TDCi
CVFF
CVF5
CV55
CVR5
CYFA
CYFB
CYFF
CYFG
CYF5
CYR5
QVFA
QWFA
SRFA
SRFB
SRFC
SRFD
SRFE
UHFA
UHR5
DRFA
DRFB
DRFF
DR5F
DRR5
BGVAJPF
GBVAJQJ
PGFA
PGFB
P8FA
P8FB
2.2TDCi EcoNetic
DRFC
DRFG
CYFC
2.2 TDCi HDT
USR6
UYR6
2.2 D
QJBA
BG
3.2TDCi
SAFA
5.1. Chain Removal
5.1.1. Turn the engine so that the camshaft sprocket timing marks are at the 12 o’clock position, see g.1.
5.1.2. Fit the VSE5863.02 Crankshaft Holding Tool, with the engine in the timed position, this tool bolts to the end of the crankshaft and is
bolted to the cylinder block at approximately the 8’clock position.
5.1.3. Remove the crankshaft position sensor and t the VSE5863.01 Flywheel Locking Pin.
5.1.4. Ensure the timing mark on the high pressure fuel pump is located as shown, see g.2.
5.1.5. Lock the camshaft sprockets using the VSE5863.03 Camshaft Locking Pins, through the holes, arrowed in g.1. Lock the timing chain
tensioner in a retracted position using a suitable locking pin.
5.1.6. Remove the VSE5863.02 Crankshaft Sprocket Holding Tool and the VSE5863.03 Camshaft Locking Pins.
5.1.7. The timing chain, timing chain tensioner and timing chain sprockets can now be removed.
5.2.1. Ensure the VSE5863.01 Flywheel Locking Pin is correctly
located and the high pressure fuel pump mark is located as
shown, refer to g.2.
5.2.2. Fit the camshaft sprockets and timing chain, align the
coloured chain links with the timing marks on the camshaft
sprockets and high pressure fuel pump sprockets, refer to
g.3.
5.2.3. Lock the camshafts into position with the VSE5863.03
Camshaft Locking Pins.
5.2.4. Fit the tensioner rail and chain guides.
5.2.5. Fit the VSE5863.02 Crankshaft Holding Tool.
5.2.6. Make sure the timing chain is taught on its non-tensioned side
and remove the timing chain tensioner locking device.
5.2.7. Tighten the camshaft sprocket xing bolts to 35 Nm.
5.2.8. Remove all tooling, turn the crankshaft through two
revolutions and recheck the timing.
5.2.9. Once the timing is conrmed as correct, remove all tooling
and reassemble the engine.
5.2.10. The crankshaft pulley securing bolt tightening torque is 45 Nm
+120 degrees.
5.2. Installation
g.1 g.2
g.3
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 product.
WARRANTY: Guarantee is 12 months from purchase date, proof of which will be required for any claim.
01284 757500
01284 703534
[e-mail]
Sole UK Distributor, Sealey Group,
Kempson Way, Suffolk Business Park,
Bury St. Edmunds, Suffolk,
IP32 7AR
www.sealey.co.uk
Environmental Protection
Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be
sorted, taken to a recycling centre and disposed of in a manner which is compatible with the environment.
When the product becomes completely unserviceable and requires disposal, drain off any fluids (if applicable)
into approved containers and dispose of the product and the fluids according to local regulations.
Original Language Version VSE5863 Issue:3- 17/06/16
© Jack Sealey Limited