Sealey VS4870 User manual

Applications:
BMW N40 and N45(T) Twin Camshaft Petrol engines in
BMW
1 Series
116i. E81/E87
3 Series
316i. E46/E90
316Ci. E46
316ti. E46
B16 (N40/N45/N45T) engines
Kit contents/spares
Item Part Number Description
1 VS4801 Flywheel Locking Pin
VS4868 Camshaft Setting Plate Assembly (items 2 to 4)
2 VS4868-1 Camshaft Setting Plate (Inlet)
3 VS4868-2 Camshaft Setting Plate (Exhaust)
4 VS4805-3 Camshaft Setting Plate Securing Screw
5 VS4803 Timing Chain Tensioner Pre-Load Tool
6 VS4869 VANOS Alignment Plate
-- VS4870-84 Case + Insert
12
3
4
5
6
INSTRUCTIONS FOR:
PETROL ENGINE TWIN CAMSHAFT
SETTING / LOCKING TOOL KIT-
BMW 1.6
MODEL No: VS4870
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.
1. SAFETY INSTRUCTIONS
2. CONTENTS & APPLICATIONS
  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.
VS4870 Issue No: 1 - 07/04/09

This range of 1.6 BMW 4 cylinder twin camshaft 16v. petrol
engines have VANOS (VCT) units on inlet and exhaust
camshafts but are not Valvetronic engines.
The N40 was introduced in the BMW 3 Series (E46) in 2001,
followed by the N45 in the 1 Series (2003). The N45T appears in
both the 1 Series and 3 Series from 2006.
VS4870 Setting/Locking Tool Kit
Comprises: VS4801 Flywheel Locking Pin
VS4803 Chain Tensioner Pre-Load Tool
VS4868 Camshaft Setting Plate Assembly
Comprises: VS4868-1 (Inlet Plate)
VS4868-2 (Exhaust Plate)
VS4805-3 (Securing Screw)
VS4869 VANOS Alignment Plate
For checking and adjusting valve timing, the timing positions for
the camshafts are achieved using the VS4868 Camshaft Setting
Plate Assembly and the VS4803 Timing Chain Tensioner Pre-
Load Tool.
 ThecrankshaftislockedatTDC(viatheywheel)usingVS4801
Locking Pin.
The VANOS Units positions are adjusted with VS4869 Alignment
Plate.
3.1 Checking valve timing
3.1.1 Remove the cylinder head cover and all spark plugs.
Unscrew the bolt retaining the oil supply line and unclip the line.
Turn the crankshaft, in normal direction of engine rotation, to
TDC No.1 cylinder (ignition), using a wrench on the crankshaft
pulley centre bolt.
3.1.2 Check the timing positions of the camshafts – each camshaft
has a rectangular section at the rear which has a curved edge
on top and a straight edge on the bottom. With the engine in the
correct TDC engine timing position, the curved edge of the
rectangles, on both camshafts, will be uppermost (g.2).
An additional guide to correct camshaft position, using the
exhaust camshaft, is that in the correct TDC engine timing
position, the recesses in the sections of the exhaust camshaft
between the lobes, will be pointing towards the exhaust
 manifold(g.3).
3.2 VS4801 Flywheel TDC Locking Pin
3.2.1 Insert VS4801 Flywheel TDC Locking Pin through the datum
hole, which is located underneath the starter motor, and into the
 timingholeintheywheel(g.4).
NOTE:Thedatumholecanbedifculttolocateandmaybe 
constricted by dirt/corrosion.
IMPORTANT: On Automatic Transmissions – there is a much
 largerholeintheywheelveryneartothetimingholeand
checks are required to ensure that this hole has not been
selected in error. With VS4801 Locking Pin inserted, check that
the engine will not rotate back and forth. Use a wrench on the
crankshaft pulley bolt to rotate the engine.
VANOS Units:
IMPORTANT: If the VANOS Unit has ‘locked’ correctly, the
camshaft will not turn. If the VANOS Units cannot be locked to
the camshafts, it is likely they are faulty, and must be replaced –
refer to Removing and Installing VANOS Units.
3.3 VS4868 Camshaft Setting Plate Assembly
(comprises VS4868-1, VS4868-2 & VS4805-3)
3. INSTRUCTIONS
g.1
g.3
g.4
g.2
g.5
3.3.1 Place VS4868-1 Camshaft
Setting Plate on to the
rectangular section at the rear of
the INLET camshaft, and ensure
the Plate rests fully on the
surface of the cylinder head.
 (Donotinsertxingbolts)
If timing is correct, VS4868-1
Plate should rest on the cylinder
head without any gap, or at most,
raised 0.5mm. to the exhaust
 sideonly(g.5).
VS4870 Issue No: 1 - 07/04/09

3.3.2 Place VS4868-2 Camshaft Setting Plate on to the rectangular
section at the rear of the EXHAUST camshaft, and ensure the
Plate rests fully on the surface of the cylinder head (Do not
 insertxingbolts)(g.6).
If timing is correct, VS4868-2 should rest on the cylinder head
without any gap, or at most, raised 1.0mm to the exhaust side
only.
If the above position cannot be achieved with the Setting Plates,
then it will be necessary to adjust the timing.
Remove the Camshaft Setting Plates.
3.4 Adjusting timing
3.4.1 Slacken the bolts of the VANOS Units on the inlet and exhaust
 camshafts(g.7).
WARNING: These bolts are likely to be tight. It will be
necessary to counter-hold against engine rotation at the
crankshaft pulley centre bolt. Do NOT rely on the Flywheel
Pin to counter-hold when loosening these bolts.
3.4.2 ScrewintheVANOSUnitboltstonger-tightonly,sufcientso
there is no play or tilt on the units.
3.4.3 EnsurethattheVS4801FlywheelTDCLockingPinisttedinto
 thetimingholeintheywheel.
3.4.5 Place VS4868-1 Camshaft Setting Plate on to the rectangular
section at the rear of the INLET camshaft, ensuring that the
curved edge of the rectangular plate is uppermost. Align the
camshaft so the Setting Plate rests fully on the surface of the
 cylinderhead(Donotinsertxingboltatthisstage)(g.8).
3.4.6 Fit VS4868-2 Camshaft Setting Plate on to the rectangular
section at the rear of the EXHAUST camshaft, ensuring that the
curved edge of the rectangular plate is uppermost. Align the
camshaft so the Plate rests fully on the surface of the cylinder
 head(g.9).
3.4.7 Screw in the two xing bolts and tighten to secure the
Setting Plate VS4868-2 to the cylinder head.
3.4.8 Screw in VS4805-3 Securing Screw into Setting Plate VS4868-2
 untilitpressesonSettingPlateVS4868-1(g.10).
3.4.9 Screw in the xing bolt for VS4868-1 and tighten to secure
this Setting Plate to the cylinder head.
3.5 VS4803 Timing Chain Tensioner Pre-Load Tool
g.6
g.10
g.11
g.7
g.8
g.9
3.5.1 Remove the timing chain tensioner, and in its place insert
 VS4803TensionerPre-LoadTool(g.11).
3.5.2 Screw in the adjusting screw of VS4803, by hand, until it makes
contact with the tensioner rail but does not apply pressure.
3.5.3 Remove the old bolts of the VANOS Units on the inlet and
 exhaustcamshaftsandtnewbolts.Screwintheboltsto
 nger-tightonly,sufcientsothereisnoplayortiltontheunits.
3.6 VS4869 Vanos Alignment Plate
3.6.1 Fit VS4869 VANOS Alignment Tool to the front of the Units
ensuring that its two location pins enter into the holes in the
 VANOSUnits(g.12b)andthattheAlignmentToolts fully on to
 thesurfaceofthecylinderhead(g.12a).
3.6.2 Screw in the two bolts and tighten to secure VS4869 to the
cylinder head. Slacken the VANOS Unit bolts half turn and
 re-tightentonger-tight(g.13).
g.12a g.12b
g.13
VS4870 Issue No: 1 - 07/04/09

3.6.3 Attach a suitable torque wrench to the adjusting screw of
 VS4803(g.14).Turntoapplyapre-loadtothetensionerrail
of 0.6Nm.
3.6.4 Tighten the bolt of the exhaust camshaft VANOS unit to the
 speciedtorque,followedbytheboltoftheinletVANOSUnit,
 again,tothespeciedtorque–Torque20Nm.+90°+90° 
 (g.15).
3.6.5 Remove the VS4869 VANOS Alignment Tool.
3.6.6 Unscrew the adjusting screw of VS4803 and remove the Pre-
Load Tool.
IMPORTANT: Install the chain tensioner.
3.6.7 Remove all timing tools and turn the crankshaft twice (at the
crankshaft pulley centre bolt), in normal direction of engine
rotation, returning to TDC engine timing position, No.1 cylinder.
3.6.8 Insert the Flywheel TDC Locking Pin and Camshaft Setting
Plates to check timing position, follow the procedure as
described in “Checking valve timing”.
Removing, Installing and Replacing VANOS Units.
If either of the VANOS Units, on inlet or exhaust camshafts,
cannot be ‘locked’ and are faulty, they must be replaced.
3.7 Removal
3.7.1 Slacken the bolts of the VANOS Units on the inlet and exhaust
 camshafts(g.16).
WARNING: These bolts are likely to be tight. It will be
necessary to counter-hold against engine rotation at the
crankshaft pulley centre bolt. Do NOT rely on the Flywheel
Pin to counter-hold when loosening these bolts.
3.7.2 Screwintheboltstonger-tightonly,sufcientsothereisno 
play or tilt on the units.
3.7.3 EnsurethattheVS4801FlywheelTDCLockingPinisttedinto
 thetimingholeintheywheel.
3.7.4 Place VS4868-1 Camshaft Setting Plate on to the rectangular
section at the rear of the INLET camshaft, ensuring that the
curved edge of the rectangular plate is uppermost. Align the
camshaft so the Setting Plate rests fully on the surface of the
 cylinderhead.(Donotinsertxingbolt)(g.17).
3.7.5 Place VS4868-2 Camshaft Setting Plate on to the rectangular
section at the rear of the EXHAUST camshaft, ensuring that the
curved edge of the rectangular plate is uppermost. Align the
camshaft so the Plate rests fully on the surface of the cylinder
 head(g.18).
3.7.6 Screw in the two xing bolts and tighten to secure the
Setting Plate VS4868-2 to the cylinder head.
g.14
g.18
g.15
g.16
g.17
3.7.7 Screw in VS4805-3 Securing Screw into Setting Plate VS4868-2
 untilitpressesonSettingPlateVS4868-1(g.19).
3.7.8 Screw in the xing bolt for VS4868-1 and tighten to secure
this Setting Plate to the cylinder head.
3.7.9 Remove the timing chain tensioner.
3.7.10 Fully remove the bolt of the VANOS Unit on the exhaust
camshaft. Lift chain off the sprocket and feed out and remove
the complete VANOS Unit.
3.7.11 Repeat this procedure on the VANOS Unit on the inlet
camshaft.
3.8 Replacement
WARNING: It is important to note that the Inlet and exhaust
VANOS Units are different. It is essential to keep the parts
of Inlet Unit separate from the Exhaust Unit. Under no
circumstances should the parts be mixed or parts from any
other engine variant be used.
Inlet Unit part is marked “EIN / IN”(g.20a)andtheExhaust 
Unit part marked “AUS / EX” (g.20b).
Installation
3.8.1 Assemble the Unit of the Inlet camshaft, including the sensor
 gear(frontplate),andfeedontotheinletcamshaftttingthe 
chain onto the sprocket. Screw in a new bolt and tighten only so
 thereisnoplayortilting(nger-tight).
g.19
g.20a g.20b
VS4870 Issue No: 1 - 07/04/09

3.8.3 Insert VS4803 Tensioner Pre-Load Tool and screw in the
adjusting screw by hand, until it makes contact with the
 tensionerrail(g.21).
3.8.4 Fit VS4869 VANOS Alignment Tool to the front of the Units
ensuring that its two location pins enter into the holes in the
 sensorgearsandtheTooltsfully on to the surface of the
cylinder head. Screw in the two bolts to secure VS4869 Tool to
 thecylinderheadandtighten(g.22).
3.8.5 Unscrew the bolts of the VANOS Units half turn and then tighten
 tonger-tight,ensuringthatthereisnoplayortiltingofthe 
VANOS units.
3.8.6 Attach a suitable torque wrench to the adjusting screw of
 VS4803(g.23)andturntopre-loadthetensionerrailto 
0.6Nm.
3.8.7 Tighten the bolt of the exhaust camshaft VANOS unit to the
 speciedtorque,followedbytheboltoftheinlet VANOS Unit,
 again,tothespeciedtorque–Torque20Nm.+90°+90° 
 (g.24).
3.8.8 Remove VS4869 Alignment Tool.
3.8.9 Unscrew the adjusting screw of VS4803 and remove the Pre-
Load Tool
3.8.10 IMPORTANT: Install the chain tensioner.
3.8.11 Remove all timing tools and turn the crankshaft twice (at
crankshaft pulley centre bolt), in normal direction of engine
rotation, returning to TDC engine timing position, No.1 cylinder.
3.8.12 Insert the Flywheel TDC Locking Pin and Camshaft Setting
Plates to check timing position as described in
“Checking valve timing”.
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www.sealey.co.uk
01284 703534
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Bury St. Edmunds
Suffolk.
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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.
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g.21
g.22
g.23
g.24
3.8.2 Assemble and install the Exhaust camshaft Unit and screw in a
new bolt and tighten only so there is no play or tilting.
IMPORTANT: Press the chain rail, by hand, and ensure the
timing chain is guided within the rail.
VS4870 Issue No: 1 - 07/04/09