Sealey VS4910 User manual

VS4910
INSTRUCTIONS FOR:
PETROL ENGINE SETTING /LOCKING KIT -
ALFA ROMEO 1.4, 1.6, 1.8, 2.0
TWIN SPARK, 2.0JTS - BELT DRIVE
Model No:VS4910
 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.
Locking tools suitable for Alfa Romeo engines. Kit includes two pairs of
camshaft locking plates and timing/balancer shaft belt tensioner tools.
Alfa Romeo Twin Spark twin cam petrol engines in;
145 (96-01), 146 (96-01), 147 (01-11), 155 (95-98), 156 (97-06),
166 (98-07), Spider (95-06), GTV (98-06), GT (04-10)
Engine Codes:
1.4 16v TS: 335.03
1.6 16v TS (105CV): 372.03
1.6 16v TS (120CV): 321.02, 321.03, 321.04, 671.06
1.8 16v TS: 322.01, 322.05 (156) , 671.06
2.0 16v TS: 162.01, 323.01, 323.10, 341.03, 363.01, 672.04
2.0 JTS: 932A2.000, 937A1.000
VS4910 Kit for ALFA ROMEO is based on the AL-Fi
UNIVERSAL CAMSHAFT SETTING PLATE SYSTEM.
PATENTS APPLIED FOR.
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. APPLICATIONS
© Jack Sealey Limited Original Language Version VS4910 Issue:3 (SP) - 08/07/15
Refer to
instruction
manual.
Wear eye
protection.

© Jack Sealey Limited Original Language Version VS4910 Issue:3 (SP) - 08/07/15
4. CONTENTS
Item Part no. Description OEM no.
1 VS4900/1 Support block assembly (inlet camshaft)
c/w retaining bolts (2), securing screws (2)
& location pin assy.
1.825.042.000
2 VS4900/2 Support block assembly (exhaust camshaft)
c/w retaining bolts (2), securing screws (2)
& location pin assy.
1.870.797.000
3 VS900/6 Hex key
4 VS4901 Set of 4 setting plates
A & B inlet camshaft
C & D exhaust camshaft
1.870734.0000
1.825.041.0000
1.870.859.000 (2.0JTS)
5 VS1403/04 Timing belt tensioner adjuster 1.822.149.000
6 VS1409/03 Balancer shaft belt tensioner
adjuster
1.822.154.000
Associated Tools
AK9634M Dial gauge metric 8mm deection
VSE2515 TDC position tool - Alfa Romeo, Fiat
VSE5885 Variator socket - variable camshaft/valve
timing unit - Alfa Romeo , Fiat

Alfa Romeo 1.4, 1.6, 1.8 & 2.0 Twin Spark + 2.0JTS petrol engines.
5.1 General Guide - Setting & Locking engines.
Timing belt replacement on these Alfa Romeo twin cam engines is
carried out with the crankshaft at TDC No.1 cylinder, established by
using VS1404 TDC Position Tool together with a Dial Gauge
(AK9634M), to determine the piston position.
5.1.1 VS1404 TDC Position Tool - Associated Tool - not in kit.
The correct engine/crank TDC position is established using VS1404 tool
together with a suitable Dial Gauge such as AK9634M.
VS1404 Tool determines when the piston of No.1 cylinder is at its
highest point - NOTE: piston must be on its ignition stroke.
Remove the spark plugs and install the Dial Gauge into VS1404 and
secure with the thumbscrew.
Screw the VS1404 fully into the centre spark plug hole of No.1 cylinder,
taking care not to over tighten (Fig.1).
By turning the crankshaft, in the normal direction of engine rotation, the
piston will raise the indicator pin of VS1404 and in turn, move the
needle of the Dial Gauge.
TDC is achieved when the Dial Gauge needle reaches its highest
reading and starts to move in the reverse direction.
Check that all timing marks align.
Fig.1
Fig.2
5.1.2 Camshaft timing.
The camshafts are retained in their 'timed' positions by use of Camshaft
Setting Plate Assemblies which are fixed on the engine in place of
designated bearing caps, at specified cylinder locations (Fig.2).
The VS4910 Timing Kit is based on the unique AL-Fi Camshaft
Setting Plate System.
The AL-Fi range of Universal Camshaft Setting Plates provide wide
application coverage across engine ranges by utilising common Support
Blocks - one for all Inlet Camshafts, and one for all Exhaust Camshafts.
Interchangeable Setting Plates are mounted onto these support blocks
The position of the Setting Plates on the Support Blocks is adjustable in
order to provide maximum coverage of engine ranges.
Refer to 4.3 "The AL-Fi System Of Camshaft Setting Plates"
5.1.3 Both camshaft sprockets are released and free to turn on their
camshafts, when fitting new belt.
Marks on the new belt are aligned to marks on the sprockets/pulley and
fitted in the following order: crankshaft, guide, camshaft (exhaust),
camshaft (inlet), tensioner, water pump. Initially the timing belt tension is
adjusted to maximum using Tensioner Adjuster VS1403/04.
The camshaft sprocket bolts are then tightened, and all setting/locking
tools removed and bearing caps re-fitted. The engine is rotated by hand,
and VS1404 re-fitted to ensure return to TDC position.
The tensioner is adjusted so the pointer aligns with hole, the engine is
rotated again and returned to TDC. All timing marks must align.
5.1.4 For 2.0 engines the balancer shaft belt is tensioned using VS1409/03
Adjuster. With the crankshaft at TDC, align the balancer shaft timing
marks and fit the belt. Adjust tensioner to position detailed below.
5.2 VS1403/04 Timing Belt Tensioner Adjuster & VS1409/03 Balancer
Shaft Belt Tensioner Adjuster (Fig.3).
1403/04 Adjuster is used for all these twin cam engines. The correct final
adjustment for the timing belt tensioner is with the pointer of the tensioner
aligned with the reference hole - see fig.3.
VS1409/03 adjusts the tensioner of the balance shaft belt on 2.0 engines.
The correct final position is with the hole on the tensioner aligned to the
centre point of the tensioner movement - see fig.3.
Fig.3
© Jack Sealey Limited Original Language Version VS4910 Issue:3 (SP) - 08/07/15
5. INSTRUCTIONS

5.3 The AL-Fi System of Camshaft Setting Plates.
The Al-Fi range of Universal Camshaft Setting Plates provides
wide application coverage across engine ranges by utilising
common Support Blocks - one for all Inlet camshafts, and one for
all Exhaust camshafts. Interchangeable Setting Plates are mounted
onto these Support Blocks.
The position of the Setting Plates on the Support Blocks is
adjustable in order to provide coverage of a range of engines.
The required Setting Plate position on the Support Block, is
accurately achieved, and maintained, via the 'location pin' which
is inserted through a numbered location hole in the Support
Block and through a hole in the Setting Plate. When mounted on
the engine, this assembly fixes the position of the camshaft lobe
to achieve correct camshaft timing position.
5.4 Selecting the correct Al-Fi parts and assembling the Camshaft
Setting Plate system for use.
5.4.1 The Inlet Camshaft Setting Plate Assembly.
Select the "INLET" Support Block (Fig.4).
Refer to the Data Chart to establish which Setting Plates are
required for the application.
Example: Alfa Romeo 145 2.0 16v TS (96-01) Engine code 323.01
= Plates "A" and "B" (Fig.5).
Fix the Setting Plates to the "INLET" Support Block with the
securing screws (Do not tighten fully at this stage) (Fig.6).
Note: Plate "A" to the left and Plate "B" to the right, with the
"A" and "B" lettering visible.
Refer to Data Chart to establish which hole number location is
required for this application.
Example: Alfa Romeo 145 2.0 16v TS (96-01) Engine code 323.01
= Plate A location "6" and Plate B location "6" (Fig.5).
Select the Location Pins/Chain Assembly and pass the pins
through the correct hole locations in the Support Block and into
the Setting Plates (Fig.7).
Retain the Location Pins in place by applying pressure to the
sides of the Setting Plates whilst fully tighten the setting plate
Securing Screws using the allen key provided in the kit (Fig.8).
5.4.2 The Exhaust Camshaft Setting Plate Assembly.
Select the "EXHAUST" Support Block (Fig.9).
Refer to Data Chart to establish which Setting Plates are
required for the application.
Example: Alfa Romeo 145 2.0 16v TS (96-01) Engine code 323.01
= Plates "C" and "D" (Fig.5).
Fix the Setting Plates to the "EXHAUST" Support Block with the
securing screws (Do not tighten fully at this stage) (Fig.10).
Note: Plate "C" to the left and Plate "D" to the right, with the
"C" and "D" lettering visible.
Refer to Data Chart to establish which hole number location is
required for this application.
Example: Alfa Romeo 145 2.0 16v TS (96-01) Engine code 323.01
= Plate C location "3" and Plate D location "3" (Fig.5).
Select the Location Pins/Chain Assembly and pass the pins
through the correct hole locations in the Support Block and into
the Setting Plates (Fig.11).
Retain the Location Pins in place by applying pressure to the
sides of the Setting Plates whilst fully tighten the setting plate
Securing Screws using the allen key provided in the kit (Fig.12).
Fig.7
Fig.6
Fig.8 Fig.9
Fig.4
Fig.11
Fig.12
Fig.5
Fig.10
© Jack Sealey Limited Original Language Version VS4910 Issue:3 (SP) - 08/07/15

Fig.14
Fig.15
5.5 Fitting the Al-Fi Camshaft Setting Plate Sets to the engine.
Camshaft Setting Plate Assemblies are fixed in place of
designated bearing caps, at specified cylinders.
Refer to Data Chart to establish at which cylinder position the
"INLET" and the "EXHAUST" Setting Plate Assemblies are to be
fitted on to the camshafts for the model/engine.
Example: Alfa Romeo 145 2.0 16v TS (96-01) Engine code 323.01
= Inlet "Cylinder No.2" and Exhaust "Cylinder No.3" (Fig.5).
5.6 For timing belt replacement applications with the old timing
belt still in-situ/engine timing correct.
With the crankshaft correctly positioned at TDC No.1 cylinder, the
camshaft lobes should be in the correct timed position to accept
the Al-Fi Setting Plate Assemblies.
Remove the bearing caps of the inlet and exhaust camshafts at
the appropriate cylinder locations.
NOTE: Clearly mark which is the inlet and exhaust, and keep
clean at all times (Fig.13).
Place the Inlet and Exhaust Al-Fi Setting Plate Assemblies in
position over the appropriate camshaft lobes.
NOTE: Ensure that the fixing holes in the Support Blocks match
the offset bearing cap holes in the cylinder head (Fig.14).
When viewed from the camshaft sprockets, the lettering on
the Setting Plates should be visible.
CHECK THAT THE BASES OF THE SUPPORT BLOCKS REST
ON THE SURFACE OF THE CYLINDER HEAD AND THAT THE
SETTING PLATES ARE ALIGNED WITH THE PROFILE OF
THE CAMSHAFT LOBES (Fig.15).
Insert the Flanged Securing Bolts (4) and tighten evenly to
10Nm (Fig.16).
The belt tensioner can now be released and the old belt removed.
NOTE: These Alfa Romeo and Fiat timing belt applications require
the camshaft sprockets to be 'free to turn' on the camshaft, when
fitting the new timing belt, and therefore it is necessary to slacken
the camshaft sprocket bolts.
WARNING: DO NOT use Al-Fi Camshaft Setting Plate
Assemblies to counter-hold camshafts in position whilst
releasing or tightening the sprocket bolts as this will damage
the Setting Plates. Al-Fi Assemblies are for retention of
timing position only. A suitable sprocket holding tool MUST
BE used to counter-hold the sprockets.
5.7 For camshaft timing applications (when timing belt not in `
place).
Al-Fi Setting Plate Assemblies can be used to 'set' the camshaft
timing on these engines after engine overhaul or repair, and prior
to installing a new belt.
The preparation involved in establishing the model/engines,
selecting the appropriate Al-Fi parts to create the correct
camshaft setting plate assemblies, and determining the correct
cylinder location, is exactly the same as described earlier.
The appropriate cylinder locations should not have their camshaft
bearing caps fitted.
Look at the lobe profile form that has been created on the INLET
Al-Fi Setting Plate Assembly and using a suitable Sprocket
Holding Tool on the camshaft sprockets, turn the INLET
camshaft until the camshaft lobe at the appropriate cylinder
location is approximately in the same orientation as the Setting
Plate Assembly (Fig.17).
Place the INLET and EXHAUST Al-Fi Setting Plate Assemblies
in position over the appropriate camshaft lobes.
NOTE: Ensure that the fixing holes in the Support Blocks match
the offset bearing cap holes in the cylinder head (Fig.18).
Fig.16
Fig.17 Fig.18
© Jack Sealey Limited Original Language Version VS4910 Issue:3 (SP) - 08/07/15
Fig.13

Using the Sprocket Holding Tool, make any final adjustment
required to the camshaft position so the lobe aligns with the
Setting Plates (Fig.19).
Whilst maintaining this position with the Holding Tool,
CHECK THAT THE BASE OF THE SUPPORT BLOCK
RESTS ON THE SURFACE OF THE CYLINDER HEAD AND
THAT THE SETTING PLATES ARE ALIGNED WITH THE
PROFILE OF THE CAMSHAFT LOBES, and insert the four
Flanged Securing Bolts. Tighten evenly to 10Nm.
Repeat the same procedure with the Exhaust Setting Plate
Assembly/camshaft.When fitting the new timing belt the
camshaft sprockets must be 'free to turn' on the camshaft and
therefore it is necessary to slacken the camshaft sprocket bolts.
WARNING: DO NOT use Al-Fi Camshaft Setting Plate
Assemblies to counter-hold camshafts in position whilst
releasing or tightening the sprocket bolts as this will damage
the Setting Plates. Al-Fi Assemblies are for retention of
timing position only. A suitable Sprocket Holding Tool MUST
BE used to counter-hold the sprockets.
When fitting the new timing belt the camshaft sprockets must be
'free to turn' on the camshafts and therefore it is necessary to
slacken the camshaft sprocket bolts.
5.8 Crankshaft Pulley Removal.
VS1403/03 Flywheel Holding Tool (Crank Pulley removal) -
Associated Tool - not in kit.
The crankshaft pulley must be removed in order to replace the
timing belt.
On 2.0 engines a centre bolt retains the crankshaft pulley and it
will be necessary to firmly and safely 'lock' the flywheel when
releasing and tightening the pulley bolt. Flywheel Holding Tool
VS1403/03 can be used to 'lock' the flywheel on this application.
Extend Your AL-Fi Application Coverage.
AL-Fi Setting Plate Sets for Fiat 1.8 16v. and 2.0/2.4 20v. twin
cam petrol engines are available to use with the support blocks in
this kit, to cover these Fiat applications.
VS4902 for 1.8 16v. Punto, Brava/Bravo, Marea/Weekend,
Barchetta, Coupe & Stilo (183A1.000, 182A2.000, 188A6.000 &
192A4.000).
VS4903 for 2.0/2.4 20v. Bravo, Coupe & Stilo (182A1.000,
182B7.000, 192A2.000, 182B3.000 & 175A3.000).
Fig.19
© Jack Sealey Limited Original Language Version VS4910 Issue:3 (SP) - 08/07/15
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.