Sealey Vs4980 User manual

Jaguar: S-Type (99-08), XF (08-09), XJR (97-10), XJ8 (97-10),

XKR (98-09), XK8 (96-09), Sovereign (97-03)

Land Rover: Discovery III (04-09), Range Rover (05-09),

Range Rover Sport (05-09)

Daimler: V8 (97-03), Super V8 (97-03)

Engine Codes:

3.2: AC, KB, KC

3.5: RB

4.0: BC, CC, CE, DC, EC, GB, GC, LB,LC, MA, MB,

NB, NC, PA, PB

4.2: 1B, 2B, 3B, 1G, 5G, 9G, HB, HG, SB,TB, PC,

428PS

4.4: 448PN

INSTRUCTIONS FOR:

PETROL ENGINE SETTING/LOCKING KIT -

JAGUAR/LAND ROVER/DAIMLER - CHAIN DRIVE

MODEL No: VS4980

1. SAFETY 2. CONTENTS

3. 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.

VS4980 Issue No: 3(SP) 08/07/15

VS4980

Associated Tool

VS4985

Original Language Version

Kit contains specialised tools required for timing chain setting and lock-

ing on Jaguar, Land Rover and Daimler 3.2, 3.5, 4.0, 4.2, 4.4 V8 AJ26/

AJ27/AJ28/AJ34 series petrol engines. Supplied with comprehensive

instructions and carry-case.

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 maintained properly, give you years of trouble free performance.

Refer to

Instruction Manual

Wear Eye

Protection

 ThisV8petrolenginewasrstintroducedbyJaguarin1997and

is still in use today. Land Rover also started to use the later

versions of the engine in 2005. There have been many

changes, both in engine capacity and components over the

years, but most of the basic procedures for checking and

adjusting engine timing, dis-mantling and assembly of the

front-end gears, timing chain, camshafts etc., applies across the

engine range.

The timing applications on early and later engines are covered

by the VS4980 Engine Setting/Locking Tool Kit.

Timing adjustment and overhaul applications involving the front

end, gears, timing chains etc., require removal of the front timing

chain cover, and to remove this, the crankshaft pulley must be

removed.

On most variants the pulley bolt has a very high torque

 specicationandremovalandinstallationofthispulleyrequires

the Special Remover and Holding Tool in Set VS4985 –

Associated Tool.

IMPORTANT: References made to “left-hand bank” and “right-

hand bank” within this Product Information, refers to the left or

right cylinder heads as viewed from the front of the engine - ie.

from the camshaft gears.

VS4980 Engine Setting/Locking Tool Kit

Comprises: VS4981 Flywheel Locking Pin (Silver)

VS4982 Flywheel Locking Pin (Gold)

VS4983 Camshaft Setting Plate Set (pair)

VS4984 Camshaft Gear Holding Tool

VS4986 Tensioner Wedge Set (Pair)

VS4975T8 Primary Tensioner Locking Pin

VS4593-1A Tensioner Depress Pin

VS4987 VVT Unit Setting Tool

VS4985 Crankshaft Pulley Remover/Installer Tool Set

Comprises: VS4921 Crankshaft Pulley Holding Tool

VS4922 Crankshaft Pulley Remover Set

4.1 Checking valve timing

To check that the valve timing is correct, a Flywheel Locking

 Toolmustbeinsertedto‘lock’theywheel(andthereforethe 

crankshaft), in timed position, and a Camshaft Setting Plate

 mustbeabletobexedinplaceacrossthe‘timingats’on

each bank of camshafts and rest fully on the surface of the

cylinder head.

“A” – VS4981 (early) / “B” – VS4982 (Late)

VS4981 Flywheel Locking Pin - Silver (early engines)

VS4982 Flywheel Locking Pin – Gold (later engines)

‘A’ ‘B’

4. INSTRUCTIONS

g.2

g.1

Associated Tools:

VS4985 Petrol Engine Crankshaft Pulley Removal/Installation

Kit - Daimler V8, Jaguar, Land Rover.

Original Language Version

Item: Part No: Description: OEM No:

1VS4981 Flywheel Locking Pin (Silver) 303-531

2VS4982 Flywheel Locking Pin (Gold) 303-645

3VS4983 Camshaft Setting Plate Set

(2 per kit)

303-530

4VS4984 Camshaft Gear Holding Tool 303-532

5 VS4986 Tensioner Wedge Set (2 per kit) 303-533

6 VS4975TB Primary Tensioner Locking Pin -

7VS4593-1A Tensioner Depress Pin -

8 VS4987 VVT Unit Setting Tool 303-654

4.2.1 In order to check the camshaft timing the camshaft covers must

be removed.

4.2.2 Withthecrankshaftlockedin‘timed’positionthe‘timingats’ 

 (g.6a)onthecamshaftshouldbeuppermost.

4.2.3 One of the VS4983 Camshaft Setting Plates is placed across

 the‘timingats’ontheleft-handbankofcamshaftsandthe

 otherPlateislocatedacrossthe‘timingats’ontheright-hand

bank.

IMPORTANT: References made to left-hand bank and right-

hand bank are as viewed from the direction of the camshaft

gears.

4.2.4 In order for the camshaft timing to be correct, both Setting

Plates MUST t ush on to the camshaft ‘timing ats’ and

rest fully on the surface of the cylinder head (g.8).

If this cannot be achieved, then timing adjustment will be

necessary.

Timing adjustment and applications involving cylinder head/

camshaft removal will involve removal/installation of gears and

timing chains.

These applications require the front timing chain cover to be

removed, for access to gears, chains and tensioners, and to

remove the cover, the crankshaft pulley must be removed.

4.3 VS4985 Crankshaft Pulley Remover/Installer Tool Kit –

Associated Tool Set – not included in VS4980 Kit

The VS4985 Set comprises VS4921 Crankshaft Pulley Holding

 ToolandVS4922CrankshaftPulleyRemoverSet(g.9).

These tools must be used together when removing the

crankshaft pulley.

g.9

g.8

g.7

4.1.1 The shapes of these Flywheel Locking Pins match the

 appropriate‘timinghole’prolesintheywheel(g.3).

4.1.2 TheFlywheelLockingPinentersintotheywheel‘timinghole’

 throughthecrankshaftpositionsensorhole(g.4).Theposition

sensor is removed, and the Flywheel Locking Pin is inserted

 throughtheengine,intotheywheel(g.4a)andboltedin

position.

g.4a

WARNING: Under certain circumstances it may be possible

to insert the VS4982 Locking Pin for later engines into the

ywheel of early engines. However it will not feel a good,

positive t and it will not be possible to t the securing

screw for the Pin as the securing hole will be off-set (g.5).

If this occurs, remove and t VS4981 Pin.

4.2 VS4983 Camshaft Setting Plate Set (Pair)

g.6

g.5

g.3

g.4

g.6a

These two Flywheel Locking Pins cover the complete range of

engines.

 Theyarecolourcodedandforadditionalidenticationitcan 

 alsobeseening.2,thatVS4981(Silver)hastwoparallelat 

 faces,whereasVS4982(Gold)hasthreeatfaces.

Original Language Version

4.4 VS4922 Pulley Remover Set – Removal of crankshaft pulley

NOTE: To remove the crankshaft pulley, the Holding Tool and

the Pulley Remover are assembled together onto the pulley.

The VS4921 Holding Tool is used to prevent the crankshaft

pulley from rotating whilst the force screw of the Pulley Remover

 isscrewedintoremovethecrankshaftpulley(g.14).

4.4.1 Pre-assemble the Bridge Piece, Force Screw and Securing

Bolts (the longer bolts in VS4895 Set) to make up the VS4922

Pulley Remover.

IMPORTANT: Insert the Thrust Plate into the centre hole of the

 pulley(g.15).

4.4.2 Screw the Guide Pin in to one of the threaded holes in the

 pulley(g.15a).

4.3.5 Using a breaker bar and socket, release the bolt of the

crankshaft pulley whilst counter-holding with the VS4921

 HoldingTool(g.13)

4.3.6 Undo the bolts attaching the VS4921 and remove the Holding

 Tool(g.13a).

4.4.3 Slide the VS4921 Holding Tool over the Guide Pin and into the

 recesstothepulley(g.16).

4.4.4 Attach the VS4922 Remover on to the Holding Tool, and to

the crankshaft pulley, by inserting one of the securing bolt

through the opposite hole to the Guide Pin (in the VS4921

Holding Tool), and into the crankshaft pulley threaded hole

 (g.16a).

g.14

g.15

g.16

g.15a

g.16a

The VS4922 Holding Tool is also used to counter-hold the

crankshaft pulley during installation.

WARNING: Some crankshaft pulley bolts require a torque

as high as 375Nm. making the tools in VS4895 Set an

essential part of the procedures requiring removal/

installation of the crankshaft pulley.

Crankshaft pulley removal

WARNING: The Flywheel Locking Pin MUST NOT be used

to counter-hold ywheel/crankshaft for releasing or

tightening the crankshaft pulley bolt as engine damage will

result.

4.3.1 VS4921 Crankshaft Pulley Holding Tool – releasing and

tightening pulley bolt.

The VS4921 Holding Tool is attached to the pulley using the

shorter securing bolts supplied in the Set. The bolts pass

through the Holding Tool and are screwed in to the threaded

holes in the pulley.

IMPORTANT: The threaded holes in the crankshaft pulley,

which accept the securing bolts, can be corroded or blocked.

Always check these threads and ensure they are clean and clear

to accept the securing bolts.

NOTE:Itcanbedifculttoalignthethreadedholesinthepulley

when attaching the Holding Tool, therefore utilise the Special

 GuidePinfromtheVS4922RemoverSet(g.11).

4.3.2 First, screw the Guide Pin into one of the threaded holes in the

pulley and then locate one of the holes in VS4921 Holding Tool

on to the Guide Pin and slide the Holding Tool in place in to the

 recessofthepulley(g.11a).

4.3.3 Insert a bolt in to the opposite hole in the Holding Tool and

 screwitintothepulley(g.12).RemovetheGuidePinand

 replaceitwiththesecondbolt,screwingintothepulley(g.12a).

4.3.4 Tighten both bolts, rmly, to secure the Holding Tool to the

crankshaft pulley.

g.11

g.10

g.12

g.11a

g.12a

g.13 g.13a

Original Language Version

4.5.3 Screwinanewpulleysecuringbolttonger-tightonly.

4.5.4 Fit VS4921 Holding Tool to the crankshaft pulley and use it to

 counter-holdwhilsttighteningthesecuringbolttothespecied

 torquefortheenginevariantbeingworkedon(g.20).

4.5.5 If the pulley utilises a split locking ring–tanewo-ringseal

to the pulley and apply petroleum jelly to the bore and O-ring.

4.5.6 Fitthepulleyontothecrankshaftandtthesplitlockingring 

 insidetheboreofthepulley(g.21).

4.5.7 Screwinanewpulleysecuringbolttonger-tightonly(g.22).

4.5.8 Fit VS4921 Holding Tool to the crankshaft pulley and use it to

 counter-holdwhilsttighteningthesecuringbolttothespecied

 torquefortheenginevariantbeingworkedon(g.22a).

4.6 Adjusting valve timing

The following procedure covers valve timing adjustment and

also applies to setting up the valve timing when installing

camshafts, gears after cylinder head overhaul etc.

4.6.1 Check that the crankshaft is in its ‘timed’ position and that the

appropriate Flywheel Locking Pin has been inserted, as

described in “Checking valve timing”

4.6.2 Remove the water pump pulley.

4.6.3 Remove the front timing chain cover.

4.6.4 Remove the VVT solenoid housing from the inlet camshafts (if

 tted).

g.20

g.21

g.22

g.23

g.22a

4.4.5 Remove the Guide Pin and replace it with the second securing

bolt, passing it through Pulley Remover and the Holding Tool

 andintothethreadedholeofthepulley(g.17).

4.4.6 Tighten both bolts, rmly, to secure the Pulley Remover and

Holding Tool assembly to the crankshaft pulley.

4.4.7 Prevent the crankshaft pulley from rotating by counter-holding

with the VS4921 Tool. Screw in the Force Screw of the VS4922

 Removertoextractthepulleyoffthecrankshaft(g.18).

4.4.8 RemovetheThrustPlate(g.19),thecrankshaftpulleyandthe

 splitring(iftted)(g.19a).

4.5 Installing crankshaft pulley

IMPORTANT: The thread in the end of the crankshaft must

be cleaned out before installing a new pulley securing bolt. All

mating surfaces should be cleaned.

All except very early pulleys utilise a split locking ring.

4.5.1 If the pulley is a type without a locking ring - apply Loctite

648 to the bore of the crankshaft pulley. DO NOT apply to the

faces or to the crankshaft.

WARNING: The pulley must be tted and the securing bolt

fully tightened, within 7 minutes of the Loctite being

applied.

4.5.2 Fit the pulley to the crankshaft and wipe off any excess

Loctite.

g.19

g.18

g.17

g.19a

Original Language Version

4.6.9 Remove VS4984 Holding Tool from the camshaft gear and

 slowlyturnthecamshaftstopositionthe‘timingats’to 

achieve the correct alignment to the Setting Plate. This will

allow the Camshaft Setting Plate to be bolted down, using the

securing bolts provided, in order that the Plate rests fully on

 thesurfaceofthecylinderhead(g.27).

WARNING: The camshaft ‘timing ats’ MUST BE in correct

alignment to the Setting Plates BEFORE the securing

screws of the Setting Plates are tightened down. The action

of tightening the securing screws of the Setting Plates

MUST NOT be used to turn the camshaft to position the

‘timing ats’ alignment, as damage to the cylinder head will

result.

4.6.10 Repeat this procedure on the other bank of camshafts.

NOTE:Discardtheoldcamshaftgearbolts–alwaystnew 

camshaft gear bolts.

WARNING: Tightening procedure for camshaft gear bolts:-

For early engines, Jaguar instructs that the EXHAUST

camshaft gear bolt is tightened rst, followed by the INLET

gear bolt.

However, for later engines Jaguar and Land Rover instruct

that the INLET camshaft gear bolts MUST BE tightened

before the EXHAUST gear bolts, and a WARNING is given

that failure to tighten the INLET camshaft gear bolts rst,

will result in engine damage.

4.6.11 Fit new bolts and use VS4984 Holding Tool to counter-hold the

exhaust camshaft gear. Tighten the new camshaft gear bolts to

 speciedtorque(g.28).

4.7 Removal of timing chains and gears.

Primary chains

4.7.1 Followtheprocedurefor“Checkingvalvetiming”,andtthe

appropriate Flywheel Locking Pin and the Camshaft Setting

Plates on both banks of camshafts.

4.7.2 Remove the crankshaft pulley following the procedure detailed

earlier.

4.7.3 Remove the front timing chain cover and the VVT control

 solenoidhousing,iftted.

4.7.4 Commenceworkontheleft-handbankrstastheprimarychain

from this bank is at the front of the crankshaft gear and therefore

 mustberemovedrsttoallowaccesstoremovetheother 

primary chain.

g.27

g.28

NOTE: In order for the camshaft timing to be correct, both

VS4983 Setting Plates MUST t ush on to the ‘timing ats’

and rest fully on the surface of the cylinder head.

4.6.5 To adjust the position of the camshafts to achieve this position

the inlet and exhaust camshaft gear bolts must be slackened.

Work on one bank of camshafts at a time.

4.6.6 Install an VS4983 Camshaft Setting Plate loosely across the

 ‘timingats’onthecamshafts.DO NOT tighten the securing

 boltsoftheSettingPlateatthisstage(g.24).

VS4984 Camshaft Gear Holding Tool

4.6.7 Fit VS4984 Camshaft Gear Holding Tool in to the holes in the

EXHAUST camshaft gear and use it to counter-hold whist

slackening the INLETcamshaftgearbolt(g.25).

4.6.8 Maintain VS4984 Holding Tool in this counter-holding position

and slacken the EXHAUSTcamshaftgearbolt(g.26).

NOTE:Itmaybenecessarytotabreakerbarintothesquare

drive provided in VS4984 Tool, to increase its counter-holding

leverage.

g.24

g.25

g.26

Original Language Version

4.7.9 IMPORTANT: The crankshaft gear is a two piece gear - make a

note of the orientation of the gear teeth. The teeth of the left

hand bank crankshaft gear (front) must be out of phase to the

 teethoftherighthandbankgear(rear)(g.32).

Camshaft gears / Secondary chains

4.7.10 Remove the bolts of the inlet and exhaust camshaft gears and

 discardoldbolts(g.33).

4.7.11 Remove the gears, secondary chains and chain tensioners

 (g.34).

4.8 Installation chains and gears

NOTE: Early secondary chain tensioners must be

 de-pressurisedbeforere-tting.

Crankshaft gears

g.32

g.33

g.34

4.7.5 Fit VS4984 Holding Tool to the EXHAUST camshaft gear and

use to counter-hold whilst slackening the INLET camshaft gear

 bolt(g.29).Continuetocounter-holdandslackenthe 

 EXHAUSTcamshaftgearbolt(g.29a).

4.7.6 Removetheprimarychaintensionerunitandbackplate(g.30).

4.7.7 Removethechainguiderails(g.31)andtheprimarychain

 (g.31a).

4.7.8 Carry out the same procedure on the right-hand bank.

g.29

g.30

g.31

g.29a

g.31a

Original Language Version

4.8.6 Install the primary chain on the right-hand bank (right-hand bank

primary chain is the rear chain on the crankshaft gear.

4.8.7 Fit the chain over the INLET camshaft gear and the crankshaft

 gear(g.39).

IMPORTANT: Ensure that there is NO SLACK on the drive

 sideofthechainandthattheVVTUnit(iftted),isNOT rotated

on the camshaft.

4.8.8 Check that slack is on the tensioner side of the chain.

 Re-tthechainguiderailsandtightentherailbolts.

Repeat this procedure on the left-hand bank camshaft gears.

4.9 EARLY ENGINES

Primary chain tensioners

NOTE: When installing the primary chain tensioners, ensure

 thatboththebackplateandtensionerunitarere-tted(g.40),

(the back plate creates the seal for the tensioner unit).

4.9.1 Insert VS4593-1A Depress Pin in to the centre of the tensioner

plunger and press the Pin to de-press the plunger in to its

 retractedposition(g.41).

g.39

g.40

g.41

g.36

4.8.1 Insert VS4593-1A Depress Pin, from Kit VS4980, in to the hole

 inthetensionertoallowtheplungertobedepressed(g.35).

4.8.2 Workingontheleft-handbank,re-tthesecondarychain

 tensionertotheengineandtightenbolts(g.36).

4.8.3 Re-tthecamshaftgearstogetherwiththesecondarychain. 

 Screwinnewgearbolts,nger-tightonly,allowingthegearsto

 turn,butnottilt(g.37).

4.8.4 Fit VS4984 Holding Tool and rotate and position the gears to

the most advantageous position in readiness for using the

Holding Tool when tightening the gear bolts (NOTE: once the

 primarychainistted,thecamshaftgearscannotbepositioned

 toassistToolpositioning(g.38).

4.8.5 Repeat this procedure on the right-hand bank camshaft gears.

g.35

g.37

g.38

Original Language Version

4.9.8 Fit VS4987 to the VVT Unit and rotate the Unit anti-clockwise

to the fully retarded position.ThentVS4984HoldingToolto

the EXHAUST camshaft gear and apply force in an anti-

clockwise direction in order to ensure slack on the secondary

chain on the tensioner plunger side.

4.9.9 Whilst continuing to apply this force, tighten the INLET camshaft

gear bolt.

4.9.10 Repeat this procedure on the left-hand bank.

IMPORTANT: Remove all tools.

4.10 LATER ENGINES

Primary chain tensioners

These primary chain tensioners have a ratchet system on the

tensioner plunger.

WARNING: When compressing the plunger DO NOT release

the ratchet until the plunger has fully retracted into its bore

or damage to the ratchet system will result.

The plunger is compressed using a vice, and retained in this

position using VS4975T8 Locking Pin, from Kit VS4980.

4.10.1 Slowly compress the tensioner plunger using minimal force, and

insert VS4975T8 Locking Pin to retain the retracted plunger

position.

4.10.2 Fit the tensioner to the engine.

4.10.3 Pull out VS4975T8 Pin to actuate the plunger onto the chain rail.

Tightening camshaft gear bolts:-

4.10.4 Work on the right-hand bank.

IMPORTANT: On later engines, Jaguar and Land Rover

instruct that the INLET camshaft gear bolt is tightened rst,

followed by the EXHAUST gear bolt.

WARNING: On these engines the INLET camshaft gear bolt

MUST BE tightened before the EXHAUST camshaft gear

bolt. Failure to tighten the INLET camshaft gear bolts rst,

will result in engine damage.

4.10.5 Fit VS4984 to the EXHAUST camshaft gear and apply force, in

an anti-clockwise direction, to tension the primary chain on its

drive side, allowing the tensioner plunger to fully extend

outwards.

4.10.6 Whilst applying force with VS4984 Holding Tool, tighten the

 INLETgearboltrst,andthentightenEXHAUSTgearbolt

4.10.7 Repeat procedure on the left-hand bank.

01284 757500

sales@sealey.co.uk

www.sealey.co.uk

01284 703534

Web

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.

4.9.4 TightentheEXHAUSTcamshaftgearbolt(g.44).

4.9.5 Fit VS4984 Holding Tool to the EXHAUST gear and apply force

to the Tool, in an anti-clockwise direction, in order to ensure

slack on the secondary chain on the tensioner plunger side.

4.9.6 Whilst applying this force, tighten the EXHAUST camshaft gear

bolt.

4.9.7 If engine does not have VVT, continue to apply force with

 VS4984andtightentheINLETcamshaftgearbolt(g.45).

VS4987 VVT Setting Tool

 Someearlyengines,arettedwithVTT,anditisnecessaryto

use VS4987 Setting Tool before tightening the INLET camshaft

gear bolt.

4.9.2 Fitthebackplateandtensionerunittotheengine(g.42).

VS4986 Tensioner Wedge Set

4.9.3 Fit the VS4986 Wedge between the tensioner plunger and the

 chainrailtollanygap,removingslackfromthechain(g.43).

NOTE: VS4986 is a pair of Tensioner Wedges and can be used

as a single Wedge or in a combination of two Wedges,

dependant upon the gap between plunger and rail.

g.42

g.43

g.44 g.45

Sole UK Distributor, Sealey Group,

Kempson Way, Suffolk Business Park,

Bury St. Edmunds, Suffolk,

IP32 7AR

Original Language Version

Tightening camshaft gear bolts:-

IMPORTANT: On early engines, Jaguar instruct that the

EXHAUST camshaft gear bolt is tightened rst, followed by

the INLET gear bolt.

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 dispose of it according to

local regulations.

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