Sealey VSE5939 User manual

TIMING TOOL SET FOR HYUNDAI 1.6D BELT
DRIVE
MODEL NO: VSE5939
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 & 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.
1. SAFETY
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! Wear approved eye protection. Wear appropriate Personal Protective Equipment. A full range of Personal Protective
Equipment is available from your Sealey stockist.
WARNING! Ensure that Health & Safety, Local Authority Regulations and general workshop practice Regulations are adhered to when
using tools.
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.
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).
8DO NOT use tools if damaged.
8DO NOT attempt to start or move a vehicle whilst in gear and with timing devices fitted.
9Wear suitable clothing to avoid snagging. DO NOT wear jewellery. Tie back long hair.
9Ensure that a vehicle that has been raised by a jack is adequately supported. Use axle stands.
9When timing an engine, always prevent the engine from being turned over. Use a notice and / or inhibit the engine.
9Keep children and unauthorised persons away from the work area.
9Maintain tools to ensure that they are in an adequate condition for safe use and optimum performance.
9Account for all tools, parts and components being used. DO NOT leave these in or near the engine.
9Return tools to suitable storage after use.
9When not in use, store in a safe, dry childproof place.
2. INTRODUCTION
Suitable for 1.6CRDi belt drive diesel engines. Contains the essential tools required during timing belt replacement and timing checks.
3. CONTENTS
VSE5939 Issue 1 07/07/22
Original Language Version
© Jack Sealey Limited
Refer to
instructions
Wear eye
protection
Wear protective
gloves
Wear safety
footwear
Wear protective
clothing
PART
NUMBER
DESCRIPTION OEM NUMBER
VSE5939-01 Crankshaft Locking
Tool
09240-2U100
VSE5939-02 Camshaft Locking
Tool
09240-2U300
VSE5939-03 Camshaft Sprocket
Holding Tool
09240-2U400
VSE5939-04 Tensioner Pulley
Holding Tool
09240-2U500
VSE5939-05 Tensioner Locking
Pin
N/A

4. APPLICATIONS
MODELS:
HYUNDAI
i30 (20-22)
i40 (18 - 20)
Kona (20-22)
Tucson (20-22)
i40 (18-20)
KIA
Ceed (20-22)
ProCeed (20-22)
XCeed (20-22)
ENGINE CODES: 1.6CRDi - D4FE, D4FEU3
5. INSTRUCTIONS
5.1. REMOVAL
5.1.1. Rotate the crankshaft clockwise to TDC on cylinder number one.
5.1.2. Ensurethecrankshaftpulleytimingmarksarealigned(g.1)
5.1.3. RemovethestartermotorandttheVSE5935FlywheelLockingTool.(notsupplied)
5.1.4. Remove the crankshaft pulley bolts and crankshaft pulley.
5.1.5. Remove the timing belt lower cover, ensure the crankshaft sprocket timing mark is aligned with the timing mark on the cylinder
 block.(g.2)
5.1.6. FittheVSE5939-01CrankshaftLockingToolusingthehexboltssupplied.(g.2)
5.1.7. Slacken the tensioner pulley securing bolt.
5.1.8. Fit the VSE5939-03 Camshaft Sprocket Holding Tool.
5.1.9. Use a suitable ½” drive wrench with the camshaft sprocket holding tool as a counter hold and slacken the camshaft sprocket bolts.
5.1.10. Rotatethecamshaftsprocketuntilthesprockettimingmarksarealignedwiththetimingmarksonthecylinderhead.(g.3)
5.1.11. Fit the VSE5939-04 Tensioner Pulley Holding Tool and turn the tensioner pulley anti-clockwise and lock into place with the
VSE5939-05 Tensioner Locking Pin.
5.1.12. Remove the Tensioner Pulley Holding Tool.
5.1.13. Remove the timing belt.
5.2. INSTALLATION
5.2.1. Fit new guide pulley and guide pulley bolt, tighten to 42-54 Nm.
5.2.2. Fitnewtensionerpulleyandpulleybolt,atthisstagejustngertightenthebolt.Lockthetensionerintoitsretractedpositionwith
the VSE5939-05 Tensioner Locking Pin.
5.2.3. Ensurethecamshaft,(g.3)crankshaft,(g.4)andhighpressurefuelpump(g.5)timingmarksarealignedcorrectly.
5.2.4. Fit the timing belt and ensure the timing marks on the belt are aligned with the timing marks on the sprockets.
5.2.5. Remove the VSE5939-05 Tensioner Locking Pin.
Original Language Version
© Jack Sealey Limited
TER Y
VSE5939 Issue 1 07/07/22
g.1
g.2
g.3
g.4
g.5

5.2.6. Using the VSE5939-03 Camshaft Sprocket Holding Tool, apply an anti-clockwise torque of 34-44 Nm to the camshaft sprocket.
5.2.7. Tighten the camshaft sprocket bolts to 20-25 Nm.
5.2.8. Remove the Camshaft Sprocket Holding Tool.
5.2.9. Turn the belt tensioner pulley slowly clockwise until the pointer is aligned with the notch.
5.2.10. Tighten the tensioner pulley bolt to 25-34 Nm.
5.2.11. Remove the VSE5939-02 Camshaft Locking Tool.
5.2.12. Ensure the crankshaft high pressure fuel pump, and camshaft sprocket timing marks are aligned.
5.2.13. Remove the VSE5939-01 Crankshaft Locking Tool.
5.2.14. Rotate the crankshaft through two revolutions clockwise, ensure the belt tensioner pointer is aligned with the notch.
5.2.15. Ensure the VSE5939-02 Camshaft Locking Tool can be inserted easily. If it cannot be inserted easily the timing procedure will need
to be repeated.
5.2.16. Tighten the crankshaft pulley bolts to 33-37 Nm.
5.2.17. Reassemble in the reverse order of dismantling.
ENVIRONMENT 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 any fluids (if applicable) into approved containers and dispose of the product and fluids
according to local regulations.
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 is required for any claim.
Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR
01284 757500 01284 703534 [e-mail] www.sealey.co.uk
REGISTER YOUR
PURCHASE HERE
Original Language Version
© Jack Sealey Limited VSE5939 Issue 1 07/07/22