Alfa romeo Service Manual: petrol engine TWIN CAM Setup/LOCKING tool KIT. pdf

SAFETY INSTRUCTIONS
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.
? 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.
? 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.
? WARNING: The warnings, cautions and instructions discussed in
this instruction manual cannot cover all possible conditions and
situations that may occur. It must be understood that common sense
and caution are factors which cannot be built into this product, but must
be applied by the operator.
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.
2. INTRODUCTION & APPLICATIONS
2.1 Introduction.
This new timing kit incorporates the unique AL-Fi System of Camshaft
setting plates covering all the current ALFA ROMEO Twin Spark and
2.0JTS range of engines. The kit also provides the special timing and
balancer shaft tensioning tools required for timing belt replacement
applications on ALFA engines.
4. INSTRUCTIONS
Alfa Romeo 1.4, 1.6, 1.8 & 2.0 Twin Spark + 2.0JTS petrol engines.
4.1 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.
4.1.1 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: must be when it is 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.
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. Inter-changeable Setting Plates are
mounted on to 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”
4.1.3 Both camshaft sprockets are released and free to turn on
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.
4.1.4 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.
4.2 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.
VS4910 – 1 – 050607
Page 4
4.3 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 on to 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.
4.4 Selecting the correct Al-Fi parts and assembling the Camshaft
Setting Plate system for use.
4.4.1 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).
4.4.2 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
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).
4.6
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.
4.7
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).
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.
INFORMATION: For a copy of our latest catalogue and promotions call us on 01284 757525 and leave your full name and address, including postcode.
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.
4.8 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).

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