VS12901. INTRODUCTION & APPLICATIONS

3.1. ContentFront Timing Belt1 VS1290/01 Camshaft Locking Tool (Pair)2 VS1290/02 Camshaft Locking Adaptor (Pair) SILVER (2.5 engine)3 VS1290/03 Camshaft Locking Adaptor (Pair) GOLD (2.0 engine)4 VS1290/04 Crankshaft Locking Pin5 VS125/T1 Tensioner Locking Pin (825)Rear Camshaft Belts6 VS1290/05 Rear Cam Sprocket Setting Tool7 VS1290/06 Rear Cam Sprocket Setting Tool (825)8 VS1290/07 Rear Cam Sprocket Spreader9 VS1290/08 Rear Cam Sprocket Guide Pin (Pair)-- VS1290/84 Case + Insert3.2. Associated ToolsUse with:Crankshaft Pulley Holding Tool (45/75/Freelander) VS1292Camshaft Locking Adaptor Set (MGZT/ZT-T 190 Models) VS4617.

1.1. INTRODUCTIONThe VS1290 Kit includes the engine timing belt replacement tools for the 2.0 and 2.5 variants of the KV6 quad cam engine in MG Rover 825, 45and 75 MGZS & MGZT/ZT-T (160/180) and Land Rover Freelander models (Note: For MGZT/ZT-T 190 engines - see 3.2 Associated Tools). TheKV6 quad cam engine has evolved over a number of years and the original version uses a different timing tools combination to the later enginevariants. However some of the timing tools are common to all applications.The Rover KV6 engines have a front timing belt and two rear camshaft belts and therefore replacement of all 3 belts is covered by the tools in the kit.1.2. APPLICATIONSMG Rover: 825 (96-99), 45, 75 MGZS (180), MGZT/ZT-T (160/180) (99-) Land Rover: Freelander (00-)Note: For MG ZT/ZT-T (190) models, Camshaft Locking Adaptor Set is additionally required (not included in VS1290 Kit - see 3.2 Associated Tools)

The VS1290 Kit covers timing belt replacement on the 2.0 and 2.5 litre KV6 quad cam engines which have a front timing belt and two rear camshaft belts.This information details the use of the tools required for belt replacement as - Section 4.1. - Front Timing Belt replacementSection 4.2. - Rear Camshaft Belt replacement Belt replacement procedures on all KV6 variants are basically the same and this information covers all applications. Note: Most tools are common to all engines but where a tool is required for a specific model/engine variant, it is detailed. 4.1. Front Timing Belt It will be necessary to raise and support the front of the vehicle and also to support the engine.Remove the right-hand front wheel, splash guard and rear cover of left-hand cylinder bank (to view camshaft position). 4.1.1. The crankshaft timing position is established by turning the crankshaft in a clockwise direction to -

Rover 825 - achieve position 60O BTDC and check that the hubs of the rear camshaft sprockets (left-hand bank) are positioned as fig. 1.Then insert VS1290/04 Crankshaft Locking Pin through the hole located in the lower crankcase under left-hand cylinders to 'lock' the crankshaft.

p WARNING! Ensure that Health and Safety, local authority and general workshop practice regulations are adhered to when using tools.7 DO NOT use tools if damaged.3 Maintain tools in good and clean condition for best and safest performance.3 Ensure that a vehicle which has been jacked up is adequately supported with axle stands.3 Wear approved eye protection. A full range of personal safety equipment is available from your Sealey dealer.3 Wear suitable clothing to avoid snagging. Do not wear jewellery and tie back long hair.3 Account for all tools, locking bolts, pins and parts being used and do not leave them in or near the engine.p WARNING! Incorrect or out of phase camshaft timing can result in contact between the valve head and the 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.

2. SAFETY INSTRUCTIONS

3. CONTENTS & ASSOCIATED TOOLS

4. INSTRUCTIONS

V6 PETROL ENGINE SETTING/LOCKING TOOL KITFOR MG ROVER/LAND ROVER KV6

VS1292

fig. 1VS1290, VS4617 - 2 - 230305

VS4617

Rover 45/75 & MG models/Freelander - align the white mark on the crank pulley with the 'SAFE' arrow timing mark on the mounting plate. Check that the timing marks on the rear camshaft sprockets (left-hand bank) are aligned as fig. 2.

4.1.2. It will be necessary to remove belt covers, auxiliary belt/tensioner, alternator, PAS pump (move sideways, do not disconnect hoses), AC compressor, mounting bracket etc. and drain engine oil. On automatic transmission also remove dipstick.

4.1.3. The crankshaft pulley must be removed in order to remove front timing belt on Rover 45, 75, MG models and Freelander. Use VS1292Crankshaft Pulley Holding Tool (Associated Tool, not in kit) to counter-hold the pulley whilst releasing the centre bolt - fig. 3. VS1292 must also be used when installing the pulley.

fig. 3fig. 2

4.1.4. For Rover 45/75 MG models/Freelander - remove the rubber blanking plug from around the belt tensioner.4.1.5. Turn the timing belt tensioner clockwise to release tension and then remove. WARNING! Do not loosen the allen screw which holds the

tensioner pulley.4.1.6. Using a vice, carefully compress the tensioner plunger until the holes in the body and plunger align, and insert VS125/T1 Pin to keep

the plunger depressed - fig. 4.4.1.7. Remove the front timing belt. WARNING! DO NOT rotate the crankshaft with the timing belt removed.4.1.8. Remove the front oil seals from both exhaust camshafts.4.1.9. Select the appropriate Adaptor VS1290/02 (2.5 engine except 190 variants) or VS1290/03 (2.0 engine) and attach it to VS1290/01

Locking Tool to make a Locking Tool Assembly fig. 5. Note: for MGZT/ZT-T 190 variants use VS4617 Adaptor Set (Associated Tool not in kit). These Locking Tool Assemblies are used to 'lock' the camshafts whilst the front sprocket bolts are released or tightened.

Note: Two Locking Tool Assemblies are required, one for each front camshaft sprocket.

fig. 5

fig. 64.1.10. To 'lock' the camshaft insert the pegs of the Camshaft Locking Adaptor into the front sprocket hub and then insert the Locking Tool spindle

into the end of the exhaust camshaft (location pin into slot in camshaft) - fig. 6.Note: Once the pegs have been inserted it can be difficult to align the spindle for insertion into the end of the camshaft. Use of a drivebar in the

square drive hole provided in the Locking Tool, will assist alignment. WARNING! Damage to camshafts can result if an attempt is made to release or tighten the sprocket bolts without these tools being installed.

4.1.11. Remove and discard the sprocket bolts and then remove the Locking Tools. Remove the front sprockets complete with hub assemblies.4.1.12. Clean the sprockets and hubs and assemble back onto the camshafts. Screw in new sprocket bolts to finger tight, allowing the sprockets to

turn freely but not to tilt.4.1.13. The Camshaft Locking Tool Assemblies are now refitted. However as the new belt will not pass over these tools once they are installed,

place the new belt in position prior to fitting the tools.Fit both of the Tool Assemblies to the front camshaft sprocket hubs and into the ends of the exhaust camshafts.

4.1.14. Turn the sprockets fully clockwise and commence fitting the new timing belt, in an anti-clockwise direction, starting at the crankshaft gear.WARNING! When fitting the belt over the front camshaft sprockets turn each sprocket only the minimum amount required to fit the belt ontothe sprocket teeth.

4.1.15. Turn the tensioner clockwise to rest against the belt and install the tensioner unit, applying Loctite to the bolt threads. Remove VS125/T1Locking Pin to release the tensioner plunger.

4.1.16. For Rover 45/75 MG models/Freelander - re-fit the rubber blanking plug around tensioner.4.1.17. With the camshaft Locking Tool Assemblies still in place, tighten the sprocket bolts to 27Nm + 90O.4.1.18. Remove both Camshaft Locking Tool Assemblies and, for Rover 825, remove VS1290/04 Crankshaft

Locking Pin.4.1.19. Re-assemble engine components but DO NOT replace the exhaust camshaft oil seals if the rear belts are

to be replaced. Replace engine oil.4.2. Rear Camshaft BeltsThe rear camshaft belt replacement procedure applies to both the right-hand and left-hand belts, however replacement should be carried out on one belt at a time.Replacing a rear camshaft belt involves the removal of the two cam sprockets complete with the existing belt, as an assembly, whilst using a Setting Tool to maintain the relevant position and distance between the two sprockets - fig. 7.Then, on the workbench, a new belt is fitted over the two sprockets which are spread apart to tension the belt and the Setting Tool re-fitted. Guide Pins are used to assist installation of the whole assembly back onto the camshafts - fig. 7.

fig. 4

fig. 7

VS1290, VS4617 - 2 - 230305

It will be necessary to raise and support the vehicle and to remove the right-hand front wheel, splash guard, timing covers, air filter, inlet manifold (upper)and rear engine bracket.4.2.1. Turn the crankshaft in a clockwise direction to -

Rover 825 - position the rear cam sprockets to be able to fit Setting Tool VS1290/06 - fig. 8 (825)Rover 45/75 MG models/Freelander - align white timing marks on crank pulley and 'SAFE' arrow on mounting plate and to align timing marks on the rear sprockets - fig. 8 (45/75 MG models/Freelander).

4.2.2. Select the appropriate Rear Cam Sprocket Setting Tools - fig. 9, VS1290/05 for Rover 45/75 MG models & L-R Freelander or VS1290/06 for Rover 825, and fit to the rear cam sprockets.

Note: Setting Tools must be fitted to sprockets using hand pressure only.4.2.3. Release, remove and discard the sprocket bolts and remove, as an assembly, the sprockets, existing belt and Setting Tool.

fig. 8

fig. 9 fig. 10

4.2.4. On the workbench, remove the belt from the sprockets and clean the sprockets and hubs. Assemble the hubs to the sprockets and place them on a flat surface ready to reconstruct the assembly for re-fitting to the engine.

4.2.5. Rover 825 - Place the sprockets as in fig. 10, noting flanged edges and position/alignment of centre hubs.Rover 45/75 MG models Freelander - Place sprockets as in fig. 11, noting position of locating lugs and timing marks.

4.2.6. Fit new belt around sprockets.4.2.7. Fit VS1290/07 Sprocket Spreader between the sprockets and turn its centre screw to expand

the distance between the sprockets to a position where the Setting Tool can be inserted to re-make the assembly ready to install on the engine - fig. 12.

Note: Setting Tools must be fitted to sprockets using hand pressure only.4.2.8. Remove the VS1290/07 Spreader.4.2.9. Some alignment of the exhaust camshaft will be required when installing the rear cam sprocket/belt assembly and therefore it is necessary

to remove and discard the oil seal from the front of the exhaust camshaft in order to fit the spindle from VS1290/01 Locking Tool. This sealwill already have been removed if the front belt has been replaced.

4.2.10. Fit the spindle into the front of the exhaust camshaft (location pin into slot in camshaft) and use it to carefully turn the camshaft to align thedrive slot in the camshaft rear to match the rear sprocket during installation.

Note: For this alignment application the pegs of the Locking Tool Assembly are not located into the camshaft sprocket hubs. Only the spindle ofVS1290/01 Tool is used.

4.2.11. Fit VS1290/08 Guide Pins into the rear of each camshaft to aid installation of the rear cam sprocket/belt assembly - fig. 13. 4.2.12. Slide the assembly over the Guide Pins.4.2.13. With the cam sprocket/belt assembly installed, remove the Guide Pins and fit new sprocket bolts. Tighten sprocket bolts to 25Nm + 90O.4.2.14. Remove the VS1290/05 or VS1290/06 Setting Tool from the rear cam sprockets and VS1290/01 spindle from the front of the exhaust

camshaft. Fit a new exhaust camshaft oil seal.

fig. 11

fig. 12

fig. 13

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 responsibility is accepted for incorrect use of this equipment.WARRANTY: Guarantee is 12 months from purchase, 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.

VS1290, VS4617 - 2 - 230305

01284 75750001284 703534 sales@sealey.co.uk

Sole UK DistributorSealey Group,Bury St. Edmunds, Suffolk.

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