Sealey VS301 - User Manual

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INSTRUCTIONS FOR:

SPARK PLUG THREAD REPAIR KIT

MODEL No: VS301.V2

Comprehensive and time saving kit of spark plug thread repair tools especially suitable for the repair of deep seated plug configurations. Kit of

tools incorporates taper and plug taps together with intergrated ream. Stepped tap ensures correct alignment of seat cleaner in existing spark

plug hole. Extension tools allow easy access to the bottom of the plug recess. Includes set of plug inserts.

Model No: ..........................................VS301.V2

Plug tap: ........................................... M14x1.25

Step tap: .................................. M14x1.25; M16x1.25

Insert lengths: ..................................9mm and 15mm

Replacement inserts; .............VS301.9 (10pcs), VS301.15 (10pcs)

Original Language Version

Item Description Part No: Item Description Part No:

1 Plug Tap (M14x1.25) VS301.05 5 Insert Drive VS301.02

2 Step Tap (M14x1.25; M16x1.25) VS301.06 6 Seat Cleaner VS301.04

3 Wrench VS301.03 7 Inserts 9mm/15mm VS301.9/VS301.15

4 T-bar VS301.01 8 Allen Key (2.5mm)

VS301.V2 Issue No: 1- 23/01/15

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. SPECIFICATION

4. CONTENTS

 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.

s 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).

Refer to instruction

manual

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protection

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Summary

Introduction to Spark Plug Thread Repair Kit

Operating Instructions

Spark Plug Removal and Initial Tap Insertion

Remove spark plug, insert plug tap into wrench, attach T-bar, and run tap down the hole.

Thread Cutting and Seat Cleaning

Use step tap to cut M16x1.25 thread, then use seat cleaner with plug tap to clean the seat.

Insert Installation

Screw insert onto drive, apply thread locker, install insert into cylinder head, and remove drive.

Final Checks and Cleanup

Clean debris, test internal thread, remove tools, and store kit safely.

Environmental Protection and Disposal

Summary

Introduction to Spark Plug Thread Repair Kit

Operating Instructions

Spark Plug Removal and Initial Tap Insertion

Remove spark plug, insert plug tap into wrench, attach T-bar, and run tap down the hole.

Thread Cutting and Seat Cleaning

Use step tap to cut M16x1.25 thread, then use seat cleaner with plug tap to clean the seat.

Insert Installation

Screw insert onto drive, apply thread locker, install insert into cylinder head, and remove drive.

Final Checks and Cleanup

Clean debris, test internal thread, remove tools, and store kit safely.

Environmental Protection and Disposal

This document describes the Sealey Spark Plug Thread Repair Kit, Model No: VS301.V2, a comprehensive and time-saving kit designed for repairing deep-seated spark plug thread configurations.

Function Description:

The VS301.V2 kit is specifically engineered to address damaged spark plug holes in cylinder heads. It facilitates the creation of new, robust threads, ensuring proper seating and sealing of spark plugs. The kit includes specialized tools such as taper and plug taps with integrated reams, stepped taps for correct alignment, and extension tools for easy access to deep plug recesses. The process involves removing the damaged spark plug, tapping a new, larger thread into the cylinder head, and then installing a threaded insert to restore the original spark plug thread size. The stepped tap ensures that the seat cleaner is correctly aligned with the existing spark plug hole, while the integrated ream helps to prepare the surface. Extension tools are provided to reach deep-seated plug configurations, making the repair process accessible even in challenging engine designs. The kit also includes a seat cleaner to ensure a clean and proper seating surface for the spark plug, which is crucial for optimal engine performance and preventing leaks.

Important Technical Specifications:

Model No: VS301.V2
Plug tap: M14x1.25
Step tap: M14x1.25; M16x1.25
Insert lengths: 9mm and 15mm
Replacement inserts: VS301.9 (10pcs), VS301.15 (10pcs)
Kit Components:
- Plug Tap (M14x1.25) - Part No: VS301.05
- Step Tap (M14x1.25; M16x1.25) - Part No: VS301.06
- Wrench - Part No: VS301.03
- T-bar - Part No: VS301.01
- Insert Drive - Part No: VS301.02
- Seat Cleaner - Part No: VS301.04
- Inserts 9mm/15mm - Part No: VS301.9/VS301.15
- Allen Key (2.5mm) - Part No: VS301.08

Usage Features:

The kit is designed for practical use in a workshop environment. Key usage features include:

Preparation: It is advisable to remove the cylinder head from the engine to minimize damage, or use a method to remove swarf/debris from the combustion chamber with the piston at top dead center. Eye protection is mandatory during this process.
Tapping the new thread: The plug tap (M14x1.25) is used first to clean and prepare the existing thread. Then, the step tap (M14x1.25; M16x1.25) is used with a suitable cutting fluid to cut a new M16x1.25 thread into the damaged spark plug hole. The wrench and T-bar facilitate this operation.
Seat Cleaning: After tapping, the seat cleaner is placed over the plug tap and secured in the wrench. It is then used to clean the spark plug seat on the cylinder head by rotating clockwise with moderate pressure and a suitable lubricant. Excessive force should be avoided.
Insert Installation: The appropriate length insert (9mm or 15mm) is selected and screwed onto the insert drive. The insert drive's sleeve and locking nut secure the insert. A suitable thread locking solution is applied to the exterior thread of the insert. The insert is then carefully screwed into the newly tapped M16x1.25 hole in the cylinder head until fully located. The insert drive is then removed by loosening the locking nut and releasing the sleeve.
Post-Installation: After allowing sufficient time for the thread lock to cure, the combustion chamber should be thoroughly cleaned of any remaining swarf/debris. The internal thread of the newly installed insert should be tested with a spark plug.
Safety Precautions: Users are reminded to wear approved eye protection and appropriate Personal Protective Equipment. All tools should be maintained in good condition. Vehicles must be adequately supported if raised. Jewelry should be removed, and long hair tied back. All tools and components must be accounted for and stored safely after use. The instructions emphasize applying caution and common sense throughout the repair process. It is also crucial to refer to the vehicle manufacturer's service instructions or a proprietary manual for specific procedures and data.

Maintenance Features:

Tool Condition: Tools should be maintained to ensure they are in an adequate condition for safe use and optimum performance. This implies regular cleaning and inspection for wear or damage.
Storage: When not in use, the kit and its components should be stored in a safe, dry, childproof place. This protects the tools from environmental damage and prevents unauthorized access.
Environmental Protection: The document stresses the importance of recycling unwanted materials. All tools, accessories, and packaging should be sorted and taken to a recycling center. If the product becomes unserviceable, any fluids (if applicable) should be drained into approved containers and disposed of according to local regulations.
Parts Support: Sealey provides parts support for this product. Users can log on to www.sealey.co.uk, email sales@sealey.co.uk, or call 01284 757500 to obtain a parts listing and/or diagram.
Warranty: The product comes with a 12-month guarantee from the purchase date, requiring proof of purchase for any claim. Sealey reserves the right to continually improve products and alter data, specifications, and component parts without prior notice. No liability is accepted for incorrect use of the product.