HAZET-WERK

HÖCHSTE TECHNOLOGIE IN DER WERKZEUGFERTIGUNG SEIT 1868

HIGHEST TECHNOLOGY IN TOOL MANUFACTURE SINCE 1868

2588/19
2988/7
Betriebsanleitung
Werkzeug-Sortiment für Motoreinstellung an
Operating Instructions
Engine Timing Tool Set for
Mode d’emploi
Jeu d’outils pour le calage de distribution sur
Instrucciones de uso
Juego de herramientas para el calado de distribución en
Bedieningsinstructies
Gereedschap-assortiment voor de motorafstelling van
Instruzioni d’uso
Assortimento di utensili per la messa in fase per

AUDI,
BMW SEAT,
N42SKODA,
/ N46VOLKSWAGEN
/ N46T
222590
 D .......................................... 07...16
13 ...21
USA GB ........................ 17...26
23 ...31
F .......................................... 27...36
33 ...41
E .......................................... 37...46
43 ...51
NL .......................................... 53 ...61
47...56
I .......................................... 63 ...71
57...66
III. 2.2007/0.5 be/AST
222590I.10.2008/be.PDF

HAZET-WERK• ª
HAZET-WERK •ª 101004046161• D-42804
• D-42804Remscheid
Remscheid• Germany
• Germany
ºº+49 •¬
92-0• ¬
+49(0)(0)21219191/ 7/ 792-0 +49(0)(0)21219191/ 7/ 792-200
+49 92-200•ø
375
375 •øhazet.com •©
hazet.com• © info@hazet.de
info@hazet.de

22
2988/7
1 2

3 4

5 6

7 8

3
9 10

11 12

13 14

15 16

4
17 18

19 20

21 22

23 24

5
 Applications / Affectations / Aplicaciones
Toepassingen / Applicazioni

HAZET 2988/7 Werkzeug-Sortiment für Motoreinstellung

HAZET 2988/7 Engine Timing Kit
HAZET 2988/7 Jeu de réglage du calage
HAZET 2988/7 Juego de calado del motor
HAZET 2988/7 Set Motorafstelset
HAZET 2988/7 Kit di regolazione della fasatura

BMW N42 / N46 Doppelnockenwellen-Benzinmotoren

BMW N42 / N46 Twin Camshaft Petrol Engines
BMW moteurs à essence à double arbre à cames N42 / N46
BMW motores de gasolina con doble árbol de levas N42 / N46
BMW N42 / N46 Benzinemotoren met dubbele nokkenas
Motore a benzina a doppio albero a camme BMW N42 / N46

N42 – 316i, 318Ci, 318i, 318ti (E46)

N46 – 118i, 120i, (E87)

316i, 316ti, 318Ci, 318ti, 320i, (E46 / E90 / E91)
X3 2.0i (E83)
Z4 2.0i (E85)

N46T – 118i, 120i, (E81 / E87)

318i, 320i (E90 / E91 / E92 / E93)
520i (E60)

6
 USA
USA 1 For
� For Your
Your Information
Information
Dear Customer,
You have made a good choice.
This HAZET tool in front of you is
a high-quality product that will
make your work easier.
1. General Information
• Please make sure that the user of these
tools carefully reads these operating instruc-
tions and fully understands all information
given before they are used.
• These operating instructions contain impor-
tant advice that is necessary for a safe and
trouble-free operation of your HAZET Tools.
• For effective use of the tools as intended, it
is essential that all safety and other infor-
mation in these operating instructions is
adhered to.
• For this reason, always keep these opera-
ting instructions together with your HAZET
Engine Timing Tool Set.
• This tool set has been designed exclusively
for specific applications. HAZET emphasi-
zes that any modification to the tool set
and/or use on an application not detailed to
its intended application are strictly forbid-
den.
• HAZET will not be liable for any injuries to
persons or damage to property originating
from improper application, misuse of the
tools or a disregard of the safety instruc-
tions.
• Furthermore, the general safety regulations
and regulations for the prevention of acci-
dents valid for the application area of these
tools must be observed and respected.
GB
GB
CAUTION!
This symbol marks important specifi-
cations, dangerous conditions, safety
risks and safety advice.
ATTENTION!
This symbol marks advice which if
disregarded results in damage, mal-
function and/or functional failure of
the tools.
CRANKSHAFT / FLYWHEEL
This figure marks the tool which has
to be used to lock the crank-
shaft/flywheel on the indicated
vehicle.
CAMSHAFT
This figure marks the tool which has
to be used to lock the camshaft on
the indicated vehicle.
INJECTION PUMP
This figure marks the tool which has
to be used to lock the diesel injection
pump on the indicated vehicle.
TENSIONER ROLLER
This figure marks the tool which has
to be used to operate the tensioner
roller on the indicated vehicle.
FRONT PANEL
This figure marks the tool which has
to be used to mount/dismount the
front panel on the indicated vehicle.

2. Explanation of Symbols
ATTENTION: Please pay attention to these
symbols!
Read the Operating Instructions!
The user/owner of this tool set is
obliged to observe the operating
instructions and should ensure all
users of this tool set use it according
to the information given in this
manual.
NOTICE!
This symbol marks advice which is
helpful when using the tools.

Maintenance workwork
Maintenance on engines must must
on engines be carried out only
be carried outby
only by
experienced mechanics.
experienced Always
mechanics. wearwear
Always personal protective
personal equipment.
protective equipment.

17
23
 USA
USA �
1 For Your Information
3. Liability and Warranty
Any deviation from the intended use
and/or any misapplication of the
tools is not allowed and will be con-
sidered as improper use.
• Any claims against the manufacturer and/or
its authorized agents because of damage
caused by improper use of the tools are
void.
• Any personal injury or material losses
caused by improper use of the tools are the
sole responsibility of the operator and user.
GB
GB
5. Disposal
• For disposal, clean tools and disassemble
them according to the regulations for work
safety and environmental protection.
Components can be recycled.
• Metal components can be scrapped.
• The reduction of the pollution as well as the
protection of the environment are the central
points of our activities.

4. Spare Parts
• Only use the manufacturer’s original spare
parts.
• Unsuitable or defective spare parts may
cause damage, malfunction or total failure of
the tools.
• The use of non approved spare parts will
void all warranty, service and liability claims
as well as all claims for compensation
against the manufacturer or its agents, dis-
tributors and sales representatives.

HAZET - environmental protection is of funda-

mental importance for us.

Maintenance work on engines must be carried out only by

Maintenance work on engines must be carried out only by
experienced mechanics. Always wear personal protective equipment.
experienced mechanics. Always wear personal protective equipment.
24
18
 USA � For Your Safety GB
USA
USA �
2 For
For Your
This paragraph gives an overview of
Your Saftey
Safety
service instructions, or a
GB
GB
suitable pro-
This paragraph
important gives
security an overview
advice of
to help to service instructions,
prietary or a suitable
manual, to establish pro-
the current
important
ensure thesecurity
optimal advice to help
protection to
of the prietary manual,
procedure to establish the current
and data.
ensure the as
personnel optimal
well asprotection
the safeof and
the procedure and data.
personnel
trouble-free operationas of well
the as
toolthe
set. safe and 3. Appropriate Use
trouble-free operation
Additionally, of the chapters
the different tool set. contain 3. Appropriate Use
Additionally,
security advice the
thatdifferent
is marked chapters contain
with symbols in
security
order to advice that is marked
avert immediate with
danger. symbols in
Furthermore,
order to avert Operational reliability can only be ensured, if
all stickers andimmediate
labels on danger.
the toolFurthermore,
set must be Operational
all stickersand
andmust
labels the tool set isreliability
used as can only and
intended be ensured,
in compli-if
observed beon thelegible.
kept tool set must be
the tool settheis indications
used as intended
observed and must be kept legible. ance with given inand thein compli-
operating
ance with theIn
instructions. indications
addition given
to theinsafety
the operating
advice
instructions.
given in these In addition
operating to the safety advice
instructions, the
1. General Aspects given insafety
general theseregulations,
operating regulations
instructions, for the
• This tool1. set
General Aspects
was developed and manu- general safety
prevention regulations,and
of accidents regulations
regulationsfor the
for
• This toolaccording
factured set was to developed and manu-
the technical norms prevention of accidents
environmental protection and beingregulations
valid for the for
factured
and according
standards validto at
thethe
technical
time andnormsis environmental
application areaprotection
of this toolbeing setvalid
havefor to the
be
and standards
considered to bevalidoperationally
at the time reliable.
and is applicationand
observed area of this tool set have to be
respected.
considered tothebetools
Nevertheless, operationally
can presentreliable.
a dan- observed
• This HAZET and respected.
Tool Set is intended for the
Nevertheless,
ger when they the tools
are not canaspresent
used intendeda dan-
or in • This
This HAZET
HAZET Tool Tool Set
Setisbelts
isintended
intended for for
useandon
the
replacement of timing on diesel
ger inappropriate
an when they areway not used as intended or
by non-qualified in
per- engines
replacement of BMW Vehicles,
ofoftiming e.g. - For engine
petrol engines AUDI,beltsSEAT, onSKODA
diesel and
an inappropriate
sonnel. Please make way sure
by non-qualified per-
that any person timing.
petrol engines of AUDI, SEAT, SKODA and
VW vehicles.
sonnel.this
using Please
tool or make sure out
carrying thatmaintenance
any person
usingcarefully
work this toolreads
or carrying out maintenance
these operating instruc- • VW
The vehicles.
improper use of the tools or the
work carefully
tions and fullyreads these operating
understands instruc-
all information • disregard
The improper of theuse of advice
safety the tools may orcause
the
tions and
given, fullyusing
before understands
the tools. all information disregard
severe injuryof or
thedeath.
safety advice may cause
given,
• Any before using
modification ofthe
thetools.
tools is strictly for- • severe injury orfrom
Any deviation death.
the intended use and/or
• Any modification of the tools is strictly for-
bidden. • any
Any deviation
misapplicationfrom the of intended
the tool use set and/or
is not
bidden. any misapplication
allowed of the toolasset
and will be considered is not
improper
• All indications concerning setting values and
• setting
All indications allowed and will be considered as improper
use.
rangesconcerning setting values and
must be observed.
setting ranges must be observed. use. claims against the manufacturer and/or
• Any
2. User’s / Owner’s • its
Anyauthorized
claims against agentsthe because
manufacturer and/or
of damage
2. User’s
Liability/ Owner’s its authorized
caused agentsuse
by improper because
of the toolof damage
set will
• Keep Liabilityinstructions together
the operating caused
be void.by improper use of the tool set will
• Keepthe
with the
tooloperating instructions together
set at all times. be void.
• Any personal injury or material losses cau-
• with the
This tooltool
set set at all times.
is intended exclusively for use • sed
Any by personal
improper injury
useorare
material
the sole losses cau-
responsi-
• Thisexperienced
by tool set is intended
mechanics.exclusively for use sed by
bility of improper
the operator useand
are user.
the sole responsi-
by experienced bility of the operator and user.
• The tool set mustmechanics.
only be used if it is in good 4. Storage
• The tool set
working must only be used if it is in good
order. 4. Storage
• working
All safetyorder.
equipment, e.g. fire extinguisher The tool set has be stored
• All safety
etc., mustequipment,
always bee.g. fire extinguisher
within reach and The tool set
according has
the be stored
following conditions:
etc., must
should always regularly.
be checked be within reach and according the following conditions:
should be checked • Keep tool set in a dry and dust-free place.
• In addition to the regularly.
safety advice given in •• Keep toolexpose
set in athe
drytool
and set
dust-free place.or
• these
In addition to theinstructions,
operating safety advicethe given
general in Do not to liquids
these operating
safety regulations,instructions, the the
regulations for general
pre- • Do not expose
aggressive the
substances. tool set to liquids or
safety regulations,
vention of accidents regulations for the pre-
and regulations for • Do aggressive
not storesubstances.
the tool set outdoors.
vention of accidents
environmental protection and regulations
being for
valid for the •• Keep
Do nottool
storesetthe
outtool set outdoors.
of reach of children
environmental
application areaprotection being
of this tool setvalid
haveforto the
be •• Keep tooltemperature:
Storage set out of reach
-10°Coftochildren
+40°C
applicationand
observed area of this tool set have to be
respected. •• Relative
Storage temperature:
air humidity: max.-10°C60%
to +40°C
observed and respected. • Relative air humidity: max. 60%
These instructions are provided as a
These only.
guide instructions
Always are provided
ensure as a
you pos-
guideand
sess only. Always
can make ensure
referenceyoutopos-
the
sess andmanufacturer’s
vehicle can make reference to the
appropriate
vehicle manufacturer’s appropriate
Maintenance work on engines must be carried out only by
Maintenance work on engines must be carried out only by
experienced mechanics.work
Maintenance Always wear personal
on engines must be protective
carried equipment.
out only by
experienced mechanics. Always wear personal protective equipment.
experienced mechanics. Always wear personal protective equipment.
25
25
19
 facturer’s procedures are adhered to.
• Do not use solvents or cleaning fluids like
• Before starting to work, disconnect the thinner or benzine on belts, sprockets etc.
battery’s negative terminal.
USA
USA
NOTICE: � 2 For For Your Saftey
Your Do
•
GB
GB
not twist, bend or reverse the timing belt
Safety
for inspection.
Before disconnecting the battery, • The
5. Dangers ensureemanating
that the vehicle from
ownerthe has a
Neverengine
lever ormust force only
the timing belt onto
be turned in the
sprockets.
normal direction of rotation, unless otherwise
Tool recordSet of the car radio code. • noted
Checkby therunning
free vehicleofmanufacturer.
tensioner roller, guide
Before each
• Any vehicle “jacked use, up”check the HAZET
or raised above roller(s) and watersupports
pump. and accessories
Engine • Only use parts,
ground mustTiming Tool Set supported
be adequately for full functio-
with
which are recommended by the manu-
nal efficiency.
axle stands, ramps Do etc.not use the Tool Set if • Check engine for leakages, if detected
its functional efficiency cannot be eye
ensured or if facturer.
eliminate them.
• Wear protective clothing, safety
damage is detected.
protection. EnginesIf have the Tool Set is used, • Repair
rotating Replacework mustbelts
old timing be carried
with a new outone
exclu-
and
when it is not in full
components, so avoid wearing working order, you risk sively
ensure by authorized
that it has the persons.
correct teeth profile.
severe
looseinjuries
clothing, to persons
jewelleryand which to pro- • Only
etc.damage Ensureusetimingthe tools
belt within
tensiontheis prescribed
correctly
perty.
canDefective
get caught toolsupmay in cause
the enginesevere injury. places,
adjusted and (adheregoverned under
to vehicle the current
manufacturer’s
moving In order
parts. to avoid injury or damage, it is regulations
instructions).relating to the working environ-
• Always essential
account thatforthe toolsfollowing
being fundamen-
used. • ment.
Observe torque specifications (adhere to
Do not talleave
safety themguidelines
in or near willthe
beengine
observed:when • vehicle
For safety reasons any
manufacturer’s modification of
instructions)
turning the engine over, or when the job is • HAZET
ATTENTION: Pay regard toolstois the
strictly forbidden.
timing Any modi-
belt’s direction of
Incorrect or out of phase camshaft
finished. fication
rotation of the is
which tools will result
indicated by an in arrow.
immediate
timing
Parts that canare result
not in contact
fixed can be between exlcusion from warranty and liability.
hurled • Do not reuse used timing belts. Always fit a
valves
aroundand and pistons
may cause causingsevere damage
injury new one.
to theorengine.
death toAlways persons ensure
in thethe work correct
area. • If the timing belt shows damage, find out
tools Objects
are usedmay andbe that the vehicle manu-
damaged. origin and remedy deficiencies.
• facturer’s
Do not useprocedures the lockingare pinsadhered
for lockingto. the
• Do not use solvents or cleaning fluids like
• Before
the crankshaftstarting whento work,
tightening disconnect
or releasingthe thinner or benzine on belts, sprockets etc.
battery’s
the crankshaftnegative bolt.terminal.
• Do not twist, bend or reverse the timing belt
•NOTICE:
The timing belt must not be used for locking for inspection.
the camshaft Beforesprocketdisconnecting when slackening
the battery, the
nuts. ensure that the vehicle owner has a • The engine must only be turned in the
normal direction of rotation, unless otherwise
• Do not record forciblyoftwist the car a new radiobeltcode.or bend it
noted by the vehicle manufacturer.
through a radius of less
• Any vehicle “jacked up” or raised above than 25 mm.
• Only use parts, supports and accessories
ground must be adequately supported with
which are recommended by the manu-
axle stands, rampsMaintenance etc. work on enginesfacturer.
must be carried out only by
• Wear protective clothing, safety eye
experienced
protection. Engines have rotating mechanics. Always • Repair
wear workprotective
personal must be carried
equipment. out exclu-
components, so avoid wearing sively by authorized persons.
26 loose clothing, jewellery etc. which • Only use the tools within the prescribed
can get caught up in the engine places, and governed under the current
moving parts. regulations relating to the working environ-
ment.
r Your Safety
• Always account for tools being used. GB
Do not leave them in or near the engine when • For safety reasons any modification of
e • Never
turninglever or forceover,
the engine the timing
or when belttheonto
jobtheis HAZET tools is strictly forbidden. Any modi-
sprockets.
finished. fication of the tools will result in immediate
• CheckParts free that
running are of nottensioner
fixed canroller, be hurled
guide exlcusion from warranty and liability.
ZET around
roller(s)
rtio-Your Safety and and
water may
pump. cause
or death to persons in the work area.
GB severe injury
et if • Check engine for leakages, if detected
NeverObjects
eor if • eliminate lever them.or may
forcebe thedamaged.
timing belt onto the
ed, •• sprockets.
Do not use
Replace old the
timinglocking
belts pins with a fornewlocking the
one and
risk • ensurethe crankshaft
Check free
that running
it haswhentheoftightening
tensioner
correct or
teeth releasing
roller, guide
profile.
ZET the crankshaft
roller(s) and bolt.
water pump.
pro-
tio- • Ensure timing belt tension is correctly
ry. • The timing
Check
adjusted enginebelt must
(adhere forto not
leakages,
vehiclebe used if for locking
detected
manufacturer’s
et if the camshaft sprocket when slackening the
it isif
or eliminate
instructions). them.
en- nuts.
Replace old timingspecifications
belts with a new one and
ed, • Observe torque (adhere to
d:
risk • Do not that
ensure
vehicle forcibly
it hastwist
manufacturer’s ainstructions)
the correct new belt teethorprofile.
bend it
pro- • Pay through
Ensure regard atiming
radius
to the of timing
belt lesstension
than 25 ismm.
belt’s correctly
direction of
ry.
haft adjustedwhich
rotation (adhere to vehicle
is indicated by manufacturer’s
an arrow.
een
it is • Do instructions).
not reuse usedMaintenance timing belts. work Alwaysonfitengines
a must be carried out only by
age
en- • new Observeone. torque
Maintenance (adhere
specifications work ontoengines must be carried out only by
experienced mechanics. Always wear personal protective equipment.
ect • If
d: vehicle experienced
manufacturer’s
the timing belt shows mechanics.
damage, findAlways
instructions) out wear personal protective equipment.
nu- • origin Pay regard
and to
remedy the timing
deficiencies. belt’s direction of
26
haft 20 • rotation
Do not use which is indicated
solvents by an arrow.
or cleaning fluids like
the
 -21

USA
USA2988-27
�
3 Composition
Composition and
and Function
Function
2988-21
2988-22
GB
GB
1. Technical Information / Components of the Set

2588/19 VW AUDI, SEAT, SKODA,

2988/7 BMW
VOLKSWAGEN

2988-23
2588-4 2588-13 (x2)

2588-1 -7

2588-7
2588-12 (x2)
-26

2988-25 2988-26
2588-3 (x2)
2588-9

2588-2
2588-8 2588-10 2988-24

2587
-27
2588-11
2587-1

2587-2 -21 2588-6

2588-5

2988-27 2988-22
2988-21
1 A
AAQty./Contents Audi/VW VAG SEAT SKODA
2587 1x V-159 U-30009 MP-1-302
HAZET No. 1 x
2587-1 Qty./Contents 3387 BMW Tool Reference
VAG U-30009 A
2587-2
2988-21 1x T1x
10020 11.9.270
2588-1 1x T 10050
2988-22 1x 11.9.340
2588-2 1x T 10008
2988-23 1x 11.9.350
2588-3 2x T 20102 VAG 3359 U-40074 MP-1-301
2988-24
2588-4 1x T1x
10016 / T 10074 11.9.292
2588-5
2988-25 1x 1x VAG 2065 A
11.9.291 U-20006 / U-40021
11.9.290 MP-1-300
2588-6
2988-26 1x T1x
10098 A 11.9.293 T 20038 MP-1-312
2588-7 1x VAG 2064 U-20003
2988-27 1x 11.5.120 & 11.9.190
2588-8 1x T 10115
2588-9 1x
2588-10 1x T 40011 T 20046
2588-11 1x T 10092 T 20046
2588-12 2x VAG 3369
2588-13 2x VAG 3411
2. Included
2. Included
• •
2588/19
HAZET 2988/7
Tool Tool
Set for
SetEngine TimingTiming
for Engine AUDI/ BMW
SEAT/ N42/N46
SKODA/ VW
delivered in case with soft foam insert
delivered in case with soft foam insert.
Maintenance work on engines must be carried out only by
Maintenance work on engines must be carried out only by
experienced mechanics. Always wear personal protective equipment.
experienced mechanics. Always wear personal protective equipment.
27
21
 USA 3 Composition and Function GB
3. Prior to Operation Figure 2 page 3
Always ensure tools are used, • Check the timing positions of the camshafts
inspected and maintained in – each camshaft has a rectangular section
compliance with the respective at the rear which has a curved edge on
local, state, national or federal top and a straight edge on the bottom. With
regulations. the engine in the correct TDC engine timing
• Before starting to work, disconnect engine position, the curved edge of the rectangles, on
from power supply. Carefully read operating both camshafts, will be uppermost (on top).
instructions for the engine and if necessary for
the other equipment assemblies and devices Figure 3 page 3
(e.g. radio etc.) • An additional guide to correct camshaft position,
using the exhaust camshaft, is that in the correct
ATTENTION TDC engine timing position, the recesses in
Ensure that the radio code is recorded. the sections of the exhaust camshaft between
the lobes, will be pointing towards the exhaust
CAUTION manifold.
Jacked up vehicles must be secured
adequately Figure 4 page 3
HAZET 2988-27 Flywheel TDC Locking Pin
ATTENTION
Only use appropriate spare parts. • Insert HAZET 2988-27 Flywheel TDC Locking
Pin through the datum hole, which is located
underneath the starter motor, and into the timing
4. Operation hole in the flywheel.
Engine Timing Applications • NOTE: The datum hole can be difficult to locate
N42/N46 Cylinder Petrol Engines and may be constricted by dirt/corrosion.
BMW ATTENTION
4.1 Checking and Adjusting Engine Timing On Automatic Transmissions – there is
a much larger hole in the flywheel very
4.2 Vanos Unit - Removal, Instalation near to the timing hole and checks are
and Alignment required to ensure that this hole has not
4.1 ENGINE TIMING been selected in error. With
Figure 1 page 3

HAZET 2988-27 Locking Pin inserted,
check that the engine will not rotate
• The N42 and N46 1.8 & 2.0 twin camshaft back and forth when turned using a
petrol engines have VANOS variable wrench on the crankshaft pulley bolt.
camshaft timing units on both inlet and
CHECK VANOS UNITS
exhaust camshafts and the BMW Valvetronic
system which varies the timing and the lift of When the engine is turned off, the VANOS
the inlet valves. Units on the inlet and exhaust camshafts
• The Valvetronic layout incorporates a usually ‘lock’ on the camshafts, in their
conventional inlet camshaft and a correct positions. It is essential to check that
secondary eccentric shaft, with intermediate this has occurred, in order to avoid incorrect
levers and followers, activated by a stepper timing adjustment and to check that these
motor. The stepper motor changes the units are in working order.
phases of the eccentric shaft, altering the
action of the inlet valves. All these are housed Figure 5 page 3
in a camshaft carrier bracket in the cylinder head. HAZET 2988-21 Camshaft Turning Tool
Checking camshaft timing Inlet camshaft
• Turn the crankshaft, in normal direction of • Insert HAZET 2988-21 Camshaft Turning
engine rotation, to TDC No.1 cylinder (ignition), Tool in to the slot in the rectangular
using a wrench on the crankshaft pulley centre bolt. section at the rear of the INLET camshaft.

Maintenance work on engines must be carried out only by

experienced mechanics. Always wear personal protective equipment.

22
 USA 3 Composition and Function
• Using a spanner on the hexagon of 2988-21,
check if the camshaft will rotate. If it does turn,
carefully rotate the camshaft against the
direction of rotation, as far as possible, until
it ‘locks’ the VANOS unit.
• NOTE: If the VANOS Unit has ‘locked’ correctly,
the camshaft will not turn.
Figure 6 page 3
Exhaust camshaft
• The same procedure applies to the exhaust
camshaft EXCEPT this camshaft should be
rotated in the direction of rotation.
• NOTE: The exhaust camshaft has a hexagon
to accept a spanner to rotate it but also HAZET
2988-21 Turning Tool can be used if the
vacuum pump has been removed.
ATTENTION
If either of the VANOS Units on the
camshafts cannot be ‘locked’, and are
faulty, they must be replaced – see
Removing and Installing VANOS Units.
Camshaft Setting Plate Assembly
(comprises HAZET 2988-24, HAZET 2988-25 surface of the cylinder head (Do not insert fixing
& HAZET 2988-26)
Figure 7 page 3
• Place HAZET 2988-24 Camshaft Setting Plate
on to the rectangular section at the rear of the
INLET camshaft, and ensure the Plate rests
fully on the surface of the cylinder head. (Do
not insert fixing bolts)
If timing is correct, HAZET 2988-24 Plate two fixing bolts and tighten to secure the
should rest on the cylinder head without any Setting Plate to the cylinder head.
gap, or at most, raised 0.5mm. on the inlet
side only.
Figure 8 page 3
• Place HAZET 2988-25 Camshaft Setting Plate
on to the rectangular section at the rear of the
EXHAUST camshaft, and ensure the Plate
rests fully on the surface of the cylinder head
(Do not insert fixing bolts).
• If timing is correct, HAZET 2988-25 should
rest on the cylinder head without any gap, or
•
at most, raised 1.0mm. on the inlet side only
If the above position cannot be achieved with
the Setting Plates, then it will be necessary to
adjust the timing.
• Remove the camshaft setting plates.
Maintenance work on engines must be carried out only by
experienced mechanics. Always wear personal protective equipment.
GB
Adjusting camshaft timing
Figure 9 page 4
• Slacken the bolts of the VANOS Units on the
inlet and exhaust camshafts.
CAUTION
These bolts are likely to be tight.
It will be necessary to counter-hold
against engine rotation at the crankshaft
pulley centre bolt. Do NOT rely on the
Flywheel Pin to counter-hold when
loosening these bolts.
• Screw in the bolts to finger-tight only, sufficient
so there is no play or tilt on the units. Ensure
that the HAZET 2988-27 Flywheel TDC Locking
Pin is fitted into the timing hole in the flywheel.
Figure 10 page 4
• Place HAZET 2988-24 Camshaft Setting Plate
on to the rectangular section at the rear of the
INLET camshaft, ensuring that the curved edge
of the rectangular plate is uppermost. Align the
camshaft so the Setting Plate rests fully on the
bolts at this stage).
Figure 11 page 4
• Fit HAZET 2988-25 Camshaft Setting Plate
on to the rectangular section at the rear of the
EXHAUST camshaft, ensuring that the curved
edge of the rectangular plate is uppermost.
Align the camshaft so the Plate rests fully on
the surface of the cylinder head. Screw in the
Figure 12 page 4
• Screw in HAZET 2988-26 Securing Screw into
Setting Plate HAZET 2988-25 until it presses on
Setting Plate HAZET 2988-24.
• Screw in the fixing bolt for 2988-24 and tighten to
secure this Setting Plate to the cylinder head.
Figure 13 14 page 4
HAZET 2988-22 Timing Chain Tensioner
Pre-Load Tool
• Remove the timing chain tensioner, and in its
place insert HAZET 2988-22 Tensioner Pre-
Load Tool.
23
 USA 3 Composition and Function
• Screw in the adjusting screw of HAZET 2988- 22,
by hand, until it makes contact with the tensioner
rail but does not apply pressure.
• Remove the old bolts of the VANOS Units Figure
on the inlet and exhaust camshafts and fit new • Remove the positioning motor for the eccentric
bolts. Screw in the bolts to finger-tight only, shaft by undoing the nuts retaining the motor
sufficient so there is no play or tilt on the units.
Figure 15 page 4
HAZET 2988-23 Vanos Alignment Plate
• Fit HAZET 2988-23 VANOS Alignment Tool
to the front of the Units ensuring that its two
location pins enter into the holes in the
Vanos Units and that the Alignment Tool fits
fully on to the surface of the cylinder head.
Figure 16 page 4
• Screw in the two bolts and tighten to secure
HAZET 2988-23 to the cylinder head. Slacken
the Vanos Unit bolts half turn and re-tighten to
finger-tight.
Figure 17 page 5
• Attach a suitable torque wrench to the adjusting
screw of HAZET 2988-22. Turn to apply a pre-
load to the tensioner rail of 0.6 Nm
Figure 18 page 5
• Tighten the bolt of the exhaust camshaft
VANOS unit to the specified torque, followed by
the bolt of the inlet VANOS Unit, again, to the
specified torque – Torque 20Nm. + 90°+ 90°.
• Remove the HAZET 2988-23 Vanos Alignment
Tool, Unscrew the adjusting screw of HAZET
2988-22 and remove the Pre-Load Tool.
ATTENTION
Install the chain tensioner.
• Remove all timing tools and turn the
crankshaft twice (at the crankshaft pulley
centre bolt),in normal direction of engine
rotation, returning the TDC engine timing
position, No.1 cylinder.Insert the Flywheel Figure
TDC Locking Pin and Camshaft Setting
Plates to check timing position, follow the
procedure as described in “Checking
camshaft timing”.
Maintenance work on engines must be carried out only by
experienced mechanics. Always wear personal protective equipment.
24
GB
4.2 VANOS UNITS - Removing, Installing and
replacing Units.
19 page 5
on bracket, rotating the shaft clockwise whilst
pulling the motor backwards out of its bracket.
• Follow the procedure detailed in ‘Checking
camshaft timing’ up to and including
“Checking procedure – VANOS Units”.
• If either of the VANOS Units, on inlet or exhaust
camshafts, cannot be ‘locked’ and are faulty,
they must be replaced.
Removal
Figure 20 page 5
• Slacken the bolts of the VANOS Units on the
inlet and exhaust camshafts.
• CAUTION:
These bolts are likely to be tight. It
will be necessary to counter-hold
against engine rotation at the
crankshaft pulley centre bolt. Do NOT
rely on the Flywheel Pin to counter-
hold when loosening these bolts.
• Screw in the bolts to finger-tight only, sufficient
so there is no play or tilt on the units.
• Ensure that the HAZET 2988-27 Flywheel TDC
Locking Pin is fitted into the timing hole in the
flywheel.
Figure 7 page 3
• Place HAZET 2988-24 Camshaft Setting Plate
on to the rectangular section at the rear of the
INLET camshaft, ensuring that the curved edge
of the rectangular plate is uppermost. Align the
camshaft so the Setting Plate rests fully on
the surface of the cylinder head. (Do not insert
fixing bolt).
11 page 4
• Place HAZET 2988-25 Camshaft Setting Plate
on to the rectangular section at the rear of the
EXHAUST camshaft, ensuring that the curved
edge of the rectangular plate is uppermost.
Align the camshaft so the Plate rests fully on
the surface of the cylinder head.
• Screw in the two fixing bolts and tighten to
secure the Setting Plate to the cylinder head.
 USA 3 Composition and Function
Figure 12 page 4
• Screw in HAZET 2988-26 Securing Screw into
Setting Plate HAZET 2988-25 until it presses
on Setting Plate HAZET 2988-24.
• Screw in the fixing bolt for HAZET 2988-24
and tighten to secure this Setting Plate to the
cylinder head.
Figure 13 page 4
• Remove the timing chain tensioner,
• Fully remove the bolt of the VANOS Unit on the
exhaust camshaft. Lift chain off the sprocket
and feed out and remove the complete
VANOS Unit.
• Repeat this procedure on the VANOS Unit on
the inlet camshaft.
Replacement
Figure 21 22 page 5
• CAUTION:
It is important to note that the Inlet and
exhaust VANOS Units are different. It is
essential to keep the parts of Inlet Unit
separate from the Exhaust Unit. Under 90°.
no circumstances should the parts be
mixed or parts from any other engine
variant be used.
• Inlet Unit part is marked “EIN / IN” and the
Exhaust Unit part marked “AUS / EX”
Installation
• Assemble the Unit of the Inlet camshaft,
including the sensor gear (front plate), and feed
on to the inlet camshaft fitting the chain onto
the sprocket. Screw in a new bolt and tighten
only so there is no play or tilting (finger-tight).
• Assemble and install the Exhaust camshaft
Unit and screw in a new bolt and tighten only
so there is no play or tilting.
ATTENTION:
Press the chain rail, by hand, and ensure
the timing chain is guided within the rail.
Figure 14 page 4
• Insert HAZET 2988-22 Tensioner Pre-Load
Tool and screw in the adjusting screw by hand,
until it makes contact with the tensioner rail.
Maintenance work on engines must be carried out only by
experienced mechanics. Always wear personal protective equipment.
GB
Figure 16 page 4
• Fit HAZET 2988-23 VANOS Alignment Tool to
the front of the Units
Figure 23 page 5
• Ensure that the two location pins of HAZET
2988-23 enter into the holes in the sensor
gears and the Tool fits fully on to the surface
of the cylinder head. Screw in the two bolts to
secure HAZET 2988-23 Tool to the cylinder
head and tighten.
• Unscrew the bolts of the VANOS Units half turn
and then tighten to finger-tight, ensuring that
there is no play or tilting of the Vanos units.
Figure 17 page 5
• Attach a suitable torque wrench to the adjusting
screw of HAZET 2988-22 and turn to pre-load
the tensioner rail to 0.6 Nm.
Figure 24 page 5
• Tighten the bolt of the exhaust camshaft
VANOS unit to the specified torque, followed
by the bolt of the inlet VANOS Unit, again, to
the specified torque – Torque 20Nm. + 90° +
• Remove HAZET 2988-23 Alignment Tool,
• Unscrew the adjusting screw of HAZET
2988-22 and remove the Pre-Load Tool
ATTENTION
Install the chain tensioner.
Remove all timing tools and turn the
crankshaft twice (at crankshaft pulley
centre bolt), in normal direction of engine
rotation, returning the TDC engine timing
position, No.1 cylinder.Insert the
Flywheel TDC Locking Pin and Camshaft
Setting Plates to check timing position as
described in “Checking camshaft timing”.
25
 III. 2.2007/0.5 be/AST
222590 I.10.2008/be.PDF

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