For 1990-2009 cars

#### Special Tools

• | KM-958 Valve Stem Seal Installer

• | KM-6625 Flywheel Locking Device

• | MKM-6086 Automatic Valve Spring Lever

• | SA9102E-A /KM-840 Valve Seal Remover/Replacer

### Removal Procedure

1. Remove all cup tappets. Refer to Valve Lifter Replacement .
2. Remove the spark plugs. Refer to Spark Plug Replacement .

Important: 180 degrees offset to marking ignition TDC cylinder number 1.

3. Make alignment mark on the toothed belt drive belt.
4. Turn the crankshaft to ignition TDC marking, cylinder number 1.
5. Block the crankshaft.

Attach KM-6625 .

• | Detach the screwed connection (1).

• | Insert KM-6625 (2).

• | Tighten the screwed connection (3).

6. Lower the vehicle by its full height.

Notice: Refer to Fastener Notice in the Preface section.

7. Install the supports (1).

• | Adjust the MKM-6086-6 supports.

• | Adjust the support heads so that they are centered in respect of the support feet (3) and tighten.

• | Push the MKM-6086-3 installation shaft (2) into the supports.

• | Place both supports with installation shaft onto the cylinders 2 and 3, align in the center over the spark plug bores and bolt on.

• | Tighten the 4 bolts.

• | Secure installation shaft.

• | Tighten the 2 bolts.

8. Attach the MKM-6086-15 pneumatic adapter (1).

• | Attach the adapter to cylinder number 1.

• | Apply compressed air to cylinder number 1.

9. Attach the MKM-6086-7 lever arm (3).

• | Complete the lever arm with the MKM-6086-8 joint (1) and the MKM-6086-11 removal head (2).

| Important: Removal head must point toward the intake side.

• | Slide assembly on installation shaft over the 1st cylinder

10. Remove the intake valve springs, 1st cylinder.

| Important: Removal head must be positioned vertically over the valve stem.

• | Carefully push the valve springs down using the lever arm MKM-6086-7.

| Important: Observe correct assignment.

• | Remove the valve keepers.

• | Remove the valve head and the valve springs.

11. Remove the valve stem seals.

Pull off with the SA9102E-A /KM-840 (1) remover.

12. Install the valve stem seals.

• | Coat the valve stem with engine oil.

• | Connect the new valve stem seals onto valve stem.

• | Using the KM-958 installer, drive home to limit stop.

Important: Note manufacturer provisions.

13. Complete the MKM-6086-200-1 assembly head.

• | Use the thrust piece MKM-6086-200-10.

• | Put together the assembly head consisting of mount (1), fixing sleeve (2), thrust piece (3), spring (4), screw fixing (5) and lever mount (6).

14. Install the intake valve springs, 1st cylinder.

• | Insert the valve springs and valve head.

| Important: Insert the valve cotters with the tapered end toward the valve.

• | Insert the valve cotters (1) in the assembly head MKM-6086-200-1.

- | Slide the plastic clamping sleeve (2) in the direction of the lever arm mount.

- | Push the plastic clamping sleeve toward the valve.

| Important: Assembly head must stand vertically above the valve stem. Valve cotters must engage audibly.

• | Attach the assembly head to the lever arm.

• | Carefully push the valve spring down using the lever arm MKM-6086-7.

Important: Do not make 2nd attempt without inspecting that both valve cotters are seated in the assembly head.

15. Inspect installation position.

Inspect seating of the valve keepers (visual inspection).

16. Transfer the lever arm MKM-6086-7.

• | Remove the lever arm.

• | Detach the assembly head.

| Important: Removal head must point toward the exhaust side.

• | Attach the removal head.

• | Install the lever arm.

17. Remove the exhaust valve springs, 1st cylinder.

• | Carefully push the valve springs down using the lever arm MKM-889-12.

| Important: Removal head must be positioned vertically over the valve stem.

• | Remove the valve keepers

| Important: Observe correct assignment.

• | Remove the valve head and valve springs.

18. Replace the valve stem seals.

• | Pull off with the SA9102E-A /KM-840 remover.

• | Coat the valve stem with engine oil.

• | Connect the new valve stem seals onto the valve stem.

• | Using the KM-958 installer, drive home to limit stop.

19. Attach the MKM-6086-7 lever arm.

• | Insert the valve springs and valve head.

• | Insert the valve wedges in the MKM-889-2 assembly head.

| Important: Insert the valve cotters with the tapered end toward the valve.

- | Push the plastic clamping sleeve toward the lever arm mounting

- | Push the plastic clamping sleeve toward the valve.

| Important: Assembly head must stand vertically above the valve stem. Valve cotters must engage audibly.

• | Attach the assembly head to the lever arm.

| Important: Do not make 2nd attempt without inspecting that both valve cotters are seated in the assembly head.

• | Carefully push the valve spring down using the lever arm MKM-889-12.

20. Inspect installation position.

Inspect seating of the valve keepers (visual inspection).

21. Transfer the pneumatic adapter MKM-6086-15.

• | Interrupt the compressed air feed.

• | Remove the adapter from cylinder number 1.

• | Install the adapter to cylinder number 4.

• | Apply compressed air to cylinder number 4.

22. Replace the valve stem seal of cylinder 4 by analogy with step 7-20.
23. Remove the pneumatic adapter MKM-6086-15.

• | Interrupt the compressed air feed.

• | Remove the adapter from cylinder number 4.

24. Raise the vehicle by its full height.
25. Remove KM-6625 .

Detach the screwed connection.

26. Set the crankshaft to ignition TDC of cylinder 3.

Important: Alignment marking on toothed belt drive wheel must align with marking on rear toothed belt cover.

27. Turn crankshaft evenly by 180 degrees.
28. Block the crankshaft.

Install KM-6625 . Tighten the bolted connection.

29. Lower the vehicle by its full height.
30. Replace the valve stem seal of cylinders 2 and 3 by analogy with Step 7 to Step 21.
31. Remove the pneumatic adapter MKM-6086-15.

• | Interrupt the compressed air feed.

• | Remove the adapter from cylinder number 3.

32. Remove the automatic valve spring lever MKM-6086 .

• | Release the installation shaft.

• | Loosen the bolt.

• | Remove both supports with the installation shaft.

• | Remove the 4 bolts.

• | Remove the installation head from the lever arm.

### Installation Procedure

1. Install the spark plugs. Refer to Spark Plug Replacement .
2. Raise the vehicle.
3. Remove KM-6625 .

• | Detach the screwed connection.

• | Tighten the bolted connection.

• | Use new nuts.

4. Set the engine to 60 degrees (measurement l) before TDC.

Set the crankshaft in direction of engine rotation to 60 degrees (measurement l) before TDC.

5. Install the cup tappet. Refer to Valve Lifter Replacement .