For 1990-2009 cars

#### Special Tools

• | KM-845

• | MK-6340

• | KM-6625

• | MK-6628

Important: Mark assignments.

1. Using the KM-845 (1), remove the 16 cup tappet.

Important: Observe correct assignment.

2. Lightly coat the sliding surfaces with engine oil.
3. Using the KM-845 (1), insert the 16 cup tappet.

Important: 180 degree offset to marking ignition top dead center (TDC) cylinder number 1.

4. Make alignment mark on the timing belt drive belt.
5. Remove the camshaft sensor of the exhaust camshaft.

• | Disconnect the wiring harness connector.

• | Unscrew the bolt.

6. Remove the camshaft sensor of the intake camshaft.

• | Disconnect the wiring harness connector.

• | Unscrew the bolt.

7. Remove the camshaft adjustment valve, exhaust camshaft.

• | Disconnect the wiring harness connector.

• | Unclip the wiring harness from the cylinder head.

• | Unscrew the bolt.

8. Remove the camshaft adjustment valve, intake camshaft.

• | Disconnect the wiring harness connector.

• | Unscrew the bolt.

9. Unscrew the closure bolt, exhaust camshaft adjuster.
10. Unscrew the intake camshaft closure bolt.
11. Remove the MK-6340 .
12. Slacken the exhaust camshaft adjuster.

Important: 2 mechanics are required.

13. Counterhold at camshaft hexagon.
14. Unscrew the exhaust camshaft adjuster bolt.
15. Detach the exhaust camshaft adjuster.
16. Slacken the intake camshaft adjuster.

Important: 2 mechanics are required.

17. Counterhold at camshaft hexagon.
18. Remove the intake camshaft adjuster bolt and the camshaft adjuster.
19. Remove the rear timing belt cover.

• | Unclip the wiring trough cover.

• | Unscrew the 4 bolts.

20. Remove the thermostat housing bolts and the thermostat housing.
21. Attach the thermostat housing.

• | Use a NEW gasket.

• | Tighten the 4 bolts.

Tighten
Tighten the bolts to 8 N·m (71 lb in).

22. Clean the 4 threads on the rear timing belt cover.
23. Install the rear timing belt cover.
24. Apply locking compound, red, to the 4 bolts.
25. Install the 4 bolts.

Tighten
Tighten the bolts to 6 N·m (53 lb in).

26. Clip in the wiring trough cover.
27. Attach the intake camshaft adjuster.

Important: Do not tighten the bolt.

28. Screw in the bolt.
29. Attach the exhaust camshaft adjuster.

Important: Note the markings on the camshaft sprockets.

30. Insert the MK-6340 .

Important: Align the camshafts using the hexagon until the MK-6628 can be inserted in both camshafts.

31. Insert the MK-6628 into the camshafts.

Important: 2 mechanics are required.

32. Counterhold at the camshaft hexagon.

Tighten
Tighten the exhaust camshaft adjuster to 65 N·m +120 degrees + 15 degrees (48 lb ft +120 degrees + 15 degrees).

Important: 2 mechanics are required.

33. Counterhold at the camshaft hexagon.

Tighten
Tighten the intake camshaft adjuster to 65 N·m +120 degrees + 15 degrees (48 lb ft +120 degrees + 15 degrees).

34. Replace the seal ring.

Tighten
Tighten the exhaust camshaft adjuster closure bolt to 30 N·m (22 lb ft).

35. Replace the seal ring.

Tighten
Tighten the intake camshaft adjuster closure bolt to 30 N·m (22 lb ft).

36. Install the camshaft adjustment valve, exhaust camshaft.

• | Tighten the bolt.

• | Clip the wiring harness to the cylinder head.

• | Fix the wiring harness plug.

37. Install the camshaft adjustment valve, intake camshaft.

• | Tighten the bolt.

• | Fix the wiring harness plug.

38. Install the camshaft sensor, exhaust camshaft.

• | Tighten the bolt.

• | Fix the wiring harness plug.

39. Install the camshaft sensor, intake camshaft.

• | Tighten the bolt.

• | Fix the wiring harness plug.

40. Insert the MK-6628 (1) into the camshaft.

Turn the camshaft by the hexagon until the groove on the end of the camshaft is horizontal, arrows.

41. Remove the KM-6625 .

Detach the screwed connection

42. Set the engine to 60 degrees, measurement 1, before TDC.

Set the crankshaft in the direction of engine rotation to 60 degrees, measurement 1, before TDC.

43. Unscrew the bolt (2) and remove the timing belt tensioner (1).