For 1990-2009 cars

#### Special Tools

• | KM-6333 Fixing Rod

• | MK-6340 Locking Tool

• | KM-6351 Assembly Sleeves

• | KM-6625 Flywheel Locking Device

• | KM-J-45000 Remover

### Removal Procedure

1. Open the hood.
2. Disconnect the battery.

• | Disconnect the negative connection from the negative terminal.

• | Loosen the nut.

3. Remove the air cleaner housing. Refer to Air Cleaner Assembly Replacement .
4. Remove the timing belt upper cover. Refer to Timing Belt Upper Front Cover Replacement .
5. Raise the vehicle by its full height.
6. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
7. Lower the vehicle by its full height.
8. Set the engine to "TDC".

Set the torsional vibration balancer in the direction of engine rotation to "1st cylinder TDC" (mark 1).

Important: Recognizable from the lettering "Right" (arrow).

9. Prepare the right half of MK-6340 for use on the U 18 XER engine.

• | Detach the front panel (1) from MK-6340 .

• | Remove the 2 bolts (2).

10. Insert MK-6340 in the camshaft adjuster.

• | Insert MK-6340 (1, 2) in the camshaft adjuster as shown.

| Important: The spot-type marking (4) on the intake camshaft adjuster does not correspond to the groove of MK-6340 during this process but must be somewhat above as shown.

• | The spot type marking (3) on the exhaust camshaft adjuster must correspond to the groove on MK-6340 .

11. Raise the vehicle by its full height.
12. Stop the crankshaft.

Attach KM-6625 .

• | Remove the screwed connection (1).

• | Insert KM-6625 (2).

• | Tighten the screwed connection (3).

13. Remove the torsional vibration damper (1).

Remove the bolt (2).

14. Remove the front drive belt cover (bottom) (3).

Remove the 4 bolts (4).

15. Lower the vehicle by its full height.
16. Block the drive belt tensioner.

Apply tension to the drive belt tensioner (2) in the direction of the arrow, using an allen key (1). Fix using KM-6333 (3).

17. Mark the drive belt direction of rotation.
18. Remove the drive belt.
19. Raise the vehicle by its full height.

Important: Do not damage sealing surfaces.

20. Remove the drive belt drive gear.
21. Remove the crankshaft seal ring (front) with KM-J-45000 .

### Installation Procedure

1. Insert the front crankshaft seal ring (1).

• | Clean the sealing surfaces.

• | Slide the protective sleeve of KM-6351 (2) onto the crankshaft journal.

• | Slide the seal ring over the protective sleeve on the crankshaft journal.

2. Press in the front crankshaft seal ring.

• | Remove the protective sleeve and press the seal ring into the pump housing with KM-6351 (3).

• | Use the bolt (1) and washer (2) of the crankshaft drive gear.

3. Install the drive belt drive gear.
4. Lower the vehicle by its full height.

Important: Threading the drive belt through the engine mount support is only permissible in conjunction with the assembly tool supplied with new toothed belts as otherwise it is possible to damage the toothed belt at this stage by kinking it.

5. Insert the drive belt.

• | Insert the drive belt (1) in the enclosed assembly tool (2)

• | If the drive belt has been used, observe direction of rotation.

• | Guide the drive belt through the engine mount support with the assembly tool.

• | Remove the assembly tool.

Important: Observe direction of rotation.

6. Position the drive belt.

• | Position the drive belt on the intake camshaft adjuster.

• | Position the drive belt on the exhaust camshaft adjuster.

• | Guide the drive belt past the tension roller and place on the drive belt drive gear.

• | Apply tension to the drive belt tension roller and remove KM-6333 .

7. Release tension on the drive belt tensioner.

• | Apply preliminary tension clockwise to the drive belt tension roller.

• | Remove KM-6333 .

• | The drive belt tension pulley automatically moves to the correct position.

8. Raise vehicle by its full height.

Notice: Refer to Fastener Notice in the Preface section.

9. Install the front drive belt cover (lower).

Tighten
Tighten the 4 bolts to 6 N·m (53 lb in).

Important: New bolt must be coated with screw locking compound (red).

10. Install the torsional vibration balancer.

Use a NEW bolt.

Tighten
Tighten the bolt to 95 N·m (70 lb ft) plus 30 degrees, plus 15 degrees.

11. Remove KM-6625 .

• | Detach the screwed connection.

• | Tighten the bolted connection.

• | Use NEW nuts.

12. Lower the vehicle by its full height.
13. Remove the MK-6340 .
14. Inspect the timing.

| Important: Note marking, camshaft sprockets.

• | Turn the crankshaft 720 degrees in the direction of engine rotation by the bolt on the torsional vibration damper.

• | Insert MK-6340 (1, 2) in the camshaft adjuster as shown.

| Important: The spot-type marking (4) on the intake camshaft adjuster does not correspond to the groove of MK-6340 during this process but must be somewhat above as shown.

• | The spot type marking (3) on the exhaust camshaft adjuster must correspond to the groove on MK-6340 .

15. Raise the vehicle by its full height.
16. Inspect the crankshaft position.

Markings on the torsional vibration damper and the lower part of the toothed belt cover (arrows) must align.

17. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
18. Lower the vehicle by its full height.
19. Remove MK-6340 .
20. Install the front drive belt cover (top). Refer to Timing Belt Upper Front Cover Replacement .
21. Install the air cleaner housing. Refer to Air Cleaner Assembly Replacement .
22. Connect the battery.

Attach the negative connection to the negative terminal.

Tighten
Tighten the nut.

23. For programming procedures, refer to Control Module References .
24. Close the hood.