For 1990-2009 cars

#### Special Tools

• | KM-6333 Fixing Rod

• | MK-6340 Locking Tool

• | KM-6349 Fixing Rod

• | KM-6625 Flywheel Locking Device

### Removal Procedure

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

• | Disconnect the negative connection from the ground terminal.

• | Loosen the nut.

3. Remove the air cleaner housing. Refer to Air Cleaner Inlet Duct Replacement .
4. Remove the front toothed belt cover (top). Refer to Timing Belt Upper Front Cover Replacement .
5. Raise the vehicle by its full height.
6. Remove the lower engine cover and the right engine splash guard.
7. Remove the drive belt.

• | Mark the direction of rotation.

• | Apply tension to the drive belt tensioner in the direction of the arrow at the projection (1) and lock with KM-6349 (2).

• | Remove the drive belt.

Important: The tensioner remains locked with KM-6349 (2).

8. Remove drive belt tensioner.

Remove the bolt (1).

9. Lower the vehicle by its full height.

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

10. 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).

11. Set the engine to "TDC".

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

12. Insert MK-6340 into the camshaft timing gears.

• | 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 .

13. Stop the toothed belt tensioner.

Apply tension to the toothed belt tensioner (2) in the direction of the arrow, using an Allen key (1). Install using KM-6333 (3).

14. Mark the toothed belt direction of rotation.
15. Raise the vehicle by its full height.
16. Block the crankshaft.

Attach KM-6625 .

• | Detach the screwed connection (1).

• | Insert KM-6625 (2).

• | Tighten the screwed connection (3).

17. Remove the torsional vibration damper (1).

Remove the bolt (2).

18. Remove the front toothed belt cover (bottom) (3).

Remove the 4 bolts (4).

19. Remove the toothed belt guide roller.

Remove the bolt.

20. Clean the thread for the toothed belt guide roller.
21. Lower the vehicle by its full height.
22. Remove the drive belt.

### Installation Procedure

Important: Threading the toothed belt through the engine damping block 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.

1. Insert the toothed belt.

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

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

• | Guide the toothed belt through the engine damping block support with assembly tool.

• | Remove the assembly tool.

Important: Observe the direction of rotation.

2. Position the toothed belt.

• | Place the toothed belt on the intake camshaft adjuster.

• | Place the toothed belt on the exhaust camshaft adjuster.

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

Notice: Refer to Fastener Notice in the Preface section.

3. Install the toothed belt guide roller.

Use a new bolt.

Tighten
Tighten the bolt to 25 N·m (18 lb ft).

4. Release tension on the toothed belt tensioner.

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

• | Remove KM-6333 .

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

5. Raise the vehicle by its full height.
6. Install the toothed belt cover lower section.

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

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

7. 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.

8. Remove KM-6625 .

• | Detach the screwed connection.

• | Tighten the bolted connection.

• | Use new nuts.

9. Lower the vehicle by its full height.
10. Remove MK-6340 .
11. Timing, Check

| 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 .

12. Raise the vehicle by its full height.
13. Inspect the crankshaft position.

Markings on the torsional vibration damper and the lower part of the toothed belt cover (marking 1) must align.

14. Clean thread of the drive belt tensioner.
15. Install the drive belt tensioner.

Tighten
Tighten the bolt to 50 N·m (37 lb ft).

Use a new bolt.

16. Insert the drive belt.

• | Observe the direction of rotation.

• | Apply tension to the drive belt tensioner in the direction of the arrow at the projection (1) and remove with KM-6349 (2).

• | Allow the tensioner to slide back slowly.

17. Install the lower engine cover and the right engine splash guard.
18. Lower the vehicle by its full height.
19. Remove MK-6340 .
20. Install the toothed belt cover upper section. Refer to Timing Belt Upper Front Cover Replacement .
21. Remove the air cleaner housing. Refer to Air Cleaner Inlet Duct Replacement .
22. Connect the battery.

Connect the negative connection to the ground terminal.

Tighten
Tighten the nut to 5 N·m (44 lb in).

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