For 1990-2009 cars

#### Special Tools

• | KM-422 Installer

• | KM-845 Suction Device

• | KM-6001-A Engine Mount

• | KM-6333 Fixing Rod

• | MK-6340 Locking Tool

• | KM-6361 Feeler Gage Set

• | KM-6625 Flywheel Locking Device

• | MK-6628 Locking Tool

### Removal Procedure

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

• | Detach the ground connection from the ground terminal.

• | Loosen the nut.

3. Remove the air cleaner housing. Refer to Air Cleaner Assembly Replacement .
4. Remove the front toothed belt cover (top). Refer to Timing Belt Upper Front Cover Replacement .
5. Remove the camshaft cover. Refer to Camshaft Cover Replacement .
6. Raise the vehicle by its full height.
7. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
8. Set the engine to TDC.

Turn the crankshaft in the direction of engine rotation by the bolt of the torsional vibration damper to cylinder 1 TDC of combustion stroke.

9. Cams at the intake side of cylinder number 2 (1) and the exhaust side of cylinder number 3 (2) are on top and tilted slightly towards the inside to the same extent.
10. Inspect valve lash.

Prescribed Valve Lash

• | Intake valves - 0.21-0.29 (nominal value 0.25 mm)

• | Exhaust valves - 0.27-0.35 mm (nominal value 0.30 mm)

11. Inspect the 4 valves.

• | Inspect valve lash with KM-6361 (1).

• | Note down result.

12. Turn the crankshaft through 180 degrees.

• | In the direction of the engine rotation

• | Pairs of cams (1) and (2) point upwards at an angle.

13. Inspect the 4 valves.

• | Inspect valve lash with KM-6361 (1).

• | Note down result.

14. Turn the crankshaft through 180 degrees.

• | In direction of engine rotation

• | Pairs of cams (1) and (2) point upwards at an angle.

15. Inspect the 4 valves.

• | Inspect valve lash with KM-6361 (1).

• | Note down result.

16. Turn the crankshaft through 180 degrees.

• | In direction of engine rotation

• | Pairs of cams (1) and (2) point upwards at an angle.

17. Inspect the 4 valves.

• | Inspect valve lash with KM-6361 (1).

• | Note down result.

18. Insert MK-6340 into 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 .

Important: If MK-6628 cannot be inserted, the timing must be set.

19. Insert MK-6628 (1) into the camshafts.

Align the camshafts horizontally by the hexagon (arrows) until MK-6628 can be inserted in both camshafts.

20. Raise the vehicle by its full height.
21. Block the crankshaft.

Attach KM-6625 .

• | Detach the screwed connection (1).

• | Insert KM-6625 (2).

• | Tighten the screwed connection (3).

22. Remove the torsional vibration damper.

Remove the bolt.

23. Remove the front toothed belt cover (bottom).

Remove the 4 bolts.

24. Insert KM-6173 (3).

• | Loosen the 4 bolts (arrows) and hand-tighten.

• | Align KM-6173 at the frame.

• | Position the support bearing (1).

• | Journal (2) must sit in the mount at the cylinder block.

• | Tighten the 4 bolts.

25. Attach KM-6001-A (1).

• | Loosen the 3 bolts (arrows) in adjusting rails.

• | Insert KM-6001-A .

• | The journals (2, 5) must sit in the guide holes of the frame.

• | Tighten the 3 bolts in adjusting rails.

• | Adjust the support bearings, front (4) and rear (3).

| Important: The guide journals must be seated free from play in the support bearings.

• | Raise the support bearings up to the stop on the guide journals.

26. Lower the vehicle by its full height.
27. Remove the engine damping block, right hand side.

Remove the 6 bolts (1).

28. Remove the engine damping block support (1).

Remove the 3 bolts (2).

29. Remove the front toothed belt cover (center).

Disconnect 2x from rear of toothed belt cover.

30. Block the toothed belt tensioner.

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

31. Remove the toothed belt.
32. Remove the toothed belt tensioner (1).

Remove the bolt (2).

33. Raise the vehicle by its full height.
34. Remove KM-6625 .

Detach the screwed connection.

35. Turn the crankshaft 60 degrees against the direction of engine rotation.
36. Lower the vehicle by its full height.
37. Place the collecting basin underneath.
38. Remove the closure bolt, exhaust camshaft adjuster.
39. Remove the intake camshaft closure bolt.
40. Remove MK-6340 .
41. Loosen the exhaust camshaft adjuster.

Counterhold at camshaft hexagon.

42. Remove the exhaust camshaft adjuster.

Remove the bolt.

43. Loosen the intake camshaft adjuster.

Counterhold at camshaft hexagon.

44. Remove the intake camshaft adjuster.

Remove the bolt.

45. Remove the rear toothed belt cover.

• | Disconnect the wiring trough cover.

• | Remove the 4 bolts.

46. Remove MK-6628 .

Counterhold at hexagon of camshafts.

47. Remove the 1st camshaft bearing support.

• | Remove the 4 bolts.

• | Note removal sequence 1-4.

• | Release the bearing support by striking it gently with a plastic hammer.

Important: Mark the camshaft bearing caps before removing them.

48. Remove the intake camshaft.

• | Detach camshaft bearing caps 2-5 working from outside to inside in a spiral in steps of 1/2 up to 1 turn.

| Important: Note the marking on the camshaft bearing cover with stamped numbers from 1 to 0 (there is a dot at bottom left before each number to avoid mistakes)

• | Remove the camshaft bearing cover from the cylinder head and take out the camshaft.

Important: Mark the camshaft bearing caps before removing them.

49. Remove the exhaust camshaft.

• | Detach camshaft bearing caps 2-5 working from outside to inside in a spiral in steps of 1/2 up to 1 turn.

| Important: Note the marking on the camshaft bearing cover with stamped numbers from 1 to 0 (there is a dot at bottom left before each number to avoid mistakes) .

• | Remove the camshaft bearing cover from the cylinder head and take out the camshaft.

50. Remove the cup tappet with KM-845 (1).
51. Determine cup tappet size.

#### Example of determining the size of a cup tappet, intake side:

• | Dimension of fitted cup tappet 3.20 mm (Identification number 20)

• | Measurement between cams and cup tappets + 0.31 mm = 3.51 mm

• | Required value, valve lash, intake side -0.25 mm

| Important: The identification number (arrow) is on the inside of the cup tappet.

• | Nominal dimension of the new cup tappet 3.265 mm (Identification number 27x)

• | Now use a cup tappet with this dimension or one that is nearest to it.

### Installation Procedure

1. Insert the cup tappet with KM-845 .

Lightly coat sliding surfaces with oil.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the intake camshaft.

• | Coat with MoS 2 lubricating paste.

| Important: Note the identification marking on the camshaft bearing cover.

• | Insert the camshaft.

• | Install the camshaft bearing cover.

• | Tighten the camshaft bearing caps 2-5 in a spiral from the inside to the outside.

Tighten
Tighten the camshaft bearing caps to 8 N·m (70 lb in).

3. Install the exhaust camshaft.

• | Coat with MoS 2 lubricating paste.

| Important: Note the identification marking on the camshaft bearing cover.

• | Install the camshaft.

• | Install the camshaft bearing cover.

• | Tighten the camshaft bearing caps 2-5 in a spiral from the inside to the outside.

Tighten
Tighten the camshaft bearing caps to 8 N·m (70 lb in).

Important: Sealing surfaces must be free from oil and grease.

4. Clean sealing surfaces of 1st camshaft bearing support and the cylinder head with a suitable tool, e.g. plastic wedge.

Clean the oil duct (arrow) from any sealant residue.

Important:

• | It is essential to ensure that no sealant is applied outside the marked sealing areas.

• | The grooves (1) adjacent to the sealing surfaces must remain free from sealant.

5. Apply surface sealant (green) to the sealing surfaces (arrows) of the 1st camshaft bearing support thinly and evenly.
6. Position the camshaft bearing bridge on the cylinder block and tighten the bolts hand tight, approximately 2 N·m (18 lb in).
7. Install the 2 camshaft seal rings.

• | Tighten the seal ring with KM-422 (4) on the camshaft until this is in contact with the cylinder head (arrow).

• | To install, use a camshaft sprocket bolt (1) in conjunction with shims (2) with a total thickness of approximately 10 mm.

• | Remove KM-422 .

• | Remove the bolt.

Important: No sealant may reach the camshafts.

8. Attach 1st camshaft bearing support.

• | Place the bearing support in position.

Tighten
Tighten the 4 bolts to 8 N·m (70 lb in).

• | Note installation sequence 1-4.

9. Install the intake camshaft seal ring with KM-422 .

• | Push the seal ring into the camshaft bearing cover with KM-422 (1).

• | Use the bolt (2) and the washer (3) of the camshaft adjuster.

10. Clean the 4 threads, rear toothed belt cover.
11. Install the rear toothed belt cover.

• | Tighten the 4 new bolts.

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

• | Coat the 4 bolts with locking compound (red).

• | Clip in the wiring trough cover.

12. Attach the exhaust camshaft adjuster.

• | Insert the new sealing sleeve in the adjuster.

• | Install the new bolt.

13. Attach the intake camshaft adjuster.

• | Insert the new sealing sleeve in adjuster.

• | Install the new bolt.

Important: Note markings on the camshaft sprockets.

14. Insert MK-6340 .
15. Fasten the exhaust camshaft adjuster.

Tighten
Tighten the bolt to 65 N·m (48 lb ft) plus 125 degrees plus 15 degrees.

Counterhold at camshaft hexagon.

16. Fasten the intake camshaft adjuster.

Tighten
Tighten the bolt to 65 N·m (48 lb ft) plus 125 degrees plus 15 degrees.

Counterhold at camshaft hexagon.

17. Tighten the exhaust camshaft adjuster closure bolt.

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

Replace seal ring.

18. Tighten the closure bolt, intake camshaft adjuster.

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

Replace seal ring.

19. Remove MK-6628 .
20. Raise the vehicle by its full height.
21. Set the crankshaft to cylinder number 1 ignition TDC (1).

Marking, toothed belt drive gear and oil pump housing adapter must align.

22. Block the crankshaft.

• | Insert KM-6625 .

• | Install the bolted connection.

23. Lower the vehicle by its full height.
24. Clean the thread, toothed belt tensioner.
25. Insert KM-6625 .

• | Install the bolted connection.

• | Use a new bolt.

• | Released leg of spring (1) of the toothed belt tension roller must engage in the cut-out (arrow) of the pump module.

• | Tighten the bolt.

Tighten
Tighten the bolt to 20 N·m (15 lb ft).

Important: Use the assembly tool.

26. Insert the toothed belt.
27. Release tension on the toothed belt tensioner.

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

• | Remove KM-6333 .

28. Raise the vehicle by its full height.
29. Install the front toothed 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).

30. Install the torsional vibration damper.

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

31. Remove KM-6625 .

• | Detach the screwed connection.

• | Tighten the bolted connection.

• | Use new nuts.

32. Lower the vehicle by its full height.
33. Remove MK-6340 .
34. Inspect position of the camshaft sprockets.

| 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 into the camshaft timing gears.

35. Inspect the camshaft positions.
36. Insert the front toothed belt cover (center).

Insert MK-6628 in the camshafts, align the camshafts by hexagon until MK-6628 can be inserted in both camshafts, clip in 2x to the rear toothed belt cover.

37. Install the support for engine damping block.

Tighten
Tighten the 3 bolts to 50 N·m (37 lb ft).

38. Install the engine damping block.

• | Fasten the engine bracket adapter.

Tighten
Tighten the 3 bolts to 55 N·m (40 lb ft).

• | Fasten the engine damping block.

Tighten

• | Tighten the 2 bolts to 55 N·m (40 lb ft).

• | Tighten the nut to 55 N·m (40 lb ft).

39. Raise the vehicle by its full height.
40. Inspect the crankshaft position.

Marking on the torsional vibration damper must align with the marking on the lower part of the toothed belt cover.

41. Remove KM-6001-A .

Loosen the 3 screwed connections.

42. Remove KM-6173.

Remove the 4 bolts.

43. Clean the thread of bolt, drive belt tensioner.
44. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
45. Lower the vehicle by its full height.
46. Remove MK-6628 .
47. Install the camshaft cover. Refer to Camshaft Cover Replacement .
48. Remove MK-6340 .

Attach the bracket.

Tighten
Tighten the 2 bolts to 2.5 N·m (22 lb in).

49. Install the front toothed belt cover (top). Refer to Timing Belt Upper Front Cover Replacement .
50. Install the air cleaner housing. Refer to Air Cleaner Assembly Replacement .
51. Connect the battery.

Attach the negative connection to the ground terminal.

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

52. For programming procedures, refer to Control Module References .
53. Close the hood.