Disconnect the battery terminals.
Note. On vehicles from model year 04 with ESP, each time the battery is disconnected, the steering angle sensor loses its basic setting. It needs to be recalibrated.
Disconnect the ground wire.
Disconnect the 4 engine management harness connectors: oil pressure switch 2, coolant temperature sensor 3, camshaft sensor 4, ignition module 1.
Clear the channel for the wiring harness 5.
Set the wiring harness aside.
Remove the ignition module.
Remove the ignition module cover, slide it to the right.
Loosen 2 mounting screws.
Remove the cover using tool KM-6009.
Note. Do not twist the position of the cover.
Remove the cylinder head cover.
Remove 2 crankcase ventilation hoses.
Loosen the 13 mounting bolts.
Raise the vehicle.
On the model «ECO» remove the engine cover at the bottom.
Remove the crankshaft support screw plug 1.
Lower the car.
Set the ignition TDC position of cylinder 1.
Insert tool KM-952 2.
Rotate the crankshaft evenly until the KM-952 tool is engaged.
Note. The mark on the crankshaft pulley 4 must be in line with the boss 3 on the timing case.
Insert tool KM-9531, it should fit into the groove of the camshafts.
Note. If the KM-953 cannot be inserted, then a basic valve timing adjustment must be performed.
Install tool KM-9541. Place the phase sensor 2 on the disc.
Note. KM-954 should fit into the groove of the phase sensor disc.
Take out the fixing tools.
Note. Locking tools must not be used for holding.
Raise the vehicle.
Install the crankshaft support screw plug.
Replace O-ring.
Tighten the bolt to 50 Nm.
Lower the car.
On the model «ECO» put the engine cover down.
Clean the sealing surfaces of the cylinder head and cylinder head cover.
Install cylinder head cover 1.
Replace seal 2 and o-ring.
Apply sealant (distance 1–2 mm).
Note. Installation work must be completed within 10 minutes.
Tighten 13 mounting bolts to 8 Nm.
Install 2 crankcase ventilation hoses.
Install the ignition module.
Unscrew 2 KM-6009 tools.
Tighten 2 mounting bolts with a torque of 8 Nm.
Install the engine control harness.
Route the wiring harness.
Attach the wire harness channel.
Connect the 4 wire harness connectors.
Connect the battery terminals.
Program the volatile memory.
Close the hood.
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