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.
Camshaft drive gear components: I - intake camshaft drive gear; 1 - camshaft drive gear (intake and exhaust camshaft); 2 - pressure plate, new part; 3 - phase sensor, borrowed from the old assembly of the camshaft drive gear; 4 - a fixing bolt borrowed from the old assembly of the camshaft drive gear; II – a drive gear wheel of a final camshaft; 1 - camshaft drive gear (intake and exhaust camshaft); 2 - pressure plate, new part; 3 - mounting bolt, borrowed from the old assembly of the camshaft drive gear
Note. Do not twist the position of the cover.
Remove the cylinder head cover.
Remove 2 crankcase ventilation hoses.
Remove 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 disk.
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.
Lock the chain tensioner.
Remove screw plug 1.
Load the intake camshaft in tension on the hexagon using an open wrench in the direction of the arrow.
Insert tool KM-955-1 (2).
Release the camshaft drive gears.
Loosen the 2 fixing screws 2.
Support the camshafts by the hexagon 1.
Replace the camshaft drive gear bolts.
Insert tool KM-952.
Adjust camshafts.
Insert tool KM-9531.
Turn the camshafts by the hexagon.
Install tool KM-954 (1).
Push it onto the disk of the phase sensor 2.
Note. The KM-954 tool must fit into the groove of the phase sensor disc.
Remove tool KM-955-1.
Replace O-ring.
Tighten the screw plug of the chain tensioner with a torque of 50 Nm.
Attach the camshaft drive gears.
Note. Tighten the drive gears of the camshafts and the phase sensor disk with a torque of 10 Nm.
Tighten 2 mounting bolts 2 to 10 Nm.
Note. Tighten the intake camshaft drive gear bolt first. Support the camshafts by the hexagon 1.
Take out the fixing tools.
Note. Locking tools must not be used for holding.
Tighten the camshaft drive gears.
Note. This procedure will require the participation of two people.
Tighten the 2 mounting bolts to 50 Nm + 60°.
Note. Tighten the intake camshaft drive gear bolt first. Hold the camshafts by the hexagon.
Rotate the crankshaft (720°).
Install tools KM-952, KM-953, KM-954.
Take out the fixing tools KM-952, KM-953, KM-954.
Raise the vehicle.
Install the crankshaft support screw plug.
Replace O-ring.
Tighten the bolt 50 Nm.
On the model «ECO» put the engine cover down.
Lower the car.
Clean the sealing surfaces of the cylinder head, cylinder head covers.
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 pcs. KM-6009.
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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