Note. From model year 04, KM-6394 must be used instead of KM-6169-1.
Removing
Open the hood.
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. You need to recalibrate it.
Disconnect the ground wire.
Remove the air filter housing 1.
Disconnect the 2 harness connectors, hot film mass air flow meter 3 and tank vent valve 2.
Release the tank vent valve.
Dismantle the suction pipe 4.
Loosen 2 nuts.
Dismantle the crankcase ventilation hose 5.
On Z10XEP engines: remove the air intake hose.
Release clamp.
Remove the bolt (arrow).
Release the front wheel on the right.
Loosen 4 mounting screws.
Raise the vehicle.
Remove the front wheel on the right.
Loosen 4 mounting screws.
Raise the vehicle.
Remove the V-ribbed belt cover.
Note. On model variant «ECO» remove the engine compartment cover at the bottom.
Remove 3 fixing screws 1.
Remove the clip (arrow).
Install tool KM-6169-2 on the gearbox.
Tighten 2 mounting bolts 95 Nm.
Install tool KM-61691.
KM-6169 fit on the left side of the front axle housing (arrows I).
The guide pin must be located in the hole in the front axle housing.
Install both holders on the right on the front axle housing (Arrows II).
The guide pin must be located in the hole in the front axle housing (arrow III).
Tighten 8 mounting bolts
Install the support on the KM-6169 tool.
Install mount 2 for the support.
Tighten nut 1.
Adjust the supports on the gearbox side.
Screw the spindles in such a way that the fasteners 3 on the guide pins fit without play.
From the control side of the engine, insert the support trunnion into the hole in the cylinder block without play (arrow).
Tighten nut 1.
Unscrew the engine holder on the right.
Loosen the bolt at the bottom 1.
Lower the car.
Remove the engine holder on the right.
Release the damping block of the engine.
Loosen the 2 fixing screws 1.
Loosen 2 fixing screws (arrows).
Remove poly V-belt.
Use KM-6131 2 to tension the poly V-belt tensioner in the direction of the arrow.
Insert tool KM-955-21.
Loosen tension on poly V-belt tensioner 1.
Installation
Install poly V-belt.
Use KM-6131 2 to tension the poly V-belt tensioner in the direction of the arrow.
Remove tool KM-955-21.
Loosen tension on poly V-belt tensioner 1.
Install the motor holder on the right.
Insert the bolt at the bottom.
Tighten the 2 mounting bolts at the top to 60 Nm.
Fasten the shock-absorbing engine block - tighten the 2 fastening bolts to a torque of 40 Nm.
Raise the vehicle.
Fasten the motor holder on the right.
Tighten the bolt below to 60 Nm.
Remove the supports from the control sides of the engine and gearbox.
Remove tools KM-6169, KM-6169-2.
Install the V-ribbed belt cover.
Note. On the model «ECO» install the engine compartment cover at the bottom I.
Tighten the 3 mounting bolts.
Install the clamp.
Lower the car.
Install the front wheel on the right.
Tighten 4 mounting bolts.
Lower the car.
Fasten the front wheel on the right.
Tighten 4 mounting bolts to 110 Nm.
Install the air filter housing.
Tighten the bolt.
Attach the suction pipe.
Replace O-ring.
Tighten 2 nuts.
On Z10XEP engines: Install the air intake hose.
Tighten the clamp to 3.5 Nm.
Install the crankcase ventilation hose.
Connect the tank vent valve.
Connect the 2 wire harness connectors.
Connect the battery terminals.
Program the volatile memory.
Close the hood.
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