Special Tools

1. Remove the intake manifold. Refer to Intake Manifold Replacement.
2. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement.
3. Set the engine to "TDC".

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

4. Remove the front toothed belt cover (lower). Refer to Timing Belt Lower Front Cover Replacement.



5. Insert KM-6173 Adapter (3).

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

•	Align KM-6173 at frame.

•	Position the support bearing (1).

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

•	Tighten the 4 bolts.





Note: Attaching KM-6001-A guarantees perfect alignment of the drive unit with the frame.

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

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

•	Insert KM-6001-A .

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

•	Tighten the 3 bolts in the adjusting rails.

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

Note: 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.

7. Lower the vehicle by its full height.



8. Remove the engine damping block, right hand side.

Remove the 6 bolts (1).




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

Remove the 3 bolts (2).

10. Remove the front toothed belt cover (top). Refer to Timing Belt Upper Front Cover Replacement.
11. Remove the front toothed belt cover (center). Refer to Timing Belt Center Front Cover Replacement.



12. Disconnect the wiring trough cover (1) from the rear toothed belt cover.

Release with a screwdriver (2).





Note: Recognizable from the lettering "Right" (arrow)

13. 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).




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

•	Insert MK-6340 (1, 2) in the camshaft adjuster as shown.

Note: 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 .




15. Block the toothed belt tensioner.

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

16. Mark the toothed belt direction of rotation.
17. Remove the toothed belt.
18. Remove the toothed belt guide roller.

Remove the bolt.




19. Remove the toothed belt tensioner (1).

Remove the bolt (2)




20. Remove the coolant pipe (1) between the thermostat housing and the oil filter housing adapter.

•	Remove the 2 bolts (2).

•	Remove the oil filter housing adapter.

21. Detach the 3 coolant hoses from coolant flange.

Remove the 3 clamps.

Note: Remove the cylinder head only when the engine is cold (room temperature).

22. Remove the cylinder head cover. Refer to Camshaft Cover Replacement.



23. Remove the cylinder head.

Note: Unfasten bolts in the order shown.

24. Remove the 10 bolts.

23.1.

Undo the 10 bolts (90 degrees).

23.2.

Undo the 10 bolts (180 degrees).

25. Remove the cylinder head.

•	Place the cylinder head on suitable base.

•	Remove cylinder head gasket.

1. Clean the sealing surfaces.
2. Inspect for plane surface.

•	Cylinder block, cylinder head

•	Straight-edge, feeler gauge

3. Position the cylinder head.

•	Install the cylinder head gasket.

•	Position the cylinder head.

Caution: Refer to Fastener Caution in the Preface section.

4. Install the cylinder head.

Note: Note correct tightening sequence.

5. Use new cylinder head bolts.

Tighten
Tighten the 10 bolts to 25 N·m (18 lb ft) plus 90 degrees plus 90 degrees plus 90 degrees plus 45 degrees.

6. Attach the 3 coolant hoses to the coolant flange.

Attach the 3 clamps.

7. Install the thermostat housing coolant pipe to the oil filter housing adapter.

•	Use 2 new gaskets.

•	Push into the oil filter housing adapter.

Tighten
Tighten the 2 bolts to 9 N·m (80 lb in).

8. Install the cylinder head cover. Refer to Camshaft Cover Replacement.
9. Clean the thread.



10. Intake toothed belt tensioner.

Insert the toothed belt tension roller.

•	Use a new bolt.

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

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

11. Install the toothed belt guide roller.

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

12. Insert the toothed belt.
13. Release tension on the toothed belt tensioner.

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

•	Remove KM-6333 .

14. Connect the wiring trough cover to the rear toothed belt cover.
15. Install the front toothed belt cover (center). Refer to Timing Belt Center Front Cover Replacement.
16. Install the support for the engine damping block.

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

17. Install the engine damping block.

•	Attach to the support.

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

•	Attach to the side member.

Tighten
Tighten the 3 bolts to 35 N·m (25 lb ft).

18. Raise the vehicle by its full height.
19. Remove KM-6173.

Remove the 4 bolts.

20. Remove KM-6001-A .

Loosen the 3 screwed connections.

21. Install the front toothed belt cover (lower). Refer to Timing Belt Lower Front Cover Replacement.
22. Lower the vehicle by its full height.
23. Inspect the position of the camshaft sprockets.

Note: 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.

24. Raise the vehicle by its full height.



25. Inspect the crankshaft position.

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

26. Lower the vehicle by its full height.
27. Install the exhaust manifold. Refer to Exhaust Manifold Replacement.
28. Install the intake manifold. Refer to Intake Manifold Replacement.
29. Inspect and correct the engine oil level.
30. Connect the battery.

Attach the negative connection to the ground terminal.

Tighten
Tighten the nut.

31. Fill and bleed the cooling system. Refer to Cooling System Draining and Filling.
32. For programming procedures, refer to Control Module References.
33. Close the hood.