J462060 Seal Ring – Camshaft, Replace (Y 17
DTL, without AC, LHD)
Note: KM-6394 must be used from model year 04 instead of
KM-6169-1 .
1. Open bonnet
Caution!
On vehicles from model year 04 with ESP - the steering angle
sensor loses its basic adjustment each time the battery is
disconnected. It must be recalibrated.
2. Disconnect battery
3. Detach front right wheel
4. Raise vehicle
5. Remove front right wheel
6. Raise vehicle
7. Remove ribbed V-belt cover
- Remove 3 bolts (1)
- Remove clip (arrow).
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8. Attach KM-6169 (1)
- Place left of KM-6169 onto front axle body (arrows, illus.
I)
- Note! Guide pin must be seated in bore in front axle body
- Attach both right holders on the front axle body (arrows,
Illus. II).
- Note! Guide pin must be seated in bore in front axle body
(arrow, Illus. III)
- Tighten bolts
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9. Install support
- To KM-6169
- Adjust bracket (2) for support
- Screw on nut (1)
10. Adjust supports
- Transmission side
- Note! Turn spindles until the mounts (3) are positioned at the
guide journals free of play
- Engine timing side
- Insert journal of the support in the bore of the cylinder block
without play (arrow)
- Tighten nuts (1)
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11. Lower vehicle
12. Remove air cleaner housing (1)
- Remove wiring harness plug for hot film mass air flow meter
(3)
- Release in direction of arrow
- Remove air intake hose (4)
- Remove bolt (2)
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13. Remove right engine damping block
14. Detach alternator wiring harness
- Disconnect wiring harness plug
- Unscrew nut
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15. Remove wiring trough (1)
- Unclip vacuum lines (2)
- Unclip wiring trough
- Remove bolt (3)
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16. Loosen upper part of toothed belt
cover
- Remove 8 bolts
- Note! Note dissimilar bolt lengths
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17. Detach right engine bracket (1)
- Remove 3 bolts
- Remove right engine bracket, right engine bracket adapter,
upper part of toothed belt cover
18. Raise vehicle
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19. Loosen coolant pump ribbed V-belt pulley (1)
20. Remove ribbed V-belt
- Tension ribbed V-belt tensioner in direction of arrow
- Note! Mark running direction
21. Detach coolant pump ribbed V-belt pulley
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22. Remove torsional vibration damper
(1)
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23. Detach lower part of toothed belt
cover
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24. Set 1st cylinder to TDC
- Turn crankshaft evenly until TDC-fixing bolts can be
inserted
- Camshaft gear (M6) (1)
- Injection pump gear (M8) (2)
- Note! The mark on toothed belt drive gear must align with lug
on oil pump cover (arrows)
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25. Lower vehicle
26. For toothed belt tension roller
with leaf spring:
- loosen toothed belt tensioner
- Screw in bolt (M10) in lower bore (3) of toothed belt
tensioner
- Loosen bolt (2)
- Remove tension spring (1)
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For toothed belt tension roller with
spiral spring:
- Loosen toothed belt tension roller (1)
- Rotate toothed belt tension roller anticlockwise approx.
90°
- Tighten bolt (2)
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27. Remove toothed belt
- Note! Mark running direction
28. Detach camshaft pulley
- Unscrew TDC-fixing bolt (2)
- Remove bolt (1)
- Lock with KM-6165 and KM-956-1
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29. Remove intake camshaft seal
ring
- Lever out seal ring (1)
- Caution! Do not damage sealing surface
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30. Install intake camshaft seal ring
(1)
- Coat seal lips with grease
- Slide onto camshaft
- Drive in until flush using KM-656 (2)
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31. Attach camshaft gear
- Lock with KM-6165 and KM-956-1
- Tighten bolt (63.7 Nm / 47.0 lbf. ft.)
- Install TDC-fixing bolt
32. Install toothed belt
Note: Toothed belt
must be taut from toothed belt drive gear via oil pump drive gear
and injection pump drive gear
- For toothed belt tension roller with leaf spring:
- Unscrew TDC-fixing bolt
- Rotate crankshaft 60° against direction of engine
rotation
- Tighten bolt of toothed belt tension roller
- For toothed belt tension roller with spiral spring 49 Nm
- For toothed belt tension roller with leaf spring 38.2 Nm
- For toothed belt tension roller with leaf spring: unscrew bolt
(M10) from lower bore of toothed belt tensioner
33. Check timing
- Turn crankshaft approx. 780° in direction of engine
rotation
- Mark on toothed belt drive gear (2) must align with casting lug
at oil pump cover (1)
- Screw in TDC-fixing bolts (arrows)
- Install torsional vibration damper
- Note! Mark on torsional vibration damper (3) must align with
pin (4) on oil pump cover If the TDC fixing bolts cannot be
inserted, the basic adjustment must be repeated
- Unscrew TDC-fixing bolts
34. Remove torsional vibration damper
35. Attach lower part of toothed belt cover
- Tighten bolts (9.8 Nm / 7.2 lbf. ft.)
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36. Attach right engine bracket
- Insert lower bolt
- Into right engine bracket and right engine bracket adapter
- Insert right engine bracket, right engine bracket adapter,
upper part of toothed belt cover
- Install 2 upper bolts
- Tighten 3 bolts (40 Nm / 29.5 lbf. ft.)
37. Fasten upper part of toothed belt cover
- Tighten bolts (9.8 Nm / 7.2 lbf. ft.)
- Note! Note dissimilar bolt lengths
38. Attach coolant pump ribbed V-belt pulley
39. Raise vehicle
40. Install torsional vibration damper
- Tighten bolts (19.6 Nm / 14.5 lbf. ft.)
41. Install ribbed V-belt
- Note! Observe running direction and installation position
- Release ribbed V-belt tensioner
42. Fasten coolant pump ribbed V-belt pulley
- Tighten bolts (9.8 Nm / 7.2 lbf. ft.)
43. Lower vehicle
44. Install right engine damping block
- To side member
- Tighten bolts (40 Nm / 29.5 lbf. ft.)
- On engine bracket
- Tighten bolts (65 Nm / 48 lbf. ft. + 30° + 15°))
45. Attach wiring trough
- Clip-in wiring trough
- Clip in vacuum lines
- Tighten bolt
46. Attach alternator wiring harness
- Connect wiring harness plug.
- Tighten nuts
47. Install air cleaner housing
- Tighten bolt
- Fasten air intake hose.
- Tighten clamp (3.5 Nm / 2.6 lbf. ft.)
- Connect wiring harness plug to hot film mass air flow
meter
48. Raise vehicle
49. Detach support
50. Remove KM-6169
51. Install ribbed V-belt cover
- Screw in bolts
- Install clip
52. Lower vehicle
53. Install right front wheel
54. Lower vehicle
55. Fasten right front wheel
- Tighten bolts (110 Nm / 81 lbf. ft.)
56. Connect battery
57. Calibrate steering angle sensor
Note: Rotate the
steering wheel one time from its right-hand to its left-hand
stop.
58. Program volatile memories
59. Close bonnet
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