Note. See catalog numbers for replacement parts. Here, or Here (the crankshaft pulley may differ depending on the engine and the presence of air conditioning)
Removing
Operations common to all vehicle configurations
Put the car on a two-post lift, apply the parking brake, turn off the ignition and disconnect the wire terminal "masses" from the battery.
For vehicles with K4M engine
Remove inlet pipe.
Remove intake silencer. (see here)
Figure 4-1 - Removing the camshaft plugs: 1 - camshaft plug
Pierce in the middle of the plugs 1, Figure 4-1, of the camshafts with a screwdriver and remove the plugs (flat screwdriver, technological hook).
To check the position and fix the TDC, on the front wall of the cylinder block (under the starter) there is a threaded hole into which a plug-bolt 1 is screwed, Figure 4-2.
Unscrew the bolt-plug of the hole for the TDC lock (interchangeable head Togh E14, extension, ratchet wrench).
Figure 4-2 - Removing the plug of the hole for the TDC lock: 1 - bolt-plug of the hole for the TDC lock
Remove engine crankcase protection (see here).
Remove the right front wheel.
Remove right side mudguard (see here).
Remove accessory drive belt (see here).
Position the grooves of the camshafts 1, Figure 4-3, almost horizontally and offset downwards from the shaft axes in the direction of normal rotation (clockwise as viewed from timing end) (interchangeable head 16, extension, ratchet wrench).
Figure 4-3 - Installing the TDC lock: 1 - camshafts; 2 - TDC lock
Install TDC lock (TDC lock Mot. 1489 or 67.7820-9701 L).
Figure 4-4 - Installing the crankshaft at TDC: 1 - crankshaft; 2 - TDC lock
Note: In the absence of a special clamp, an M10 bolt can be used. The length of the threaded part is 75 mm.
If the bolt is longer, then screw on the two adjusting nuts and lock them so that the length of the threaded part of the bolt is 75 mm.
Assembled Fixture (setting pin) screwed into the threaded hole of the cylinder block. When the crankshaft is in the TDC position of the pistons of the 1st and 4th cylinders, the mounting pin 1 must be screwed into the hole to the end of the thread and rest against the milled platform 2 on the crankshaft and block the shaft when trying to turn it clockwise (shown with oil pan removed. The same thing, from a different angle is shown in Figure 4-4).
Turn the crankshaft 1, Figure 4-4, clockwise until it rests against the TDC lock (interchangeable head 18, extension, ratchet wrench).
The grooves of the camshafts 1, Figure 4-5, must be in a horizontal position with an offset downwards from the axes of the shafts.
Figure 4-5 - The position of the grooves of the camshafts at TDC: 1 - camshafts
Unscrew the TDC lock.
Block the flywheel with a screwdriver (flat screwdriver).
Figure 4-6 - Removing the crankshaft pulley of the K4M engine: 1 - camshafts; 2 - crankshaft pulley
Loosen bolt 1, Figure 4-6, fasteners (interchangeable head 18, extension, ratchet wrench)
... and remove the crankshaft pulley
For vehicles with K7M engine
Remove the right front wheel.
Remove right side mudguard (see here).
Remove accessory drive belt (see here).
Remove engine crankcase protection (see here).
Unscrew the hole plug for the TDC lock (interchangeable head Torx E14, extension, ratchet wrench).
Install TDC lock (TDC lock Mot. 1489 or 67.7820-9701 L).
Set the piston of the 1st cylinder to TDC and block the crankshaft with a clamp.
Block the flywheel with a screwdriver (flat screwdriver).
Unscrew bolt 1, Figure 4-7, fixings and remove pulley 2 of the crankshaft (interchangeable head 18, extension, ratchet wrench).
Figure 4-7 - Removing the crankshaft pulley of the K7M engine: 1 - camshafts; 2 - crankshaft pulley
Installation
For vehicles with K4M engine
Attention. The crankshaft pulley bolt must be replaced.
Attention. Before installing the crankshaft pulley, degrease the bearing surface of the pulley and the crankshaft toe.
Install tool 1, Figure 4-8, to fix the camshafts (tool Mot. 1496).
Figure 4-8 - Installation of the device for setting the valve timing: 1 - Tool for setting the valve timing Mot. 1496; 2 - bolt
Fasten the fixture to the ends of the camshafts with bolt 2 (interchangeable head 10, extension, crank).
Note: In the absence of a special device for fixing the camshafts, you can make a simple retainer yourself according to the specified drawing:
Turn the crankshaft clockwise until the grooves on the camshafts are almost horizontal (parallel to the plane of the split of the cover and cylinder head) and will be shifted down relative to the axes of the camshafts.
...and install the latch
Make sure that the crankshaft is securely locked with the TDC lock, if necessary, tighten the crankshaft by turning the flywheel with a screwdriver (retainer Mot. 1489 or 67.7820-9701 L, flathead screwdriver).
The groove of the crankshaft must face up.
Install pulley 2, Figure 4-6, on the crankshaft and secure with a new bolt 1 (interchangeable head 18, extension, ratchet wrench).
Tighten the crankshaft pulley bolt to 40 Nm (4.0 kgf·m) and further tighten by 145°± 15° (interchangeable head 18, extension, torque wrench).
Unscrew the TDC lock.
Apply sealant to the threads of the plug bolt 1, Figure 4-2, holes for the TDC retainer and tighten. Plug tightening torque 20 Nm (2.0 kgf·m) (interchangeable head Torx E14, extension, ratchet wrench, torque wrench).
Remove tool 1, Figure 4-7, to fix the camshafts (interchangeable head 10, extension, crank).
Install new camshaft plugs, pressing them in with light blows.
Install the accessory drive belt.
Install the engine crankcase protection.
Install the right side mudguard.
Install the right front wheel.
Install the intake silencer.
Install the inlet pipe.
For vehicles with K7M engine
Attention. The crankshaft pulley bolt must be replaced.
Attention. Before installing the crankshaft pulley, degrease the bearing surface of the pulley and the crankshaft toe.
Make sure that the crankshaft is securely locked with the TDC lock, if necessary, tighten the crankshaft by turning the flywheel with a screwdriver (retainer Mot. 1489 or 67.7820-9701 L, flathead screwdriver).
Install pulley 2, Figure 4-7, on the crankshaft and secure with a new bolt 1 (interchangeable head 18, extension, ratchet wrench).
Tighten the crankshaft pulley bolt to 30 Nm (3.0 kgf·m) and further tighten by 100°± 5° (interchangeable head 18, extension, torque wrench).
Unscrew the TDC lock.
Apply sealant to the threads of the plug of the hole for the TDC lock and tighten the plug. Plug tightening torque 20 Nm (2.0 kgf·m) (interchangeable head Torx E14, extension, ratchet wrench, torque wrench).
Install the engine crankcase protection.
Install the accessory drive belt.
Install the right side mudguard.
Install the right front wheel.
Operations common to all vehicle configurations
Attach wire terminal "masses" to the battery.