Removing
Camshaft Pulleys
1. Disconnect the negative battery terminal.
2. Align the alignment holes on the camshaft and crankshaft pulleys with the holes on the engine and fix the pulleys with pins.
1.6 liter engine models
3. Remove the top casing of a gear belt.
4. Loosen the timing belt tensioner pulley by turning the pulley with an appropriate square wrench installed in the pulley hub in a clockwise direction and re-tighten the pulley mounting bolt.
5. Remove the locking rod from the camshaft pulley. Remove the toothed belt from the camshaft pulley.
6. Remove the camshaft pulley bolt. To prevent rotation of the camshaft when unscrewing the bolt, it is necessary to fix the pulley from turning with a special tool.
7. Remove the pulley from the camshaft.
Engine models 1.8 and 2.0 liters
8. Remove the top and bottom timing belt covers.
9. Move the wiring harness if necessary.
10. Support the engine with a jack and remove the right engine mount.
11. Loosen the bolt securing the rear belt tensioner by turning the pulley clockwise.
12. Check that the locating pins are still in the pulley bore. Remove the toothed belt from the camshaft pulleys.
13. If pulleys are removed without hubs, unscrew the three mounting bolts and remove the pulley.
14. If the pulleys are to be removed with hubs, then unscrew the central bolt of the hub. A special tool must be used to prevent rotation of the camshaft pulley.
15. Remove the three pulley mounting bolts and remove the pulley from the hub. Unscrew the hub mounting bolt and remove the hub. Please note that the hubs are marked with a number on the front for identification. On 1.8 liter engine models, the camshaft hub that controls the intake valves is marked with a number "1", and the camshaft hub that controls the exhaust valves is marked with a number "2". On 2.0 liter engine models, the camshaft hub that controls the intake valves is marked with a number "3", and the camshaft hub that controls the exhaust valves is marked with a number "4".
Crankshaft pulleys
1. Disconnect the negative battery terminal.
2. Align the alignment holes on the camshaft and crankshaft pulleys with the holes on the engine and fix the pulleys with pins.
1.6 liter engine models
3. Remove the top, center and bottom timing belt guards.
4. Loosen the toothed belt tensioner pulley bolt, turn the pulley clockwise and tighten the fastening bolt.
5. Remove the timing belt from the crankshaft pulley and remove the pulley from the crankshaft. Also remove the segment key from the crankshaft.
6. Check the crankshaft seal for leaks and replace if necessary.
Engine models 1.8 and 2.0 liters
7. Remove the top and bottom timing belt covers.
8. Move the wiring harness if necessary.
9. Support the engine with a jack and remove the right engine mount.
10. Loosen the bolt securing the rear belt tensioner by turning the pulley clockwise.
11. Check that the dowel pins are installed in the camshaft pulleys. Remove the timing belt from the crankshaft pulley, then remove the pulley from the crankshaft along with the key.
12. Check the crankshaft seal for leaks and replace if necessary.
Tensioner pulleys and idler pulleys
1. Disconnect the negative battery terminal.
2. Align the alignment holes on the camshaft and crankshaft pulleys with the holes on the engine and fix the pulleys with pins.
1.6 liter engine models
3. Remove the upper and, if necessary, the central casings of the toothed belt.
4. Unscrew the fastening bolt and remove the toothed belt tensioner pulley. Check the condition of the tensioner parts and, if necessary, replace them.
Models 1.8 and 2.0 liters
5. Remove the top and bottom timing belt covers.
6. If necessary, reposition the wiring harness to improve access to the tensioner.
7. Support the engine with a jack and remove the right engine mount.
8. Loosen the rear toothed belt tensioner pulley bolt, and using a square wrench in the pulley hub, turn the pulley clockwise and re-tighten the bolt.
9. Check that the locking pins are in the camshaft pulley mounting holes and remove the toothed belt from the pulleys.
10. Unscrew the bolts securing the tensioner and idler pulley and remove them.
Examination
1. Clean all pulleys and check them for signs of wear.
2. When cleaning the tensioner pulleys, do not use solvents that can get into the pulley bearings and damage them. The pulleys should rotate easily, without jamming or play.
Installation
Camshaft pulleys
1.6 liter engine models
1. Set the location reference to the back of the pulley. Install the pulley on the camshaft so that the orientation mark is aligned with the camshaft.
2. Screw in the pulley bolt. Use the special pulley locking tool to prevent the pulley from turning.
3. Align the hole in the camshaft pulley with the hole in the head and install the blocking rod. Check that the dowel pin is also blocking the crankshaft pulley.
4. Install the toothed belt.
5. Tension the toothed belt.
6. Install the toothed belt guards.
Engine models 1.8 and 2.0 liters
7. If the pulleys and hubs were removed, install the hub on the camshaft according to the hub identification marking.
8. Screw in a bolt of fastening of a nave the demanded moment. Temporarily install the pulleys on the hub.
9. Rotate the hub so that the locking rod can be inserted into the hole in the cylinder head pulley.
10. If only the pulleys were removed, install the pulleys and screw them with three bolts.
11. Install and tension the toothed belt.
Crankshaft pulleys
1.6 liter engine models
1. Install the gasket and keyway into the crankshaft groove.
2. Install the crankshaft pulley, aligning the groove on the pulley with the key.
3. Check that the setting rod is still blocking the camshaft pulley. Temporarily install the auxiliary belt pulley on the crankshaft and insert a dowel pin through it to check that the crankshaft is correctly positioned.
4. Remove the auxiliary belt pulley from the crankshaft. Install the toothed belt on the crankshaft pulley, water pump pulley and tensioner pulley.
5. Tension the toothed belt.
6. Install the toothed belt guards.
7. Install the auxiliary belt pulley to the crankshaft. Connect the negative terminal to the battery.
Engine models 1.8 and 2.0 liters
8. Install the keyway into the groove of the crankshaft.
9. Install the crankshaft pulley, aligning the groove on the pulley with the key.
10. Establish and adjust a tension of a gear belt.
Tensioner pulleys and idler pulleys
1.6 liter models
1. Install the tensioner pulley and screw in the mounting bolt without tightening it.
2. Check that the front section of the belt is tight. Turn the tensioner pulley counterclockwise to take up all the clearance between the pulley and timing belt.
3. Adjust the toothed belt tension.
4. Install the toothed belt guards.
Engine models 1.8 and 2.0 liters
5. Install the tensioner and idler pulleys and secure them with bolts.
6. Install the toothed belt and adjust its tension.