Table of contents: Removal the top cover 🠇 Removal the center cover (1.4 l…🠇 Removal the bottom cover 🠇 Removal the inner cover (1.6 l…🠇 Installation 🠇
Removal the top cover
1.4L engines
1. Remove two bolts (one in front and one in back) and remove the upper timing cover from the cylinder head (figure 5.1, a, b).
Figure 5.1, a. Remove the bolts (marked with arrows)...
Figure 5.1, b....and remove the upper timing belt cover
1.6L engines
2. Place a trolley jack under the engine, placing a block of wood between the jack head and the oil pan to prevent damage. By raising the jack, relieve the load on the engine mounts.
3. Remove the two bolts and move the accelerator pedal position sensor and support bracket away from the right engine mount (figure 5.3).
Figure 5.3. Accelerator pedal position sensor support bracket mounting bolts (marked with arrows)
4. Release the purge valve vapor hose from the clamp on the right engine mount and move the hose slightly to the side.
5. Unscrew the three bolts securing the upper bracket of the right engine mount to the bracket on the engine and unscrew the central nut securing the bracket to the rubber mount on the body (figure 5.5). Remove the upper support bracket, then remove the three bolts and remove the engine support bracket from the engine.
Figure 5.5. Remove the three bolts (A), the center nut (B) and the upper engine support bracket
6. Loosen the two lower bolts, remove the five upper bolts and remove the upper timing belt cover (figure 5.6).
Figure 5.6. Timing belt upper cover mounting bolts (marked with arrows)
Removal the center cover (1.4 l engines)
Note: On later engines, the center cover is integrated with the lower cover and is not a separate element.
7. Remove the top cover as described in paragraph. 1, and then release the electrical wiring from the corresponding clips on the center cover.
8. Remove three bolts (one on the back of the cover, under the engine backing plate, and two just above the crankshaft pulley) and remove the central cover from the engine compartment (figure 5.8).
Figure 5.8. Remove three bolts (marked with arrows) and remove the central cover
Removal the bottom cover
9. Remove the accessory drive belt as described in Chapter 1A.
10. Remove the top and, if applicable, center cover as described above.
11. Remove the three crankshaft pulley mounting bolts and remove the pulley, noting how it is installed (figure 5.11, a, b).
Figure 5.11, a. Remove the bolts (marked with arrows)
Figure 5.11, b....and remove the crankshaft pulley
12. Remove the bolts and then remove the lower cover from the engine (figure 5.12).
Figure 5.12. Remove the bolts (marked with arrows) and remove the lower timing belt cover
Removal the inner cover (1.6 l engines)
13. Remove the camshaft timing pulleys and tensioner pulley as described in paragraph 7.
14. Unscrew the bolts and remove the inner cover (figure 5.14).
Figure 5.14. Remove the bolts (marked with arrows) and remove the inner cover
Installation
Top cover
15. Installation is carried out in the reverse order of removal. On 1.6L engines, tighten the engine mount bolts to the specified torque.
Central cover (1.4 l engines)
16. Bring the central cover into its normal position, correctly orienting it relative to the lower cover, and tighten the corresponding bolts.
17. Secure the wiring harness to the appropriate clips on the front of the center cover, then install the top cover as described in step. 15.
Bottom cover
18. Install the lower cover over the timing belt pulley and tighten the corresponding bolts.
19. Install the pulley onto the end of the crankshaft, correctly oriented, and tighten the corresponding bolts to the specified torque.
20. Install the center (if applicable) and the top cover, as described above.
21. Install and tension the accessory drive belt as described in Chapter 1 A.
Inner cover (1.6 l engines)
22. Installation is performed in the reverse order of removal. Make sure that when installing the cover, the cup-shaped lower edge of the cover engages correctly with the protrusion on the top of the crankshaft oil seal housing.