Camshaft gears
1. Remove the timing belt (see Removal and installation the timing belt), then, in order to prevent the risk of damage to components due to piston contact with valves, move the engine out of the TDC position by turning the crankshaft 60° counterclockwise.
2. Acting in accordance with the description (see Removal and installation the timing belt tensioner and timing drive gears), remove the gear from the camshaft that needs servicing. If necessary, repeat the procedure and remove the gear from the second shaft.
On 1.4, 1.6 and 1.8 L engines, the exhaust shaft gear can be identified by the protrusions for the CMP sensor. On 2.0 L engines, the exhaust wheel, unlike the intake wheel, has only four spokes instead of seven, plus the "EXHAUST" marking is applied.
3. Before reinstalling the timing belt, remember to return the engine to TDC.
Crankshaft gear
Engines 1.4, 1.6 and 1.8 l
Cm. Removal and installation the timing belt tensioner and timing drive gears.
2.0L Engines
Removal
1. Remove the timing belt (see Removal and installation the timing belt).
2. On models with a manual transmission, ask an assistant to engage the highest gear and fully depress the foot brake pedal to prevent the crankshaft from turning. On models with automatic transmission, unscrew one of the torque converter mounting bolts and tighten it to the transmission housing using a steel bar and suitable bolts with washers (see Chapter Automatic transmission). If the engine is removed from the vehicle, the flywheel/drive plate must be locked (see Removal, checking condition and installing flywheel/drive disk).
3. Unscrew the mounting bolt (don't forget the puck) and remove the gear wheel from the shaft journal.
Installation
The crankshaft gear mounting bolt must be replaced without fail.
1. Place the gear wheel on the shaft journal (flange outwards), — make sure that the key fits correctly into the keyway. Screw in a new mounting bolt with a washer.
2. Block the crankshaft from turning (see above Removal) and tighten the gear mounting bolt to the first stage torque (see Specifications). Next, use the angle measuring attachment to the key and tighten the bolt to the second stage angle (if it is not possible to use a protractor attachment, apply reference marks with paint or a marker).
3. Install the timing belt (see Removal and installation the timing belt).
Tensioner
Cm. Removal and installation the timing belt tensioner and timing drive gears.
Intermediate rollers
Removal
1. Remove the timing belt (see Removal and installation the timing belt).
2. Remove the mounting bolts and remove the rollers from the engine.
Installation
1. Install the rollers, screw in and tighten the bolts that secure them to the required torque.
2. Install the timing belt (see Removal and installation the timing belt).
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