Removing
1. Remove the toothed belt.
Camshaft pulleys
2. To unscrew the bolt securing the camshaft pulley, fix the camshaft before turning or by the camshaft pulley or a wrench in the grooves of the camshaft.
3. Unscrew the bolt and remove the pulley from the end of the camshaft. On 1.6L engines, the intake and exhaust camshaft pulleys are different from each other. The camshaft pulley that controls the exhaust valves must be identified by the lugs that activate the camshaft position sensor. On 1.8 and 2.0L models, both pulleys are the same.
1.6L model crankshaft pulley
4. Remove the pulley from the end of the crankshaft.
Crankshaft Pulley Models 1.8 and 2.0L
Warning! A new bolt must be used to secure the crankshaft pulley.
5. Loosen the crankshaft pulley bolt. In order to prevent the crankshaft from turning, the assistant must shift into any gear and apply the brake.
6. Unscrew the bolt and remove the pulley from the end of the crankshaft.
Toothed belt tensioner
7. Unscrew the bolts and remove the belt tensioner assembly from the engine.
idler pulley
8. Unscrew the bolt and remove the idle pulley from the engine. On 1.8 and 2.0L models, if necessary, unscrew the bolt from the pulley hanger or remove the pulley with hanger.
Installation
Camshaft pulleys
Warning! When installing the camshaft pulleys, new bolts must be used.
1. Before installing the pulleys, check the oil o-ring for wear and damage and replace if necessary.
2. Check that the adjusting pulley is in the camshaft socket.
3. On 1.6L models, align the groove on the pulley with the dowel pin and secure the pulley with the bolt.
4. On 1.8L and 2.0L models, the pulleys have two slots for a dowel pin. If the pulley is mounted on the intake camshaft, the dowel pin is located in the groove labeled IN. And if the pulley is installed on the camshaft that controls the exhaust valves, the dowel pin is installed in the groove marked EX.
5. Correctly install the pulleys on the camshafts and secure them with bolts, tightening them to the required torque. At the same time, fix the camshaft with a wrench from turning.
6. Install the toothed belt and install the cylinder head cover.
1.6L model crankshaft pulley
7. Install the pulley on the crankshaft. In this case, the installation mark must be aligned with the pointer.
8. Install the toothed belt.
Crankshaft Pulley Models 1.8 and 2.0L
9. Install the crankshaft pulley. In this case, the installation mark must be aligned with the pointer.
10. Secure the crankshaft from turning and tighten the pulley mounting bolt.
11. Install the toothed belt.
Toothed belt tensioner
12. Install the tensioner with the tab on the base plate in the hole in the oil pump housing. Pre-tighten the bolt securing the tension mechanism. Using a hex wrench, turn the tension lever clockwise until it stops and finally tighten the mounting bolt.
13. Install the toothed belt.
idler pulley
14. On 1.8L and 2.0L models, install idler pulley hanger to cylinder block and secure with bolts to torque.
15. On all models, install the idler pulley and secure with the bolt, tightening it to the required torque.
16. Install the toothed belt.
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