Removing
1. Remove the front timing belt cover (see above, «1.6i engine timing belt - checking condition and adjusting tension»).
2. Remove the front right wheel and the right side of the engine mudguard.
3. Remove the alternator belt (see «Alternator drive belt - replacing the belt and tensioner»).
4. Using a 17 mm socket wrench with an extension for the pulley mounting bolt, turn the crankshaft until the mark on the camshaft pulley and the protrusion of the timing belt rear cover are aligned.
5. Remove the rubber plug installed at the top of the clutch housing.
6. Using a 17 mm socket wrench, unscrew the bolt securing the crankshaft pulley; at the same time, an assistant with a screwdriver inserted through the opened window between the teeth of the flywheel crown keeps the shaft from turning.
7. Remove the pulley (see «Timing belt - replacement»).
8. We unscrew the nut of the tension roller and loosen the tension of the toothed belt as much as possible (see above, «Timing belt for engine l,6i - checking the condition and adjusting the tension»).
Camshaft Drive Diagram:
1 - toothed pulley of the crankshaft of the engine;
2 - toothed pulley of the coolant pump;
3 - tension roller;
4 - rear timing belt cover;
5 - a gear pulley of a camshaft;
6 - toothed timing belt;
7 - tide on the cover of the oil pump;
And - a label on a gear pulley of a cranked shaft;
B - mark on the tide of the oil pump cover;
C - protrusion on the back cover of the timing belt;
D - mark on the camshaft sprocket.
9. Remove the toothed belt from the pulleys.
10. Rotating the tension roller, check its condition. The roller, which has play and makes a lot of noise during rotation, is replaced (see below, «1.6i engine timing belt tensioner - removal and installation»).
Installation
1. We check the coincidence of the marks on the crankshaft pulley and on the tide on the oil pump housing.
2. We also make sure that the mark on the camshaft pulley and the protrusion of the rear cover of the timing belt match (see point 4 above).
3. We install a new belt in the following sequence: preventing the crankshaft and camshaft toothed pulleys from turning relative to the marks, we put the belt on the crankshaft pulley; slightly pulling the right branch of the belt, we put it on the camshaft pulley; we pass the belt from the inside of the tension roller and put it on the coolant pump pulley.
4. Adjust the belt tension (see «1.6i engine timing belt - checking condition and adjusting tension»).
5. We wrap the crankshaft pulley mounting bolt and, turning the engine crankshaft two turns, make sure that the marks on the pulleys and the engine match. Reinstall the belt if necessary.
6. Install the crankshaft pulley in place and tighten its fastening bolt to a torque of 97.9-108.8 Nm (9.9-11.1 kgf·m).
7. We reinstall the front cover of the timing belt, the alternator belt and the parts removed during disassembly.