Removal
1. Remove the front timing belt cover (see above, "Timing belt drive engine 1.6i - checking the condition and adjusting the tension").
2. Remove the front right wheel and the right part of the engine mudguard.
3. Remove the alternator belt (see "Generator Drive Belt - Replacing the Belt and Tensioner Roller").
4. Using a 17 mm socket wrench with an extension, turn the crankshaft by the pulley mounting bolt until the mark on the camshaft pulley and the protrusion on the rear timing belt cover are aligned.
5. Remove the rubber plug installed in the upper part of the clutch housing.
6. Using a 17 mm socket wrench, unscrew the crankshaft pulley mounting bolt; at the same time, the assistant uses a screwdriver inserted through the opened window between the teeth of the flywheel ring to keep the shaft from turning.
7. Remove the pulley (see "Timing Belt - Replacement").
8. Unscrew the tension roller mounting nut and loosen the toothed belt tension as much as possible (see above, "Timing belt of the engine l,6i - checking the condition and adjusting the tension").
Camshaft drive diagram:
1 - toothed pulley of the engine crankshaft;
2 - toothed pulley of the coolant pump;
3 - tension roller;
4 - rear timing belt cover;
5 - camshaft toothed pulley;
6 - timing belt;
7 - lug on the oil pump cover;
A - mark on the toothed pulley of the crankshaft;
B - mark on the tide of the oil pump cover;
C - protrusion on the rear timing belt cover;
D - mark on the toothed pulley of the camshaft.
9. Remove the toothed belt from the pulleys.
10. Rotate the tension roller to check its condition. The roller that has play and makes a lot of noise when rotating is replaced (see below, "1.6i Engine Timing Belt Tensioner Roller - Removal and Installation").
Installation
1. Check the alignment of the marks on the toothed pulley of the crankshaft and on the boss on the oil pump housing.
2. We also make sure that the mark on the camshaft pulley and the protrusion on the rear timing belt cover match (see above p. 4).
3. Install the new belt in the following sequence: without allowing the toothed pulleys of the crankshaft and camshaft to turn relative to the marks, put the belt on the crankshaft pulley; slightly tightening 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 "Timing belt drive engine 1.6i - checking the condition and adjusting the tension").
5. Tighten the crankshaft pulley mounting bolt and, after turning the engine crankshaft two revolutions, make sure that the marks on the pulleys and the engine match. If necessary, reinstall the belt.
6. Install the crankshaft pulley in place and tighten its mounting bolt to a torque of 97.9-108.8 Nm (9.9-11.1 kgf·m).
7. Install the front timing belt cover, alternator belt and parts removed during disassembly in place.