4 cylinder engine
Top cover
Disconnect the wire from the minus AB. Loosen the alternator adjusting bolts, turn the alternator up and tighten the drive belt.
Loosen the A/C compressor mounting bolts and remove the drive belt.
Loosen the valve cover nuts and remove the valve cover and retaining strips.
Loosen the nuts on the upper toothed belt cover. Note position of washers and spacers when removing cover.
Installation is made in an order, the return to removal.
After installation is complete, adjust the tension of the drive belt.
Bottom cover
Disconnect the wire from the minus AB. Remove the top toothed belt cover.
Using a large bolt on the toothed pulley (gear) crankshaft, turn the engine so that the number 1 cylinder is at TDC, corresponding to the compression stroke. At this point, both valves of cylinder #1 will be closed and the mark "0" on the flywheel will be aligned with the pointer on the casing.
Loosen the crankshaft pulley bolts. If the toothed pulley (gear) or back cover to be repaired, loosen the crankshaft sprocket bolt.
Caution: To remove the crankshaft sprocket bolt on vehicles with a manual transmission, disengage 5th gear and have an assistant apply the brake. This will prevent the motor from rotating while the bolt is being loosened. On vehicles with automatic transmission, remove the starter and hold the flywheel from turning with tool VW10-201 or similar.
Remove the crankshaft pulley.
Remove the lower timing belt cover bolts and remove the pulley.
Loosen the nuts securing the bottom cover and remove the cover. Be careful not to lose washers or spacers.
Installation is made in an order, the return to removal.
Tighten the toothed pulley bolt (gears) crankshaft to 89 Nm, then tighten another half turn.
5 cylinder engine
Top cover
Disconnect the wire from the minus AB.
Loosen the power steering pump adjusting bolts and remove the drive belt.
Loosen the nuts and remove the toothed belt cover. Be careful not to lose washers or spacers.
Installation is made in an order, the return to removal.
After installation is complete, the tension of the drive belt must be adjusted.
Bottom cover
Disconnect the wire from the minus AB. Remove the top toothed belt cover.
Loosen the A/C compressor mounting bolts and remove the drive belt.
Remove the crankshaft balancer center bolt.
Attention. To remove the crankshaft balancer bolt on vehicles with a manual transmission, shift to the maximum gear and have an assistant apply the brake. This will prevent the engine from turning when the bolt is loosened. On vehicles with automatic transmission, remove the starter and hold the flywheel from turning with tool VW10-201 or similar. This bolt is very tight.
Remove the water pump pulley bolts and remove the cover.
Installation
Installation is made in an order, the return to removal.
Use the same procedure to install the crankshaft center bolt as you did when removing it.
Apply a locking compound to the bolt threads and tighten the bolt to 35 Nm in several stages.
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