4-cylinder engine
Top cover
Disconnect the wire from the negative battery terminal. Loosen the generator adjusting bolts, turn the generator upward and tighten the drive belt.
Loosen the air conditioning compressor mounting bolts and remove the drive belt.
Unscrew the valve cover nuts and remove the cover and retaining strips.
Unscrew the nuts of the upper toothed belt cover. Note the position of the washers and spacers when removing the cover.
Installation is carried out in the reverse order of removal.
After installation is complete, adjust the drive belt tension.
Bottom cover
Disconnect the wire from the negative battery terminal. Remove the upper toothed belt cover.
Using a large bolt on the gear pulley (pinion) of the crankshaft, turn the engine so that cylinder # 1 is in the TDC corresponding to the compression stroke. At this point, both valves of cylinder No.1 will be closed and the "0" mark on the flywheel will be aligned with the pointer on the casing.
Loosen the crankshaft pulley mounting bolts. If the toothed pulley (gear) or rear cover needs to be repaired, loosen the crankshaft toothed pulley bolt.
Caution: To remove the crankshaft timing pulley bolt on vehicles with a manual transmission, disengage the transmission from 5th gear and have an assistant apply the brake. This will prevent the engine from turning while you loosen the bolt. On vehicles with an automatic transmission, remove the starter and hold the flywheel from turning using the VW10-201 or similar tool.
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 the washers or spacers.
Installation is carried out in the reverse order of removal.
Tighten the crankshaft toothed pulley (gear) bolt to a torque of 89 Nm, then tighten it another half turn.
5-cylinder engine
Top cover
Disconnect the wire from the negative battery terminal.
Loosen the power steering pump adjusting bolts and remove the drive belt.
Loosen the nuts and remove the timing belt cover. Be careful not to lose the washers or spacers.
Installation is carried out in the reverse order of removal.
After installation is complete, it is necessary to adjust the tension of the drive belt.
Bottom cover
Disconnect the wire from the negative battery terminal. Remove the upper toothed belt cover.
Loosen the air conditioning compressor mounting bolts and remove the drive belt.
Remove the crankshaft balancer center bolt.
Caution: To remove the crankshaft balancer bolt on vehicles with a manual transmission, engage the highest gear and have an assistant apply the brakes. This will prevent the engine from turning when the bolt is loosened. On vehicles with an automatic transmission, remove the starter and hold the flywheel from turning using the VW10-201 or similar tool. This bolt is very tight.
Remove the water pump pulley mounting bolts and remove the cover.
Installation
Installation is carried out in the reverse order of removal.
Use the same procedure to install the crankshaft center bolt as you did to remove it.
Apply a locking compound to the bolt threads and tighten the bolt to a torque of 35 Nm in several stages.