Removal and Replacement

Removing and installing drive belt

Preliminary work
1. Remove air cleaner housing.

Removal

Removing drive belt

Drive belt routing:

Drive belt on engine (view with engine removed)

1 - Drive belt
2 - Generator pulley
3 - Power-steering pump pulley (plastic)
4 - Air-conditioning compressor pulley
5 - Crankshaft vibration balancer
6 - Coolant pump pulley
7 - Belt tensioner tensioning roller

1. Slacken the drive belt.

Warning
Do not remove the drive belt when it is warm!
^ Risk of damage or deformation!

- Only remove the drive belt when it is cold.

Information
^ Mark running direction of drive belt with a colored pen.
^ Even minor damage means that the drive belt must be replaced (even if the maintenance interval has not expired).
^ The drive belt can be cut if it has to be replaced.

1.1. Fit a ring wrench (a/f 30) -2- on the hexagon on the tensioner -3-, turn it clockwise as far as it will go and hold it at that position.
1.2. Remove the drive belt -1- from the pulley on the generator.
1.3. Carefully allow the tensioning roller to slide back to its original position.

Slackening/tensioning the drive belt

2. Remove number board at the rear apron. The special screw can be removed through the additional bore -arrow-.

Additional bore in rear apron and rear cross member (USA)

Additional bore in rear apron and rear cross member (RoW)

3. Remove special screw for engine carrier (M10 x 130) -1- through the additional bore on the rear carrier.

Special screw on engine carrier and spacer sleeve

Tool: Ratchet -1- with long extension.

Removing special screw through additional bore

3.1. Pull spacer sleeve -2- out towards the right at the top (past the power-steering pump pulley). Press the engine carrier back slightly if necessary.
3.2. Pull out screw -1- using a bar magnet -2-.

Pulling out screw with a magnet

4. Slide the drive belt (flat side) up past the coolant pump pulley.

Drive belt on coolant pump pulley

5. Turn the drive belt 90 degrees, guide the flat side past the vibration balancer and remove it.

Drive belt on vibration balancer

6. Check pulley for damage.

Information
^ Check for foreign objects in the grooves of the pulley.

Installation

Installing drive belt
1. Guide the drive belt with the flat side -1- first past the vibration balancer -2-.
If you intend to reuse the old belt, make sure to observe the running direction marked earlier.
1.1. Position the belt on the running track on the vibration balancer.

Drive belt on vibration balancer

2. Guide the drive belt -1- to the left past the coolant pump pulley.

Guiding drive belt through coolant pump

2.1. Then guide the flat side of the belt through between the pulley and engine carrier -arrow-.

Drive belt (flat side) on coolant pump pulley

3. Fit the drive belt on the pulleys for the air conditioning compressor -4-, power-steering pump -3- and generator -2-.
3.1. Then, pre-position it on the tensioning roller -7-.

Slackening/tensioning the drive belt

5. Check that the drive belt is fitted correctly.

Subsequent work
1. Install air cleaner housing.