Drive Belt - Derailed from Pulley and Damage

Boxster

5/99

1379

1

Binder - Engine, Part 1

JANUARY 20, 2000

Damaged Drive Belt

Vehicle Type:
Boxster, Boxster S

Model Year:
As of 1997 (V)

Concern:
Torn or damaged drive belt

Information:
Certain driving conditions (very low engine RPMs with high engine load) can bring about engine vibrations/oscillations that may cause the engine drive belt to derail from the crankshaft pulley. Should this occur, the lip of the crankshaft pulley can damage the engine drive belt.

Figure 1:

To prevent the possibility of drive belt damage, a guide clip was installed in production as of August 24,1999, and the following engine numbers:

M9621 67 Y 00778
M9622 65 Y 01615

With the introduction of a new freewheeling alternator, (which over-runs to prevent drive belt vibrations; beginning with engine numbers M9621 67 Y 00936 and M9622 65 Y 02460) the above guide clip is no longer installed in production, as it is not necessary.

The new guide clip can be retrofitted to vehicles produced prior to August 24, 1999 for concerns of drive belt damage. Note: Replacement engines will now be equipped with the guide clip.

Parts Information:

Part Number Description:

996 102 235 01 New/drive belt guide clip
996 102 151 64 Polyrib drive belt (M573)

Work Procedure: Retrofitting drive belt guide clip.

1. Remove drive belt.

Figure 2:

2. Remove the two fastening screws on the coolant housing (Figure 2).

3. Fasten the guide clip using the same screws removed in step 2.

Note:
The open side of the guide clip faces the crankshaft pulley. Tightening torque: 10 Nm (7.5 ft lb)

4. Install a new drive belt by fitting into the guide clip first, then routing onto the engine pulleys.

Working Time:

Labor Operation Time Units Description

13 79 23 03 70 TU Installing drive belt guide clip.
Includes: Removing/installing drive belt, fitting guide clip

Literature:
Boxster Technical Manual, Group 1, Section:
13 78 19 - Removing/installing drive belt