Drive Belt: Service and Repair

Removing and Installing Drive Belt (Engine Installed)


Remove drive belt

Removal Overview:

Designations and removal notes
1 Remove air cleaner assembly
2 Loosen servo pump wheel
3 Relieve drive belt
4 Remove servo pump wheel
5 Remove drive belt





1. Remove air cleaner assembly
Remove the complete air cleaner assembly.
1. Undo hexagon-head bolt M6 x 34.
2. Undo the hose clamp on the throttle body.
3. Pull off plug from hot film mass air flow sensor and remove air cleaner assembly.





2. Loosen servo pump wheel
1. Mark belt travel direction with a colored pen.
2. Undo the three -hexagon-head bolts- on the servo pump by approximately one half turn.





3. Relieve drive belt
Relieve drive belt. To do this, turn the tensioning roller clockwise and simultaneously remove the belt from the drive pulleys.





4. Remove servo pump wheel

Note: Only remove the servo pump wheel when the drive belt is completely relieved.

1. Remove servo pump wheel with drive belt to the rear.
2. Remove the belt from all drive wheels and lift up to remove.


Install drive belt

Installation Overview:

Designations and installation notes
1 Fit drive belt
2 Position servo pump wheel
3 Tension drive belt drive belt
4 Tighten fastening screws on servo pump
5 Install air cleaner





1. Fit drive belt
- Fit the belt onto the drive wheels.





2. Position servo pump wheel
1. Put on the servo pump wheel together with the drive belt.
2. Slightly tighten the three fastening screws on the servo pump wheel.





3. Tension drive belt

Note: It is absolutely necessary to check that the drive belt is correctly seated on all belt pulleys.

1. To tension the drive belt, turn the tensioning roller -7- in clockwise direction and simultaneously fit the drive belt on the deflection roller -8-.
2. Then slowly relieve. To do this, turn the tensioning roller slowly anti-clockwise.





4. Tighten fastening screws on servo pump
- Tighten the fastening screws of the servo pump drive wheel.
Tightening torque: 23 Nm (17 ft. lbs.)





5. Install air cleaner assembly
Install air cleaner assembly completely.
1. Attach connector onto mass air flow meter.
2. Tighten the hose clamp on the throttle body.
3. Tighten the M6 x 34 hexagon-head bolt to 10 Nm (7.5 ft. lbs.)