Drive Belt: Service and Repair

Removing and installing drive belt
Removing drive belt

Warning: Risk of damage!
^ Never remove drive belt when it is hot.
^ If the drive belt is removed when it is hot, it may become deformed and damaged.

Caution: Danger of injury!
^ The vehicle fans can continue running or start up automatically.
^ The power supply to the fans must be disconnected before starting work on the radiator or radiator fans.

Note: If the drive belt is to be re-used, mark the direction of motion with chalk so that the belt can be re-installed later in the same direction of motion.

1. Remove front engine compartment cover.





2. Pull engine cover vertically upwards and off.





3. Remove connector tube from air cleaner to engine. To do this, loosen the tube clamp on the engine, unplug the electric connector on the mass air-flow meter and remove the two fastening pins on the air cleaner cover.





4. Remove the vacuum line on the throttle body from the connector tube. Then take the pressure pipe out of the engine compartment.





5. Mark the direction of motion of the drive belt with chalk.





6. Slacken off the belt tensioner. To do this, screw an M8 x 50 screw into the belt tensioner. Do not turn the belt tensioner as far as the stop; only slacken the tensioner until the drive belt is loose.
7. Remove the drive belt from all pulleys.

Installing drive belt





Note: The following shows the complete belt threading course. The pulleys are numbered according to the sequence of fitting.





1. Place drive belt around the crankshaft gearwheel and bundle in left direction of travel.





2. Guide the top end of the belt around the coolant pump. Then, position the belt vertically (turn by 90°) and guide in behind the belt tensioner.





3. Guide the lower end of the belt on the crankshaft gearwheel around the air-conditioning compressor and then around the hydraulic pump. Push the belt upwards from there.





4. Guide the drive belt over the drive roller of the generator and then pull a loop down around the deflection roller and lay into position.
5. Check that the drive belt is positioned correctly on the pulleys.





6. Fit the intake manifold. To do this, push the intake manifold onto the throttle body and fit the vacuum line at the same time. Then attach the other end to the cover of the air cleaner housing.





7. Attach the hose clamp, the electric connector on the mass air-flow meter and the 2 fastening pins on the air cleaner housing.





8. Press the 4 rubber elements in the cover onto the 4 ball socket holders. The fastening elements must be felt to engage.
9. Fit front engine compartment cover.