Removing and Installing Drive Belt 1

Removing and installing drive belt

Removing drive belt

ATTENTION Risk of damage!
^ If the drive belt is removed when it is hot, it may become deformed and damaged.
^ Never remove the drive belt when it is hot - let the engine cool down!

ATTENTION Consequential damage of broken pulley belt!
^ Due to a broken drive belt during driving, surrounding components (panelling, electric cables etc.) can be damaged by thrashing or flying belt parts.
^ Parts of the drive belt can jam behind deflection rollers or vibration balancers and damage surfaces and sealing rings there. In particular, the sealing ring of the crankshaft vibration balancer can become leaky as a result of a broken belt.
^ Following a belt breakage the surrounding components and the interior of the engine compartment must be inspected for damage, and if necessary damaged parts (sealing ring of the crankshaft vibration balancer, deflection rollers, panelling, lines, electric cables etc.) repaired or replaced.
^ The reason for the belt breakage must be established. Check deflection rollers or crankshaft vibration balancers for prior damage.

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

1. Remove front engine compartment cover.





2. Pull the design cover vertically upwards and off.
3. Remove connecting tube from air cleaner to engine.





4. Mark the rolling direction of the drive belt with chalk.





5. 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.
6. Remove the drive belt from all pulleys.

Installing drive belt

Note: The figure 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.
6. Fit connecting tube from air cleaner to engine.





7. Fit the design cover.
8. Install front engine compartment cover.