Removing And Installing Drive Belt

→ Only remove the drive belt when it is cold.

→ Replace damaged drive belt.

→ Following belt breakage, check adjacent components and the interior of the engine compartment for damage, and repair or replace damaged parts if necessary.

→ Find out why the belt broke. Check deflection rollers or crankshaft vibration balancer for prior damage.

→ If the drive belt is jammed, replace vibration balancer.

Information 

• 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. Mark the rolling direction of the drive belt with chalk. -arrow- 
   Fig 1: Rolling Direction Of Drive Belt

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2. 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 it will go; only slacken the tensioner until the drive belt is loose and easily accessible. -arrow- 
   Fig 2: Loosening Belt Tensioner

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3. Remove the drive belt from all pulleys.
   Fig 3: Drive Belt Pulley Routing Diagram

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   1. -1-  - Crankshaft vibration balancer (crankshaft pulley)
   2. -2-  - Coolant pump
   3. -3-  - Drive belt tensioning roller
   4. -4-  - Air-conditioning compressor
   5. -5-  - Power-steering pump or tandem pump
   6. -6-  - Generator
   7. -7-  - Deflection roller
4. Place drive belt around the vibration balancer and loop in direction of travel going left.
   Fig 4: Positioning Drive Belt Around Vibration Balancer

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5. Guide the top end of the belt around the coolant pump. Then, position the belt vertically (turn by 90°) and guide it in behind the belt tensioner.
   Fig 5: Positioning Coolant Pump Belt Threading Course

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6. Guide the lower end of the belt from the vibration balancer around the air-conditioning compressor and then around the hydraulic pump (power-steering pump/tandem pump). Push the belt upwards from there.
   Fig 6: Positioning Air-Conditioning Compressor Belt Threading Course

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7. 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.
   Fig 7: Positioning Generator Belt Threading Course

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8. Check that the drive belt is positioned correctly and is placed correctly on the rollers.
9. Tighten the belt tensioner. To do this, remove the M8 x 50 screw on the belt tensioner. -arrow- 
   Fig 8: Locating Belt Tensioner

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