Installing Drive Belt

Information 

The pictures shown in this document may differ from the original.

Information 

Fig 1: Drive Belt Routing

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Components 

1. Coolant pump pulley -1-  .
2. Deflection roller, cylinder bank 5 - 8 -2- 
3. Air-conditioning compressor pulley -3- 
4. Hydraulic pump pulley -4- 
5. Crankshaft pulley -5- 
6. Generator pulley -6- 
7. Deflection roller, cylinder bank 1 - 4 -7- 
8. Tensioning roller -8- 

• The figure  > Components  shows the complete belt threading course. The pulleys are numbered according to fitting sequence.

Fig 2: Drive Belt Components Location

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Belt drive 

1. Deflection roller
2. Hydraulic belt tensioner
3. M8 screw
4. Deflection roller
5. Dual poly V-belt

1. Bend the drive belt to form a loop and guide it through between the coolant pump pulley -1-  and crankshaft pulley -5-  towards to the tensioning roller -8-  .

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   Fitting drive belt - Step 1 

2. Place the top part of the belt loop over the coolant pump pulley

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   Fitting drive belt - Step 2 

3. Place the lower part of the belt loop around the crankshaft pulley at the bottom -5-  .

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   Fitting drive belt - Step 3 

4. Guide the belt section from the coolant pump pulley -1-  around the deflection roller -2-  on cylinder bank 5 - 8.

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   Fitting drive belt - Step 4 

5. Then guide the section of the belt around the air-conditioning composer pulley -3-  at the bottom.

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   Fitting drive belt - Step 5 

6. Lay a loop around the power-steering pump -4-  .

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   Fitting drive belt - Step 6 

7. Lay the loose end of the drive belt from the coolant pump downwards and around the generator pulley -6-  and deflector roller -7-  of cylinder bank 1 - 4.

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   Fitting drive belt - Step 7 

8. Gather the belt section between the deflection roller -7-  of cylinder bank 1 - 4 and the crankshaft pulley -8-  to form a loop and guide it upwards to the tensioning roller -8-  .

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   Fitting drive belt - Step 8 

   Information 

   • Using an open-ended wrench can damage the belt tensioner.
   • Using a tool with a width across flats of 32 mm can damage the belt tensioner.
9. Use a ring wrench or socket (width across flats 30) to turn the belt tensioner in a clockwise direction at the hexagon.

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   Belt tensioner hexagon 

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   Loosening the belt 

10. Lay the drive belt on the tensioning roller. Slowly relieve the tensioning roller.
11. Check that the drive belt is routed correctly. > Components 
12. Check that the drive belt is seated correctly on the pulleys.
13. Clip the coolant hose -1-  into the holder -2-  .

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    Hose 

14. Turbo only: 

    Connect the wastegate line at tie clamp

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    Wastegate line 

15. Turbo only: 

    Attach the check valve -1-  to the air box and fit a new clamp -2-  .

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    Check valve for positive crankcase ventilation 

16. Turbo only: 

    Attach hoses to the check valve and fit with new clamps.