Removing Drive Belt

→ Only remove the drive belt when it is cold.

Information 

Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:

• Torx screws: (E..) for external Torx, (T..) for internal Torx. 
• Hexagon-head bolts (internal and external hexagon): Wrench size (a/f) 

Belt drive routing: 

Fig 1: Engine Drive Belt Routing Diagram

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Drive belt
2. Generator pulley
3. Power-steering pump pulley (plastic)
4. Air-conditioning compressor pulley
5. Crankshaft vibration damper
6. Coolant pump pulley
7. Belt tensioner tensioning roller

Information 

• Mark running direction of drive belt with a colored pen. 
• Even minor damage means that the drive belt must be replaced (even if the maintenance interval has not expired). 
• If the drive belt has to be replaced (change interval), it can be cut to facilitate removal. 

1. Mark the running direction of the drive belt (with a paint marker, for example) if you intend to reuse it.
2. To slacken the drive belt -1-  , at the tensioning roller -3-  , turn the belt tensioner clockwise using an open-ended -2-  wrench (a/f 32).
   Fig 2: Slackening/Tensioning Drive Belt

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3. Remove the drive belt at the tensioning roller under the generator.
4. Allow the belt tensioner to slide back to its initial position.
5. Remove number plate on the rear apron. The special screw can be removed through the additional bore -arrow-  .
   Fig 3: Locating Rear Apron And Rear Cross Member Bore (USA Variant)

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   View of ROW variant

   Fig 4: Locating Rear Apron And Rear Cross Member Bore (ROW)

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6. Remove special screw for engine carrier (M10 x 130) -1-  through the additional bore on the rear carrier.
   Fig 5: Identifying Special Screw On Engine Carrier And Spacer Sleeve

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   Tool: Change-over ratchet -1-  with long extension (half-inch).

   Fig 6: Removing Special Screw Through Bore

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   1. 6.1. Pull spacer sleeve -2-  out towards the right at the top (past the power-steering pump pulley). Press the engine carrier back slightly if necessary.
   2. 6.2. Pull out screw -1-  using a bar magnet -2-  or use a magnetic socket-wrench insert.
      Fig 7: Pulling Out Screw With Magnet

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7. Slide the drive belt (flat side) up past the coolant pump pulley.
   Fig 8: Locating Drive Belt On Coolant Pump Pulley

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8. Turn the drive belt 90 degrees and guide the flat side past the vibration damper and remove it.
   Fig 9: Identifying Drive Belt On Vibration Damper

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9. Check pulley for damage.