Installing Drive Belt

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Information

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

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Fig 1: Drive Belt Components Location

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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: Belt Drive 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

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
Place the top part of the belt loop over the coolant pump pulley -1- .

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Fitting drive belt - Step 2
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
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
Then guide the section of the belt around the air-conditioning compressor pulley -3- at the bottom.

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Fitting drive belt - Step 5
Lay a loop around the power-steering pump -4- .

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Fitting drive belt - Step 6
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
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.
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
Lay the drive belt on the tensioning roller. Slowly relieve the tensioning roller.
Check that the drive belt is routed correctly. > Components
Check that the drive belt is seated correctly on the pulleys.
Clip the coolant hose -1- into the holder -2- .

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Hose
Turbo only:
Connect the wastegate line at the clamp -1- .

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Wastegate line
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
Turbo only:
Attach hoses to the check valve and fit with new clamps.