Drive Belt Tensioner: Service and Repair

Tensioner accessory drive belt

Special tools:
999 7109 Wrench 999 7109 Wrench
999 7103 Lifting beam 999 7103 Lifting Beam
999 5185 HOOK 999 5185 Hook

Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Preparatory work

Removing components
Raise the vehicle.

Remove:
- the right front wheel
- the right-hand fender liner. Slacken off the screws at the front edge and fold back the fender liner.

Removal

Removing the auxiliaries belts





Outer belt
Relieve the load from the belt tensioner. Use: 999 7109 Wrench 999 7109 Wrench. Turn the belt tensioner clockwise as far as it will go. Remove the belt.

Inner belt
Relieve the load from the belt tensioner using a Torx-wrench. Turn the belt tensioner counter clockwise as far as it will go. Remove the belt.
Lower the vehicle.

Removing the belt tensioner




Install lifting beam: 999 7103 Lifting beam 999 7103 Lifting Beam together with hook: 999 5185 HOOK 999 5185 Hook. Tension the tool. Lift the expansion tank and place on the engine.

Note! Ensure that no coolant escapes.

Marking the position of the engine pad




Mark the position of the engine pad on the frame member. Use a marker pen.

Removing the power steering pump pressure line





Caution! Seal the openings.

Note! Clear up any oil spillage under the delivery line.

Disconnect the delivery line from the power steering pump.

Removing components





Remove:
- the screws (1) for the limiter for the engine pad in the right-hand frame member
- the limiter
- the screws (2) for the engine mounting in the cylinder head
- the engine mounting. Lower the engine approximately 60 mm.

Removing the belt tensioner

Remove:
- screw for outer belt tensioner
- outer belt tensioner
- screw for inner belt tensioner
- inner belt tensioner

Installation

Note! For tightening torques, see Specifications. Tightening Torque.

Installing the inner belt tensioner

Note! Ensure that the guide on the belt tensioner is correctly positioned.

Install:
- inner belt tensioner
- screw for inner belt tensioner. Tighten.

Installing the outer belt tensioner




When installing the outer belt tensioner, turn the belt tensioner clockwise (1) and hold it in that position.
Tighten screw (2).

Checking belt tensioner




Check using a feeler gauge.
The dimension between the inner belt tensioner and deflection limiter on the outer belt tensioner should be 2.5 - 3.0 mm.

Installing the auxiliaries belt





Caution! Ensure that the belts are correctly positioned in all the grooves.

Inner belt
Relieve the load from the belt tensioner. Turn the belt tensioner counter clockwise as far as it will go. Use a Torx-wrench. Install the belt.

Outer belt
Slacken off the tensioner. Use: 999 7109 Wrench 999 7109 Wrench. Turn the belt tensioner clockwise as far as it will go. Install the belt.
Lower the vehicle.

Installing the inner belt tensioner
Relieve the load from the belt tensioner. Turn the belt tensioner counter clockwise as far as it will go. Use a Torx-wrench. Install the belt.

Installing the engine pad




Install the engine pad according to the markings.

Fit the front engine bracket
Raise the engine. Use: 999 7103 Lifting beam 999 7103 Lifting Beam and hook 999 5185 HOOK 999 5185 Hook. Raise the engine to its original position.

Install:
- the engine mounting on the cylinder head. Tighten. See: Tightening torque, B5254T7 Tightening Torque.
- the limiter over the engine pad on the right-hand side. Tighten. See: Tightening torque [1][2]Specifications.

Remove:
- the special tool. Use: 999 7103 Lifting beam 999 7103 Lifting Beam
- the expansion tank. Secure the hoses.

Finishing

Installing components

Install:
- the pressure hose for the power steering pump. Remove the seals
- the fender liner
- the front wheel. See: Wheels Service and Repair.