Removal
54. Perform the actions described in paragraph. points 1 and 2, if you haven't done so yet.
55. Disconnect the ground cable from the battery (refer to paragraph "Disconnecting the battery").
56. Release the clips on the right side and on the top plane of the engine cover, and then remove the cover, being careful not to let the corresponding rubber supports fall out (figure 4.6, a-c).
57. Loosen the bolt on the idler pulley shield and loosen the pulley adjuster nut located behind the power steering pump to move the pulley away from the drive belt (figure 12.57). Once you have enough slack in the belt to remove it, remove the belt from the pulleys and then from the engine.
Figure 12.57. Accessory drive belt and tensioner (dW series engines with power steering and manual tensioner)
Note: If the belt is to be reused, mark the direction of rotation on it before removing it. This will ensure that the belt is installed correctly.
Installation
58. When replacing a belt, ensure that the new belt is the correct type, and if installing a removed belt, follow the marks made during removal to ensure it is installed correctly. Place the belt on the pulleys in the following order:
- a) power steering pump;
- b) tension pulley;
- c) generator;
- d) lower intermediate pulley;
- d) crankshaft;
- e) upper intermediate pulley.
59. Place the belt on the pulleys so that the belt ribs fit correctly into the grooves on the pulleys and take up the belt slack by tightening the adjusting bolt. Then tighten the belt as described below.
Stretching
60. Perform the actions described in paragraph. points 1 and 2, if you haven't done so yet.
61. Correct drive belt tension will ensure long belt life (see "Haynes Advises" above).
62. The belt should be tensioned so that when pressing hard with your thumb, there is a deflection of approximately 5.0 mm in the middle of the lower section between the alternator pulley and the idler pulley.
63. To make the adjustment, loosen the bolt on the tensioner pulley shield and turn the adjusting nut until the correct tension is achieved. After ensuring the correct belt tension, rotate the crankshaft two revolutions and check the tension again.
64. Once you have verified that the belt tension is correct, securely tighten the bolt on the tensioner pulley shield and lightly tighten the adjusting nut.
65. Secure the coolant hoses in their normal position (if applicable) and install the locker (or a technological lid). Install the wheel and lower the vehicle.
66. Make sure that the rubber supports on the engine cover are installed correctly, install this cover and secure it in the standard position with the appropriate fasteners.
67. Finally, connect the ground wire to the battery.
Tip: Attach the tensioner locking bolt/pin to a long, narrow metal plate. This allows the bolt/pin to be easily passed between the engine and inserted into the provided hole.
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