To drive the auxiliary units, two belts are installed on the engine. The front belt drives the power steering pump. The rear belt rotates the pulleys of the air conditioning compressor, generator and water pump.
According to the manufacturer's recommendations, the power steering pump drive belt should be cut with a knife to remove it, after which it becomes unusable. This is explained by the fact that the belt, even after removal without damage, cannot be reused, since it is designed only for one-time stretching when put on the pulleys (belt tension adjustment is not provided). In addition, belt replacement is regulated after a certain mileage or service life, so when replacing the rear drive belt (air conditioning compressor, generator and water pump) the front drive belt should also be replaced at the same time (power steering pump).
However, the power steering pump drive belt can be removed without cutting it. The sequence of actions for this is described below.
To remove the front belt without cutting it, perform the following steps.
1. Place the vehicle on a lift or inspection pit.
2. Remove the right front wheel.
3. Remove the mudguard liner and the right engine splash guard (see "Removal and installation mudguards and engine crankcase protection").
4. Turn the crankshaft by the crankshaft pulley mounting bolt so that any of the holes in the power steering pump pulley is opposite the head of the lower pump mounting bolt.
5. Loosen the lower pump mounting bolt by one or two turns through the hole in the pump pulley.
6. Turn the crankshaft pulley again so that any of the holes in the power steering pump pulley are opposite the head A of the upper pump mounting bolt.
7. Place an 18 mm open-end wrench on the edge of the pump body.
8. Using an open-end wrench to hold the pump body from moving towards the block, unscrew the upper pump mounting bolt and remove it from the holes.
9. Release the holding key and the pump will move towards the engine block, releasing the belt tension.
10. First remove the belt from the power steering pump pulley...
11. ...and then from the water pump pulley. Remove the belt.
NOTE: The power steering pump is driven by belt 4PK 643.
12. Install the power steering pump drive belt in the reverse order of removal.
13. Rotate the crankshaft three full revolutions to ensure that the belt is correctly positioned on the pulleys.
For removal rear belt perform the following tasks.
1. Place the vehicle on a lift or inspection pit.
2. Remove the right front wheel.
3. Remove the mudguard liner and the right engine splash guard (see "Removal and installation mudguards and engine crankcase protection").
4. Remove the power steering pump drive belt (see above in this subsection).
5. Turn the tensioner lever counterclockwise with the key until the belt tension is released.
NOTE: Rotate the tensioner lever by placing a 12-point socket wrench on the special protrusion on the bottom of the lever.
6. Fix the tensioner in the pressed position by inserting a pin of the appropriate diameter into the aligned holes of the roller lever and the tensioner housing.
7. Remove the belt.
NOTE: The 6PK 1557 belt is used to drive the air conditioning compressor, alternator and water pump.
8. Install the air conditioning, alternator and water pump drive belt in the reverse order of removal, as shown in the figure.
9. Rotate the crankshaft three full revolutions to ensure that the belt is correctly positioned on the pulleys.