Pictorial DIY: How to replace the aux fan belt
 

On a 1996 E320

1. Remove the front grill using a plier or a screwdriver to loosen the clamps.

http://s245.photobucket.com/albums/g...t/cf46633c.jpg

2. the grill is ready to be removed.

http://s245.photobucket.com/albums/g...t/622b9747.jpg

3. aux fan exposed, it is a duo fan, one with the motor driving the other with a belt, which is the subject of this DIY.

http://s245.photobucket.com/albums/g...t/93dc05c9.jpg

4. Remove the cover plate above the fan by removing four 10mm bolts, two at each side;
and a 10mm bolt in the middle between the fans as in the picture above using a flat wrench.

http://s245.photobucket.com/albums/g...t/f8353493.jpg



http://s245.photobucket.com/albums/g...t/059fc8ac.jpg


5. The cover plate removed and turned over:

http://s245.photobucket.com/albums/g...t/d1236483.jpg

5. Remove the electric connector behind the small plastic cover at top right of the fan assembly

http://s245.photobucket.com/albums/g...t/052b91ab.jpg

http://s245.photobucket.com/albums/g...t/74f5436a.jpg

- to be continued -

7. Fan assembly loosened from the screws and ready to be taken out. Note that the tube in front of the fan motor is in the way and need to be bent a little, or according to Matt L you can make the job a bit easier if you remove the horn and the extra bracket. Also, it is not necessary to bend the power steering cooler pipe. Remove the screw on the left side, and one additional screw just in front of the window washer fluid tank, and the cooler pipe will easily move out of the way. I was a bit lazy :-)


http://s245.photobucket.com/albums/g...t/803cb1ab.jpg

8. The fan assembly taken out, with the broken belt and the new one

http://s245.photobucket.com/albums/g...t/2e5e2227.jpg


http://s245.photobucket.com/albums/g...t/534df02b.jpg

New belt inserted, ignore my foot bottom right :-)

http://s245.photobucket.com/albums/g...t/859ade8f.jpg

9. Cleaning the radiator with a vacuum cleaner

http://s245.photobucket.com/albums/g...t/1b515e24.jpg

10. and everything back in reverse order

http://s245.photobucket.com/albums/g...t/622b9747.jpg

The job is a bit easier if you remove the horn and the extra bracket. Also, it is not necessary to bend the power steering cooler pipe. Remove the screw on the left side, and one additional screw just in front of the window washer fluid tank, and the cooler pipe will easily move out of the way.

Thanks Matt for the tip! I guess I was half lazy half ignorant :-)