Remove/install belt pulley/vibration damper

AR03.30-W-1600D

Remove/install belt pulley/vibration damper

30.6.10

24.8.09

Work procedure completely modified

 

Remove/install

1

Swivel tensioner pulley for the poly-V belt tensioning device (5) for the hydraulic pump downwards and remove poly-V belt (7)

 Installation: Inspect condition of poly-V belt (7), replace if necessary.

Damage profiles for poly-V belt (7)

AP13.22-D-1351-01A

Observe poly-V belt (7) routing diagram.

AR13.22-W-3902-02D

2

Remove poly-V belt tensioning device (5) for hydraulic pump

 Only if tensioner pulley for the poly-V belt tensioning device (5) projects out on the vibration damper (2).

AR13.25-W-3203A

3

Swivel tensioner pulley for the poly-V belt tensioning device (1) for the AC generator, coolant pump upwards and remove poly-V belt (3) on the vibration damper (2)

 Installation: Inspect condition of poly-V belt (3), replace if necessary.

Damage profiles for a poly-V belt (3)

AP13.22-D-1351-01A

Observe poly-V belt (3) routing diagram.

AR13.22-W-3902-02D

4

Remove guide pulley (4)

 Only for vehicles with code (H03) A/C in the front end and for which the guide pulley (4) projects out on the vibration damper (2).

5

Attach turning device for engine

 Block cranking/blocking device by inserting the pin.

AR03.30-W-1600-03J



*BA01.60-N-1002-01A



*BA01.60-N-1003-01A



*904589046300

6

Remove two opposing bolts (8) on the vibration damper (2)



*BA03.30-N-1002-01C

 Screwdriver bit (M141.5)

*904589001000

 Screwdriver bit (M161.5)

*904589011000

7

Screw drifts/centering drift (9) into the threaded holes

 Drift (M161.5)

*403589026300

 Centering drift (M141.5)

*904589026300

8

Remove remaining bolts (8) on vibration damper (2)



*BA03.30-N-1002-01C

 Screwdriver bit (M141.5)

*904589001000

 Screwdriver bit (M161.5)

*904589011000

9

Remove vibration damper (2) with attached belt pulley (6)

10

Remove belt pulley (6) from vibration damper (2)

 Only if the vibration damper (2) is replaced.



*BA03.30-N-1004-01C

11

Measure the shank length of bolts (8)

 Installation: If the maximum shank length (L) is exceeded, replace bolt (8) in question.

Bolt M141.5

*BE03.30-N-1001-02B

Bolt M161.5

*BE03.30-N-1002-02B

12

Install in the reverse order

Number

Designation

Engine
900.9, 902.9, 904.9, 906.9

Engine
924.9, 925.9, 926.9

BE03.30-N-1001-02B

Bolt, vibration damper to crankshaft

Thread

M

141.5

141.5

Length of shank when new

mm

60.0

60.0

Permissible shank length

mm

61.0

61.0

BE03.30-N-1002-02B

Bolt, vibration damper to crankshaft

Thread

M

161.5

161.5

Length of shank when new

mm

61.0

61.0

Permissible shank length

mm

61.8

61.8

Number

Designation

Engine
900.9, 902.9, 904.9, 906.9

Engine
924.9, 925.9, 926.9

BA01.60-N-1002-01A

Inspection hole closure cover to timing case

Nm

25

25

BA01.60-N-1003-01A

Bolt, turning device to timing case

Nm

25

25

Number

Designation

Engine
902.9, 906.9 with code MS8

Engine
904.9,

Engine
902.9, 906.9
without code MS8

Engine
924.9, 925.9
926.9

BA03.30-N-1002-01C

Bolt, vibration damper to crankshaft

M16

Stage 1

Nm

50

50

50

Stage 2

Nm

200

200

200

Stage 3

°

90

90

90

M14

Stage 1

Nm

50

50

50

Stage 2

Nm

125

125

125

Stage 3

°

90

90

90

BA03.30-N-1004-01C

Bolt, belt pulley to vibration damper

Nm

60

60

60