Remove/install belt pulley/vibration damper

AR03.30-W-1600BA

Remove/install belt pulley/vibration damper

12.12.08

15.3.05

Work procedure completely revised.

 

Remove/Install



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 Danger!

Risk of injury caused by being caught or pinched as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure with the safety strut.

AS60.80-Z-0001-01A

1

Tilt cab



Notes on tilting the cab

AH60.80-N-0003-01A

2

Remove trim panel in front of radiator (1)

3

Remove side noise encapsulation from engine on left and right

4

Detach coolant expansion reservoir from radiator (1) and put to one side

 Do not separate coolant lines.

5

Remove red charge air hose



*BA09.41-N-1006-01C

6

Detach oil dipstcik guide tube and oil filler pipe at radiator (1)

7

Remove black charge air hose at charge air cooler



*BA09.41-N-1006-01C

 Danger!

Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under load

Use only approved tensioning devices; shield off hazard area if necessary.
Inspect special tools for damage and proper operation (visual inspection).
Wear protective gloves.

AS00.00-Z-0001-01A

8

Slacken poly-V-belt fan (5) and remove from the belt pulley of the coolant pump

 Installation: Inspect condition of poly-V-belt fan (5), replace if necessary.

Observe poly-V-belt routing plan.

AR13.22-W-3902-02A



Damage patterns of poly V-belt

AP13.22-D-1351-01A

9

Unscrew bolts at the radiator mounting (2) on right and left and press radiator (1) to the front

 Fix radiator (1) on right and left with spacers (arrow).

10

Remove noise encapsulation below the radiator (1).

11

Detach fan wheel (3) with viscous fan clutch (4) at the belt pulley fan drive (6)

 Block the belt pulley fan drive (6) with the corresponding tool.



*BA20.40-N-1012-01C

12

Detach viscous fan clutch (4) at fan wheel (3) and take out downwards



*BA20.40-N-1002-01C

13

Secure fan wheel (3) to the radiator shroud

14

Detach fan drive belt pulley (6) at the intermediate piece with the freewheel bearing (7)

 Block the belt pulley fan drive (6) with the corresponding tool.



*BA20.40-N-1013-01C

15

Detach the intermediate piece with the freewheel bearing (7) at the belt pulley/vibration damper (9)



*BA20.40-N-1011-01C

 Danger!

Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under load

Use only approved tensioning devices; shield off hazard area if necessary.
Inspect special tools for damage and proper operation (visual inspection).
Wear protective gloves.

AS00.00-Z-0001-01A

16

Release the tension on the poly-V-belt of the alternator (8) and take if off the belt pulley of the alternator

 Installation: Check the condition of the poly-V-belt of the alternator (8), replace it if required.

Observe poly-V-belt routing plan.

AR13.22-W-3902-02A



Damage patterns of poly V-belt

AP13.22-D-1351-01A

17

Take off end cover at timing case



*BA01.60-N-1001-01B

18

Attach cranking device to timing case



*407589006300



*BA01.60-N-1009-01B

19

Block engine with cranking device

20

Undo the two opposite bolts at the belt pulley/vibration damper (9)



*422589020900



*BA03.30-N-1002-01F

21

Screw in the drifts (11)



*403589026300

22

Unscrew the remaining bolts at the belt pulley/vibration damper (9) and remove the belt pulley/vibration damper (9) via the drifts (11)

 Installation: Check the belt pulley/vibration damper (9) and the belt pulleys for the remaining driven parts for damage and smooth running, if necessary, replace any affected part(s)



*422589020900



*BA03.30-N-1002-01F

23

Remove slinger (10)

24

Install in the reverse order

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near engine

Secure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

25

Crank the engine and check the crankshaft radial sealing ring for leaks

Number

Designation

Engines
541.9, 542.9

BA01.60-N-1001-01B

Bolt of end cover of TDC inspection hole to timing case

Nm

25

BA01.60-N-1009-01B

Bolt of engine cranking device to timing case

Nm

25

Number

Designation

Engine
541.9, 542.9

BA03.30-N-1002-01F

Bolt, vibration damper to crankshaft

Nm

200

Number

Designation

Engine 541.9

Engine 542.9

BA09.41-N-1006-01C

Clamp of charge air hose to charge air housing/charge air pipe and charge air cooler

Nm

7.5

7.5

Number

Designation

Engine
541.9, 542.9 with
code ML3

BA20.40-N-1002-01C

Bolt, fan to viscous fan clutch

Nm

30

BA20.40-N-1011-01C

Intermediate piece with freewheel bearing to vibration damper

Nm

30

BA20.40-N-1012-01C

Bolt of fan with viscous fan clutch to belt pulley of fan drive

Nm

50

BA20.40-N-1013-01C

Bolt, fan drive belt pulley to intermediate piece with freewheel bearing

Nm

30